Aircraft Aluminum A-Frame in one shot

Process an Aircraft Aluminum A Frame in one operation with 5-axis cutter compensation, dynamic pocket milling and 5-axis wall finishing.

Aluminum A-Frame - one shot

Aluminum A frames provide stability for wing components in commercial aircraft. Machined from 7074 or 6082 aluminum, these structural parts include complex radial wall features and require tight tolerances. The typical production approach uses two operations – one for each side – with the workpiece mounted on tombstone fixtures.

Our customers have expressed a desire to produce the component in one operation.

Reduction of this process to one operation on a 5-axis machine tool would increase throughput and optimize production of this high-volume, high-value part. However, the demanding features of this part and the high amounts of material removal required to produce it make it difficult to fixture and machine on multi-axis equipment. Additionally, a one-operation approach would reduce tooling use if the process can compensate for the size of reground tools.

Aluminium A-Frame component

In collaboration with trusted partners, Seco developed and demonstrated a one-operation approach that machines this part on a multi-axis machine tool with a single fixture and 5-axis compensation. The process adds sustainability, with the ability to regrind and reuse tools up to four times. Reduced cycle times and energy use also promote sustainable production. Automation and advanced programming make dynamic pocket milling and 5-axis wall finishing easy to accomplish with fewer tools. Simulation through digital twins provides proof of concept prior to the cut.

The ability to control cutting diameter for circumferential finishing enables this process to achieve repeatably accurate geometric tolerances. This is essential to meet part specifications and set up automated production for potential lights-out manufacturing.

Challenge 1: Produce aircraft frame component in one operation with 5-axis cutter compensation

Challenges:

Achieve feature access for a demanding, complex aerospace component in a single operation.
Combine two separate operations for the front and back of an aircraft frame into one operation on a multi-tasking machine.
Maintain part stability throughout roughing with high material removal rates in one operation for a high-volume product.
Optimize the operation for the machine, aircraft structural component and fixture through digital twins.
Collaborate with partners to ensure dimensional accuracy of demonstration part.
Apply through-spindle coolant to enhance the cut and manage swarf from aluminum and aluminum alloys.
Increase sustainability with fewer operations, fewer tools and less energy usage for a high-volume product.
Adjust 5-axis

The Seco Solutions:

Collaborate with partners to demonstrate one-operation production before prove-out for aerospace manufacturing.
Use virtual design and operation simulation to verify demonstration part before the cut.
Produce high value, high-complexity aerospace component in one operation with 5-axis machining.
Collaborate with partner to develop a fixture that provides access to both sides of the part for 5-axis machining.
Design part with snap-off tabs so it removes easily.
Reduce cycle times with single-operation machining to increase sustainability.
Increase material removal rates to boost part output.
Meet demanding specifications with reground tooling.
Enhance production efficiency for high-volume durable aluminum aerospace component.

Challenge 2: Produce A frame component with dynamic pocket milling and 5-axis wall finishing

Challenges:

Maintain tolerances on radial geometry of 5-axis wall features.
Increase production efficiency and accuracy.
Minimize human intervention in production.
Produce precise aircraft part with reground tooling.
Compensate automatically for size of reground tools through on-machine probing and CNC software.

The Seco Solutions:

In partnership with Siemens, 5-axis cutter compensation adds circumferential finishing with repeatably accurate tolerances, even with reground tools.
Siemens control system command "CUT3DCD" activates 5-axis cutter compensation in programming for accurate part geometries.
Tool reuse through up to three regrind cycles cuts costs and boosts sustainability.
Accurate measuring tools from partner Zoller keep tool usage consistent for automated processes.
Multi-tasking production in one operation reduces the manual intervention and error likely with multiple setups.
Leading Seco regrind capabilities ensure proper dimensionality of finishing tools for demanding application.

ITI demo - Aluminium A-Frame

Products and Partners

Seco ø50 aluminum face mill Cutter body R220.97-0050-X12.4A / H25 insert XPKX12T320PDER-E08
Seco aluminum ripper 20 mm ripper 490V200R050Z3.0A-MEGA-T / 12 mm XHEAD XSE450 E12120D2R050Z3 AXT
Seco pocket milling Solid end mill S4531-160E2R400.0Z3 AXT
Seco outer profile milling Solid end mill S4531-160D3C.0Z3 AXT
Siemens CNC control with NX CAD/CAM
Siemens "My Virtual Machine" digital twins
Heller HF3500 5-axis machine tool
Heller fixturing solutions
Renishaw in-process probing
Zoller tool measuring system

Collaborative Partners:

Heller
Siemens
Renishaw
Zoller

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