AEROSPACE SUPPLEMENT
PRODUCTION CASE STUDIES
spark and wire erosion, the arrival of the
Sodick ALC600G wire EDM and AG60L diesink
16
EDM will underpin a number of important
contracts across both the civil and military
aerospace markets.
Established in 1978, Excel Precision
Group operates from two modern facilities in
Gloucester and Leeds, which together house
over 30 CNC wire and spark erosion
machines.
“Few EDM subcontractors have both
AS9100 and NADCAP approval,” states Steve
Batt, operations director at the Gloucester
facility. “This level of process control allows
us to serve an extensive number of
aerospace and defence customers. In
addition, we currently hold company approvals
from BAE Systems, Rolls-Royce, Goodrich,
Safran Landing Systems, Dowty Propellers,
Messier Dowty, MT Satellite, GE Aviation,
Moog Aircraft Group, UTC Aerospace
Systems, Mettis Aerospace and Triumph
Actuation Systems.”
Along with the need to replace older
machines, part of the reason behind the
company’s investment in Sodick technology
was due to the imminent ramp-up of an
existing defence contract that is currently
scheduled to run until 2022.
“We looked at both Sodick and our
existing supplier of EDM machines, but the
test cuts provided by Sodi-Tech EDM were
simply better,” Batt says. “In particular, the
surface nish produced by the AG60L spark
eroder really caught our attention. Due to the
presence of debris, some machines struggle
to replicate the surface nish achieved on the
sides of parts on the bottom face. However,
this proved no such issue for the AG60L.”
The AG60L has been set to work producing
a variety of aerospace parts, including
stainless steel actuator components. In total,
the aerospace sector commands about 40%
of the machine’s time. The other Sodick
machine, the ALC600G wire EDM, has around
50% of its output sent to aerospace
customers, including the titanium defence
part mentioned.
“Compared with our old machines and
process, using the ALC600G has transformed
our operation for this component,” Batt
highlights. “For a start, we previously needed
two machines, whereas now the part is
completed in its entirety on the ALC600G.
Also, our old machine would only achieve a
90% pass rate on an angled face with a 5
micron tolerance. With the Sodick machine,
the pass rate is 100%. That step-up in quality
makes a real difference on high-value-added
parts such as these.”
He concludes: “We’ve not had Sodick
machines at Excel since before 1995, but
we’re very pleased to make the switch back.
The technology has moved on considerably
and we cannot fault the machines or the
team at Sodi-Tech EDM, who have been very
supportive since installation in early 2019.
Through our own mistake, we once accidently
set off the re extinguisher on the AG60L, but
the response was excellent and we were back
up and running the next day.”
ITC sets Widia tooling to work at
aerospace fi rm, delivers welcome
benefi ts
With a host of 3- and 5-axis machine tools
from DMG Mori (https://is.gd/equmos), Mazak
(https://is.gd/otocah) and Hurco (https://is.gd/
utebev), a Preston-based company has
bene tted from the technical expertise of
Industrial Tooling Corporation (ITC, https://is.
gd/etamit).
The aerospace rm boasts accreditations
from OEMs like Airbus, BAE Systems,
Leonardo, Gardner, Magellan and many more,
and challenged ITC with the task of improving
productivity on an aluminium solid billet subassembly
for the aerospace industry that
initially saw competitor tooling used.
Working against the other rm’s 50 mm
October 2019 www.machinery.co.uk @MachineryTweets
xExxxcxexxl xP xrexcision has opted for
Sodick EDM technology
ITC put Widia tooling to work at a leading
aerospace fi rm, scoring multiple benefi ts
Innovative Performance
The E Series Concept
Combines conventional, manual
data input and CNC versatility
within one machine and control
system
E30/E40/E50/E60/E70
Apprentice, vocational training
• Machining of
simple/complex components
E90/110/120/150/175
Oil and gas industries
• Robust design for precision
and stablility
• Multiple tooling turret options
• Large spindle bores upto
580 mm diameter
• Automated cycles fast and
simple communication
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Kyal Machine Tools Limited.
Foundry Road, Stamford,
The Settling Rooms, Springfield Street.
Lincs. PE9 2PP
Tel: 01780 765965
Fax: 01780 765877
MARKET HARBOROUGH
Leicestershire LE16 8BD
Tel No. 01858 467182
e-mail: offi ce@kyalmachinetools.co.uk
e-mail: simon@kyalmachinetools.co.uk
/equmos)
/otocah)
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/www.machinery.co.uk
link
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