Re coy SANT a ss RU ag a0 A=ROSPAC= MANUFACTURING and DESIGN Ce UR ue ee cee TECHNICALLY SWEET SOLUTIONS =eagatte & eas a if Pe, New Products i we Ao ENE Ba a US Cea avd eS ee amiesoaring high above the clouds Flight tested daily...turbine components machined on Blohm and Magerle grinding machines perform flawlessly. More than machines, United Grinding provides total grinding solutions for the world's leading manufacturers of jet engines and ower generation turbines. Ask us about our aerospace grinding technology events. @ UNITED GRINDING 510 Earl Boulevard, Miamisburg, OH 45342 Phone: 937-847-1214, Fax: 937-859-1115 ST aHIGH PERFORMANCE SUPERSIZED INTRODUCING OUR LARGEST HORIZONTAL EVER Oe SX Aes! ee Larger-than-life performance for large-part production. LEARN MORE AT www.toyoda.com/FH1250SX or 847-253-0340 TOYODA ENGINEERING A BETTER WAY FORWARD eee ewerASROSPAC= jan/feb 2008 Aaa) ONLINE 8 TAKEOFF 10 FROM THE FLIGHT DECK 16 84 AVIATION APPRECIATION 18 NEWS YOU CAN USE Waza’ Investment in People, Technology 20) Delivering Socially-Responsible Machine Tools. FEATURED PRODUCT 54 TECHNICALLY SPEAKING Hydraulic Coupling Testing ‘Accomplishes Quality Goals 40 Viscoelastic Materials, MWCNT Enhance Composites REFERENCE GUIDE rowing in a Demanding Market 86 : i 48 Tombstones, Plates Aid Increased Aero Productivity ON THE RADAR EXPERT OPINION 56 VLis: The Future of Commercial AviationintegralBoxways HighTorque Spindle B-Axis DO ) : ] Doosan Infracore Financing available through Doosan Global Finance www.infracoremt.com Corporate Office & Technical Center: Midwestern Technical Center: ikGrove Vl Wester Technical Cente DIA Engineering Center: 14 Call your local Doosan distributor for information, IT TAKES A DOOSAN TO CUT TITANIUM Machining titanium, or any ofthe space-age, high strength, high temperature materials, takes ‘ machine with exceptional power, precision and rigidity - characteristics found in the HM horizontal machining centers from Doosan. 8" wide, hardened and ground boxways that withstand the heaviest cutting forces, and. fine-grain meehanite casting to dampen vibration combine for an ultra-igid platform, Beaxis movement supported by triple oversized roller bearings that provide greater rigidity and a large diameter hydraulic brake that resists ‘movement, even at the extreme ends of the X axis, provide greater precision. ‘A3-speed gearbox that generates up to 11250 ft/Ibs of torque over a broad speed range generates all the power you'll need, The result is the HM series of machines that takes heavy cuts in tough-to-machine materials, and delivers higher productivity, greater precision, and superior finishes. fee i AGASRUS PATS asa le f TECHNICALLY stu, Bran 62 re shop thrive ac building the tly impossible” components BEYOND BAGGAGE non ther are en 66 andthe eco of be indy CHASING THE MICRONS OF ACCURACY 70 DIX produces extremely high-accuracy machines, which require hours of hand-scraping precision, IS ONE GRADE ENOUGH? Comte rinageuiiectdentste | 76 right combination of productivigy and reliability. SPECIAL SECTION EIR Tees econ arkforce Developmenta | E. | \ Bel eats) a Col) é . We're thé first choice in aerospace manufacturing. 4 od om ~~ Visit www.SiemensCNC.com today and click Case Studies. s Energy & Automation iCer me oe PC eISI Nee ie Rm Ua Cn ics discussed in the magazine, as Peete men Caeser ei mCs our online readers. The user-friendly web- Reet ia MCR Renna mY Tene ee Mecee Ie M R Comal Caen) Gem eRCrOnmccehOrcaa CnC Lce’ A=ROSPAC= CNY WereThree brands, one company, one goal: to increase your productivity. For every component and all types of materials, we offer the most comprehensive and applicable tooling combinations to ensure machining of the highest efficiency. We've joined forces to guarantee you more productive processes using the most advanced standard and special tools for turning, drilling, threading and milling. So cut your procurement load and boost your pro- duction: get one supplier, one contact and one invoice with The Power of 3. PH: (800) 945-5554aise Nioa a SWEET SOLUTIONS Pe eee er ee ee to find out how Brazilian aerospace machine shop Toyo Matic routinely completes near-impossible tasks. SI a eon a clients in the Americas, Europe, and Asia, Toyo Matic takes on projects that other machine shops have Cee a nee eet Sr Ee Ree ie Ia Ce nm Ree ec Ce ete Ua eae geen a) Ree eae ema ERJ-170/190 aircraft into a simpler monolithic unit, it proved to be anything but simple to make. Belmont’s Turn-key EDM Drilling Systems With over 4 decades of industry knowledge, Belmont