RUAG: Engine manufacturing concept improved
The Swiss Company RUAG Aerospace invested in new Deckel Maho machining centres for combined milling and turning of the engine housing in one clamping position, thus realizing an essential part of its supply chain. The complete manufacturing process of the forward and aft fan case including assembly was relocated to Emmen, while the machining of the acoustic panels continued as before.
RUAG is still committed to optimizing its supply chain, while meeting demanding standards, and is continuing to invest more than ever in the latest machining centres in the engine manufacturing market for customers such as General Electric, Airbus, Boeing or Saab. A further example from Emmen is the delivery of the complete assembly group of an A380 wing section.
Since 2000, RUAG has been manufacturing complex components such as core components and acoustic panels in Emmen for short- and medium-range aircraft engines. The Chinese regional jet programme offers further sales opportunities and the huge market success of Embraer engines alone has led to an increase in production from 140 to 250 units per year. The optimization of the machining technology significantly improved the entire engine manufacturing concept. The RUAG production site in Emmen has developed into a site of excellence for the high-tech machining of titanium, hard metal and aluminium, making it possible to increase production figures as required.
Gildemeister AG, with its Aerospace Center of Excellence at Deckel Maho in Pfronten, Germany, supplies the milling/turning centres. The future in the two centres of excellence started with their joint commitment in engine construction. However, the successes of the Aerostructure specialists did not come easily. Despite all endeavours, the devil is in the details and in the parts to be machined. 95% of these parts consist of aluminium alloys. The remainder are made of high-quality steel and titanium alloys.
The 30-strong machining team predominantly work on the two Deckel Maho milling/turning centres DMC 200 FD. The gantry machines, with NC swivel type milling head as the B axis, have a motor spindle with HSK-A100 milling and turning tool holder, 44 kW, 10,000 rpm and a unique balancing cycle to guarantee the concentricity of the parts machined on the pallet. The milling/turning table with torque motor and 1,850 mm diameter has a maximum rotational speed of 200 rpm. Traverse paths of 1.8 x 2 x 1.1 m (X/Y/Z) are excellently suited to the workpieces machined in Emmen.
Team Manager, Markus Graber, recalls: “After comparing our requirement specifications with five rival machine tool manufacturers and following extensive test machining, we ordered two machines of the type DMC 200 FD at the beginning of 2006. The requirement was to save at least 10% of costs with the new machines. The DMC 200 FD fully met our requirement specifications both with regard to the good test results and its equipment featuring 5 axis simultaneous milling and turning in one clamping position, milling and turning tools with diameters of up to 250 mm and lengths of up to 450 mm, and short make-ready times thanks to the pallet changer. The DMC 200 FD also convinced us with its balancing cycle, its high degree of machining precision, and its simple installation without the need for foundations, thanks to its inherently stable machine bed with 3-point support.”
RUAG also ordered the options: Torque support, electronic measuring probes and the Siemens 840D’s SINTDT tool management system. In addition, they ordered the 120 tool magazine with HSK-A100 tool holders, the Blum laser tool measuring system in the machining compartment and the 2,500 litre temperature-controlled coolant lubricant system. With the CNC option “3D quickSET”, the axis precision in the compartment can be quickly and easily checked and restored. Today, Markus Graber can smile about their initial uncertainty: “The delivery of two DMC 200 FDs in the autumn of 2006 represented a huge leap for the team.
We had to optimize the NC programs right from day one with the assistance of the specialists from Pfronten, and start production immediately. Now, both DMC 200 FDs are in three-shift operation with a technical availability of 95% as agreed. These results are due in particular to the Deckel Maho gantry concept, with its crossbeam driven on both sides, and the exceedingly rigid B-axis milling head. The version with pallet changer and two pallets for a load of 3,000 kg each fulfilled our expectations right from the start. The concept of a large, inherently rigid machine permitted unusually fast installation and particularly favourable machine arrangement for multi-machine shift operation. The evidence of quality conformance is documented by the extensive 100% test in separate areas according to the mentioned certifications.
The use of state-of-the-art milling and milling/turning technology is one of the key components of success, for RUAG in Altdorf too. It operates two larger DMC 340 FD gantry milling/turning centres and a DMC 200 FD from Deckel Maho, in addition to those in Emmen, for manufacturing varying quantities of large precision components. The other prerequisites for achieving good results are a highly skilled workforce and a professional training programme. This particularly applies to the important Swiss contribution to the development of the booming aviation and aerospace industry.
German Summary
RUAG Aerospace investierte in neue Deckel Maho Bearbeitungszentren für das kombinierte Fräs-Drehen der Triebwerk-Gehäuse in einer Aufspannung und realisierte damit einen wesentlichen Teil seiner „Supply-Chain”. Die komplette Bearbeitung des Forward- und Aft Fan Case bis zur Montage wurde an den Standort Emmen verlegt und die Bearbeitung der Acoustic Panels wie bisher vollständig weitergeführt. Mit der Optimierung der Zerspanungstechnologie wurde das gesamte Triebwerks-Fertigungskonzept entscheidend verbessert. Ein reibungsloses Hochlaufen der geforderten Produktionszahlen ist damit gewährleistet. Der RUAG-Standort Emmen entwickelte sich damit zu einem Kompetenzzentrum für die Bearbeitung von Titan, Hartmetall und Aluminium. Der deutschsprachige Beitrag ist nachzulesen auf www.aerotec-online.com
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