CNC Machines Enhance Product Quality and Improve Efficiencies

Contract aerospace manufacturing is very competitive. In order to stay competitive several things need to happen. You have to be willing to invest in modern equipment, have continuous staff training and improvement initiatives and have a powerful integrated ERP/MRP  systems. Intrex recognizes that CNC machines enhance product quality and improve efficiencies. Our  investments in equipment and software systems address several key aerospace manufacturing requirements: part accuracy, process repeatability and uniformity, production scheduling, all interfaced with quality process and documentation support.

These strategic considerations are evaluated while planning  future needs. At Intrex Aerospace we evaluate  the factors mentioned above to achieve our goals of providing precision components with on-time deliveries.  Foundational to meeting our goals is having  precision CNC machines and a powerful Epicor ERP/MRP system. We continually make significant investments in advanced CNC technologies. As a contract aerospace manufacturer we recognize that CNC machines are indispensable to our success. Having modern CNC machines, coupled with an experience engineering and machining staff is part of our successful formula.  The combination ensures  end products of the highest quality, that can be delivered on-time.

What are CNC Machines?

Computer Numerical Control (CNC) machines are machine tools that are given instruction via a computer controller. They come in different configurations and sizes, depending on the machine type. Intrex has multiple configurations of CNC machines that are used for metal removal and measurement. They include lathes for turning, mills (both vertical and horizontal) for milling and  machines with combination capabilities for performing  both turn and mill functions. Several of the CNC mill/turn machines can machine up to 5 axes simultaneously.  These machining operations include: turning, milling, drilling, tapping, and in-process gaging, all performed with high degrees of precision and repeatability. Prior to introduction of CNC these operations were performed on manual equipment, with a strong dependence on operator skill. Accuracy and repeatability were difficult to achieve on non-CNC machines, due to multiple setups required resulting in tolerance stack-up and frequent operator intervention, adding to repeatability issues.

How CNC Machines Help Improve Quality

Accuracy

Machine movements (slide movement and spindle speed) are achieved by sending electronic instructions through the CNC controller to the spindle for RPM control and to the servos that control slide or turret  movement. All instructions are looped back to the controller, in a closed loop system. This programming loop confirms  instructions are received and confirmed to the correct slide position and spindle feeds and speeds.

Repeatability

One of the many advantageous of CNC machines is that it can repeat the same speeds and movements over and over, producing parts to the same size, shapes, finish, and tolerance.  Once a production part has been through the initial setup-measure-offset process,  it repeats. In aerospace, part uniformity with minimum deviation from part-to-part is mandatory. Using CNC equipment, no longer is operator skill level the key driver for machining precision parts. Operators may perform many important tasks but  the accuracy and repeatability of the parts, is largely determined by the CNC machine.

Flexibility

As a contract aerospace manufacturer, one of the machine elements that is desired is flexibility. Change  in customer supply chain schedules is the norm, not the exception. Many times production schedules move in and move out with  short notice. Even with this ongoing shuffling of part scheduling, our customer expectation is still provide parts deliveries  “on-time”.

The moving of schedules in and out presents multiple challenges that need to be addressed in order to meet expected deliveries: securing needed raw material, setup flexibility, shuffling  and balancing machine schedules, arranging special outside processing, etc. Having multi-purpose CNC equipment with adequate tool stations capable of turning and milling, simplified work-holding, gives a great amount of flexibility for meeting this ever-changing scheduling challenge .

The machining platforms for CNC machines were designed for  accuracy and flexibility. Some of the most popular CNC platforms are:

Turn & Turn/Mills – Multiple Configurations

• Multiple tool stations capable of holding different tool types and performing different machining operations (turning/drilling/boring/roughing/finishing)
• Many CNC lathes have multiple turrets (2-3 turrets) giving machines tool redundancy and in-process gaging capabilities
• Twin spindles with multiple turrets gives the ability to machine from both spindles simultaneously and transfer the work piece from one spindle to the 2^nd spindle without operator intervention
• Turn/Mills with fixed turning and live milling stations
• Turn/Mills w/Automatic Tool Changer (ATC) giving additional tool storage capacity outside the machining zone. Allowing for single setup for “families” of similar parts, greatly reducing setup numbers and setup requirement/per part
• Automatic tool touch setter for automatic tool offset. Offsets can be programmed internal to the machine cycle

CNC Machining Centers  (Vertical & Horizontal)

• Large tool storage capacity for storing tools with multiple operations, or redundant tools for “families” of parts
• Multiple pallet configurations. Some pallets can be configured for multiple parts
• Automatic tool touch setter for auto tool offset internal to the machine cycle
• Automatic gaging for part measurement
• Multiple pallet pools or pallet stacking system for part and fixture application

CNC machines for the reasons listed above give the contract manufacturer a better means to respond to ever changing customer schedules. It gives flexibility. With the expansion of CNC control capabilities the list of what is possible is growing and ongoing. The greater level of technologies applied usually have common purposes of: decreasing direct operator intervention, maximize  higher spindle utilization, give better control of  monitoring the machining process, which improves overall machining efficiencies.

Quality Control

Quality is essential in producing aerospace parts. At Intrex Aerospace, quality drives  production. We are ISO 9001 and AS 9100 certified. We implement Total Quality Management (TQM) as a process improvement methodology. Through TQM we identify effective strategies for continuous improvement. Intrex has quality management professionals trained and knowledgeable in total quality management. In addition  to our CNC cutting machines, we also employ CNC coordinate measuring machines (CMM) on our shop floor and in our quality lab. This technology utilization provides higher levels of part accuracy and process efficiency.

Conclusion

At Intrex Aerospace, keeping up-to-date with CNC  technology and merging it with customer needs and staff resources is ongoing. Continuous improvement of products and deliveries are a given. CNC Machines Enhance Product Quality and Improve Efficiencies. We are committed to our customers.

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