can provide more efficient EDM manufacturing solution tha result in long-term savings ‘and better return on your investment. Our Tur-key Systems reduce start up times, eliminate on-site problems and allow you to start production faster. Belmonts one source process delivers your ‘complete sytem from start to finish, including Breakthrough and Shaped Hole technology Project design and engineering DNR coed Cee ond Pee ee Ce OC eT) Cee en Aw Le ‘rom graphite and tubing to siners. Contact us today for more Information on how our single source systems can hep you Paseo roo) Leer ma eens eee ee ee ee eredmiata deceived rue postoning ABSOLUTE PERFORMANCE “We use the Johniord DMC-1500H double column machining center in our small pars and smal engine uit. Were doing everyting ont single pointing nickel to sie, grinding, deburing and ckcular interpolation of threads. The Jtnord is ighly accurate, reliable, and gives us the fexbilty and capabites to go afer ational work. And Absolute's suppor is excelent which was very important ous. nthe scat repair business, we have tobe sharp and offer excellent quay so we can compete {and stayin the game. Has the Johnford DMC-S00H been a good investment for us? Absolutely I's a great machine ‘Andrew LaTourette, General Manager Component Repair Technologies, inc., Mentor, OH Pera | ABSOLUTE MACHINE TOOLS, INC. SB 7420 Industrial Parkway » Lorain, OH 44053 "ECOCA Phone: 800 852.7825 » Fax: 440.960.6918 E-mail: AMTsales@absolutemachine.com www.absolutemachine.comTAKEOFF ULTRA-HIGH-SPEED SCANNING TECHNOLOGY YIELDS FASTER THROUGHPUT Manufacturers, retrofitting ¢x- isting CMMs with Renishaw’s Renscan5 system and infnive positioning REVO head, have applied the system 0 speed up inspection on some of dhe more comple, time-consuming pats For example, on a jet engine Disk, results consisted of 922% The inspection sequence comprised throughput. improvement. nine sections seans ofthe airfoil profile, eight longicudinal scans of the blade, evo scans of the 1o0t profile, and one scan of the annulus profile, ‘Asa practical matter, conven- tional 3axis CMMs sean at rates of Smmisce to ISmmisce in or- det 10 hold accuracy. This isc avoid high aecfdec rates and rap- id axis changes that can induce inertia errors, causing deteriora- ‘on ip measurement accuracy. ‘The RenscanS enabling tech- nology encompasses a range of breakthrough S-axis scanning products that measure at up (0 500mm and 4,000 data points persecond, while virally eli 1 Blis scanning with Renscan 5 and infinite positioning REVO head ‘and positioning capabiliy. The REVO measuring head performs synchronized Y- and Z-axis mo- tion ta quickly follow changes in pare geometry during inspection routines, avoiding the dynamic ‘ertors caused when moving the larger mass of a CMM struccue. Where X-axis motion is required forthe probing ru moves the CMM ata constant vo- locity along a constane vector as measurements are being taken, removing the acceleration/decel- ‘conventional scanning. nating the measurement erm normally associated with exist eax scanning systems. ‘A 3D measuring device in fas own eight, the REVO head feacures two rotary axes — one Renishew Ine in vertical plane, one in hori- Haffngn Etats IL zontal ~ to give infinite rotation renishaw.com IG De cs eA WORK aSTAWIO Bie R iW Ae hel Miners Mina -sleis f without complicating the structure, This 48" wide workstation is ‘ated to hold 1000 pounds without complicated cross bracing or doubling up on pipes. Buit wth Creform 42mm pipes and joints it demonstrates how you can simplify your structures ‘while increasing capacities and lowering assembly time using Jess components... and possibly less flor space. 4 Creform sales engineer ca help you met your ean ‘manficoring ‘nus for material handling races, == ™ Thread and Form Milling Specialists URN wr me ENDURO Ce oe Te ‘The Problem: “Proprietary, one-of -knd thread form ‘+ Seep taper on form, + Tipe lead hnead «Fall form right and lft hand thre None of your wong vendors can get over “Why? et alone “How? ‘The Solution: ADVENT TOOL. & MANUFACTURING ‘+ Blueprint special in record ‘Complete desig, engineer ‘Complete programming assistance, o cod ‘Thread & form miling tools are all we do _— aes 1-B00-THREAD 4 and manufacturing in-house 847-549-9737 «TAR BAT 549.9714COMMONSENSE SAYS THAT THIS IS ABOUT AS LOGICAL AS A SERVICE VAN WITHOUT AN INVENTORY OF PARTS AND TOOLS ON BOARD. [At Haas, we know that the only way you make money is by making chips and that means Keeping your 22s equipment running in top condition. Our Platinum