Near Dry Machining of Aluminum

Work has begun on the evaluation of the readiness of near dry machining technology for production use on three fronts:

1. Long-term tests are in progress for durability, reliability, sustained accuracy and productivity, and part costs. A run of 10,000 parts has been completed using near dry technology only; a run of 10,000 parts is underway using a combination of near dry lubrication and vacuum chip and vapor evacuation technology. Finally, for comparison, a run of 10,000 parts will be made on the same machine tool using conventional wet machining. The part is an engine mount bracket made from A319 aluminum. Operations include drilling, tapping, straddle milling, and face milling. MEI, a project participant and a Tier 1 supplier to the automotive industry who operates and maintains the machine tool, is conducting the tests on a machine tool built by Horkos. Data will include the quality parameters Cp and Cpk, tool wear measurements, spindle torque, tool consumption, maintenance and repair logs, and part costs and chip sales for the three operating modes.
2. A plant floor production study of near dry machining technology is also being conducted using two side-by-side machine tools. Both machines produce the same transmission housing extension part, which is made from A308 aluminum. Operations include drilling, boring, milling and tapping. One machine tool, which is the same as the machine tool making the bracket part, is set up to run with near dry technology only. The other machine tool uses a conventional flood of metal working fluid. Data recorded includes machine up time, tool life, part quality, cost and environmental impact. Both the machine tools successfully completed a 75-piece run off as well as a 300-piece reliability run prior to installation at the Ford Livonia Automatic Transmission plant. After installation, the 75-piece run off study was repeated on the plant floor. Quality figures for Cpk ranged from 1.76 to 5.21 for all significant part features. The minimum Cpk is 1.67. Production parts are now being machined and sent to transmission assembly. At the completion of the pilot study in March 2002, a report will be issued comparing the relative performance of the wet and near dry machining process for the extension housing manufactured under typical production conditions.
3. The third front is principally concerned with productivity. The goal is to demonstrate a combination of technologies that will cut the cycle time for producing parts such as the extension housing by a factor of two. These technologies include near dry lubrication of cutting, linear slide drives, advanced multi-part fixturing, optimized tooling and the opportunity for robotic load/unload. The demonstration machine tool is being built by Ex-Cell-O and is scheduled for run off in late November. The plan is to validate reliable performance in the lab, then install the machine tool system in the Livonia plant following the same sequence as outlined in Item 2. The major result will be an evaluation report of all the technologies.

Further project information is available from Jack McCabe (734-995-4919).

Projects Seek Participants

Retrograde Parts Identification Using 2^nd Generation Marking and Reading Techniques 

The USAF Aging Landing Gear Life Extension (ALGLE) Program has agreed to host the project definition meeting at OO-ALC, Hill AFB, Utah on December 6, 2001.  The meeting will start at 8 am and adjourn at 4 pm. 

Government and industry parties who responded to an earlier project announcement have crafted four program objectives:

1. Develop robust marking methods that will survive harsh operational conditions and overhaul processes (during and after manufacturer).

2. Design, manufacture, test, and commercialize a family of portable part identification marking devices designed to mark parts in the field (both installed and uninstalled)
3. Develop portable reading devices that can be used to image and decode symbols that have been discolored, contaminated, or coated over with protective coatings and paints.
4. Assure compatibility with data interface standards to AIT and MIS systems.

Robotic Vision Systems, Inc., (RVSI) is the lead industry participant.  RVSI is a leader in the marking industry with an extensive background in selecting marking technologies for specific applications and establishing industry standards.  Three dimensions of investigation have been identified.

• Dimension 1 - Mark aircraft parts using portable markers and subject to in-flight testing.  Evaluate marking processes and optical readers.

• Dimension 2 - Develop robust markings methods that will survive harsh operational conditions and overhaul processes. Aircraft landing gear parts will be considered the primary application. Process marks through overhaul processes and conduct material tests for marks. Evaluate optical and RTP readers.

• Dimension 3 - Mark turbine engine parts. Conduct material test, and subject markings to engine run tests. Evaluate optical and  RTP readers.

Data resulting from these investigations will be shared among all participants.

If you are interested in attending the meeting at OO-ALC, or want more information, contact Gary Burkart, 612 839-4567.

Reconfigurable Tooling Systems for Depot Level Parts Repair

Just as it takes a tool to manufacture a part, it takes a tool, often an identical tool, to repair the part. Reconfigurable tooling systems consist of a state-change material that can be cycled from a liquid-like state to a solid state resembling a ceramic in order to make a tool from an existing part or master model. The state change is accomplished at room temperature without any change in volume. The resulting tool can be used with conventional repair techniques consisting of furnaces, autoclaves, etc., to accomplish the repair of the part, or it can be combined with integrated heating and vacuum to become a complete system for parts repair.

Often in a facility, only a limited number of parts can be repaired because of the need to maintain an inventory of unique tools for each part. With a reconfigurable tooling system, a unique repair tool can be created for each use utilizing either a master model or an identical good part. The time to create the tool is on the order of minutes. With the repair complete, the tooling bed can be returned to its liquid-like state within minutes to be used again for another repair.

A project is proposed with the following objectives:

Surface Finishing Facility Design Guide

A Manufacturer's Guide to Surviving a Down Economy - A NCMS Networking Event

On November 13, NCMS will be hosting an event at its Ann Arbor office. The objective of the event is to increase the awareness of the benefits of becoming an NCMS member.

The theme for the event is: A Manufacturer's Guide to Surviving a Down Economy and the featured guest speaker is Rich Pearson from Ford Motor Company.

Schedule of events:

Breakout sessions will include: Government Services (including the CTMA program), Community Services, InfraGard Manufacturing Industry Assoc., Manufacturing Alliance, Educational Services, and Manufacturing Services.

Register by calling 734-995-7962 or via e-mail to Beth Bolog.

New Project Ideas (click on topics to see descriptions)

We appreciate your feedback. Please contact Chuck Ryan with suggestions or input on other topics that would be of interest to you in this newsletter. The CTMA Program is sponsored by the Department of Defense; the content of this newsletter does not necessarily reflect the position or policy of the government; no official endorsement should be inferred.