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E-Sharp News March 2013
Materials used in aircraft have continued to evolve and have recently moved to an increased use of alloys and non-metals. The new Boeing 787 Dreamliner incorporates 50% by weight of advanced composites and is the world's first major airliner to use composite materials as the primary material in the airframe construction. It is designed to be lighter, 20% more fuel efficient, quieter and cheaper to maintain. It is also made from recyclable material designed to produce fewer emissions.
These different aircraft materials have different characteristics which has prompted United States cutting tool manufacturers such as Precorp Inc and Wichita Precision Tool Inc to develop new types of tools, geometries and materials specifically optimised for composites.
New aircraft sometimes require holes to be drilled through a sandwich of 3-4 different layers of different materials including composites, honeycomb, aluminium and titanium. All with tight tolerances and no delamination. Companies have therefore also had to develop new types of tools that are optimised for different layers and materials.
CFRP as shown on the Precorp website
Rich Garrick, President of Precorp advises that, "We have the resources to accommodate difficult and new applications. Our engineering team has a unique knowledge of the ever changing applications of our customers and they work to create the most effective tooling solutions. We have a wide range of tooling developed specifically for new-age aerospace composites. We rely on our ANCA tool grinders to grind the high quality tools our customers demand. ANCA software provides the versatility needed to develop engineered cutting tool solutions."
While the Asian market has been estimated to be responsible for approximately one third of all aircraft production during the next 20 years, many of the components for those aircraft will be manufactured in the United States. Airbus, for example, apparently plans to double the $US12 billion it currently spends with suppliers based in the United States. Europe is also the base for many Aerospace suppliers, with the Airbus A380 an example of how an aircraft is often manufactured from parts made globally.
Major structural sections of the Airbus A380 are built in France, Germany, Spain and the United Kingdom. Due to their large size they are transported by a complex system of specially built ships and barges and on modified roads. Components for the A380 are provided by suppliers from around the world such as Rolls-Royce and General Electric.
The Boeing 787 Dreamliner is also made from components purchased from global suppliers. In 2012, Boeing purchased approximately 75% of its supplier content from U.S. companies. On the 787 program, content from non-U.S. suppliers accounts for approximately 30% of purchased parts and assemblies. Spirit AeroSystems is one of the many suppliers helping to build the 787 Dreamliner.
These are only two examples of the many commercial and military aircraft that are now beginning to use more composite material in their designs.
Composite materials account for 25% of the structural weight of the Airbus A380
Certain features on the ANCA machines assist the customer's ability to achieve tight tolerances. These include the polymer concrete base which reduces vibration, the MPG Feed will allows the operator to safely step through new programs on the machine, the CIMulator3D software and improved usability in ToolRoom 2012 software. These type of features are particularly important in demanding industries such as Aerospace.
As demands for new aerospace materials are made so they are lighter and more durable, demands are also made on tool manufacturers who have also continued to innovate. ANCA tool grinders used by tool manufacturers have continued to provide the power, versatility and precision required to grind new tooling solutions.
ANCA has continued to invest significantly in Research and Development and in additional resources. This has resulted in the release of new products such as the MicroPlus work holding and tool support system which reduces runout to less than 3 micron. Also the new MX5 tool grinder and other new machines which are in development. This can only be positive for Aerospace industry suppliers where more change is expected.
2 March 2013