One-Call policy provides dependable, immediate response and expert service to keep you making chips. Through our network of Haas Factory Outlets, we've bult an elite crew of factory-trained and certified service technicians who focus ines, Arriving in fully stocked Haas service vans that have the machine parts, exclusively on Haas n ble to successfully repair your machine the tools and special equipm fist time out more than 90% of , =), FFORNIA, USATAKEOFF MAN-READABLE, UID/2D VISION-READABLE CODES FOR GEARS, COMPONENTS In response to UID/2D codes ig self contained with provisions becoming the required idemtii- for mounting all the machine cation mark for the defense and controls, che marking unit, and aerospace industry, Columbia the hand-held vision UIDI2D. Marking Tools designed and and Square Dot ead. bouilea special marking machine Tye marking unit is stan that places both man-readable dard Columbia DPS (Dot and UID/2D or Square Dot scribe) CNC marker that uses a Vision-readable codes on a vari- unique horizontal CNC stepper ety of gears and gearbox compo- mnocor driven marking spindle, nents, The identification macks esuipped with aheavy-duty bear inchde ovo lines of copy plus 2 ing suppor extended pin hou UID/2D or Square Dot code. A ing to accommodate the varying. third line of vexc ean be included ‘Typical man-eadabe and UD/2D codes placed on helicopter gears. up t 55 Re, A special diamond be incgrated with electronic eam Fer. UID/2D marking pinis available eas for mark verification. CMT if there is available space in the ene parts. The DPS marker cat for marking parts with hardness is a Cognex vision integrator anc prescribed marking location. provide ultra-fast dot-peen maths levels over 55 Re eee |The matking machine design ag wellas Square Dotslent scribe ‘The contol forthe machines wosupply the vision portion of che includesa heavy durywelded steel parks, Marking depth contol is provided by Columbias own PCS. marking system. ‘machine base construction with a adjustable for the preset mark- 20) HMI marking contollerthat master cooling plare mounted © ng area of 200mm x 150mm (4° has heen developed specifically for Columbia Marking Too the top plate for we with che var- x 6°), A carbide marking pin is applying UID/2D matrix codes CheverfeldTonship, MI ‘ous fixture designs. The machine provided for marking materials that require marking equipment to columbiamt.com reach requirements of the EDM AIRFOIL HOLE EVOLUTION SARIX Micro EDM makes short work of complex diffuser hole operations. Now high-quality EDM hole driling is faster, more economical, more accurate. With automated electrode changing and a single electrode diameter for driling round or shaped holes of all sizes, SARIX Micro EDM is less tooling-intensive for high-process repeatability and reliability. Micro EDM features: Complex geometry easily handled by SX-yEDM-CAM-AERO software ‘+ SARIX project design and engineering with onsite operation training + T-axis capability * Breakthrough detection Upgrade to a SARK Micro EDM system, A EIRP a 5 & for long-term savings and better = TREHMOLOGIES, Inc. 7 nat return on investment. UT Td A se te Contract Machining » SARIX Sales and Service » 877 2927719 » Fax 518 697 8092 ~ info@leertech.com4E GEOMETRY INSERTS FOR AEROSPACE ALLOY TURNING ATI Seellram’s 4E Turning si Geometry inserts were de- _wear-resistance in high temper abl ‘of machining aerospace-type longer tool life and higher pro- ificantly improves heac-and signed to meet the demands ature alloy machini components, manufactured ductivity The 4E'5 new precise from high nickel, high cobalt, reinforced chipbreaker profile and titanium-based alloys. with positive curting action P0819, dramatically reduces buile-up 4E Turing Geomeery insers edge, leaving a smooth surface ule an approved aerospace finish and. greater component substrare, and are enhanced dimension integrity. ‘The 4E with a Nano TiAIN layer PVD is designed to machine a wide coating forhigh performance, variety of materials including According to the company, stainless. steels, high nickel, 3 z (ACU sella ney Aes Ae hgh ale ed el ica) 45 UTE Cem) ews wt space Turning Geomewy in- alloys, helping @ reduce shop scrts provide longer tool life. inventory, operator error and improved component quality, cost. and application versatility. ‘The 4B's combination of a ATI Stel new superhard coating with LaVergne, T rmicro-grain carbide substrace azstellnam.com Available in grade ed to meet the demands of machining ENGINEERING * R&D + PROTOTYPING FABRICATION + VACUUM FORMING + URETHANE MOLDING. FOAM CONVERSION ECan aurea Whether it's a simple fabricated In our 150,000 sq. ft. facity, we die-cut piece, a thermoformed part —_ conver! foams in more ways than with various assemblies, or areaction any other company in the West. No injection molding [R.LM.) part that__job is too small or too large. has components embedded in it, we are iruly G one-stop shop. 0: 9001: 2000 Ragtered + ASP100 Cormpiant Visit our website today and see our capabilities: www.foammolders.com + infogeneral@foammolders.com CN eo LR FIS Vetere anmaneciciires MOET RCSLFROM THE FLIGHT DECK It’s time to rethink Boeing’s global manufacturing approach ‘new year gets underway, the aerospace industy ig heading down the runway at fall-throtle, However, dont look for the Boeing 787 ‘Dreamliner to takeoff ths spring as anticipated. Lase year, Richard Aboulafa, an aerospace analyse with Teal Group, an aviation research firm in Fairfax, VA, commented on Bosing’s need to reconsider how it did business in order to compete with Airbus, Eventually, this ed co the supply chain feamework forthe 787, which encompassed getting the development rsk off their books and coming up with killer application. Unfortunately, Bocing’s “killer ap tion’ is eurning out to be a serial Killer, hitting every- thing insight Bocing’ taitional produetion mode was to provide designs for suppliers co follow, a system the company called “build-t-print.” Buton the Dreamline ic asked suppliers ro both design and build theie airplane sections, I dont know who is responsible for this “killer application”, buc ap- pparenelyie was someone who lacks manufacturing and assembly experience With thece million fe of new factory floorspace built, on 135 sites in «wo dozen councties around the world to support the manufacturing of the 787, only Boeing can explain ies rationale in outsourcing components of unprecedented complesty 10 an outlandish amount of supplier. Even worse, these forciga suppliers are not just building to Bocing specifications, they are being, given the fedom and responsibility to design the components and rise the Fands for develop ment costs that are usually shouldered by Bocing itself. This “killer application” has gotten so far ‘out of hand, that even Boeing acknowledges ic fas no idea how many people around che world are working on the 787 project. [ficiency and productivity have always been a the heart of Bocing’s manufacturing problems, and by all indications, nothing has changed. Is been said thatthe 787 Dreamliner is the most complicated plane ever. So, why Boeing would outsource the design and build of components, and think i could bring chem back in-house and assemble them like a set of Lego blacks is des- tind become a cae study in MBA programs ocing’s future may well depend on the successful delivery of the 787 Dreamliner later this year. And while there isan outside chance hat hey can pull i of, time eo consider some alkemative solusions — like standardization cross the entire organization and provid~ ing supersites consisting of supplier Factories $e feof ToM GRasson aSsOr nel onlineaMp PX ele PublsheySales Joseph M. DiFanco,ifanco@ginet ph 830.528.5360 Fac 330.659.4083 Editorial irl iret / sect ubishr Tom Grason, srason@ ent sie3s0's35391 Fr 330.638.0824 Senior tar haba Modi emodiyent pin 3305255348 Assistant tor exh nal anaalli.ee i 30.5235347 ‘sian Eitor KcbeyHgnbothan,Rhigznbotham@ienet pie 330:325.5367 GraphicProduction Crane Director ‘Mark Rok Managing it rector “Andrea Vigs Grape Designer Tames Blaney Diets, Production Helen Derr Aétising Production Coariatar Lt Sala Circulation Diet Celi, Books Database Jam Cis Eitri & Soe toes “1020 Kins Lakes Pho, Suite 201 Richi OF 44286 ph 330523;5400 Fax 330.653.0624 ie Diletetrtramee gee ph; 330.523.5378 Diretr a East Coast Sales Nal). Kelly nkell@ge.nee ph: 610.584.5560 West Cast Sales “Taryn O'Flaerey roflery@ge.net phe 310.545.1367 Account Manager (Christine Zerick, crmich@yi.ne pbs 330.523.5329 Classied Ad Manager ‘Bonnie M. Vlkonya ph 830.523.5822 brelikonyaegienet somerset ees pt sit ee xa oe Eevee ferns ace See ie: GH Al i ere fare i ui ny te gai ae {toy sn een peri ‘Onerear os ences 5 Semaine so 2 en ee ee sibs ge 8 US anh dewnge 2 US Ek Sipepeieuie ‘ort ee Ream ee“Choose a tooling partner that bases its success on yours.” President, ‘Sandvik Coromant, USA Most companies gauge success in terms year by Sandvik Coromant standards. whether optimizing existing machinery or ur Productivity Improvement Programs implementing new equipment ‘and Original Tooling re th vi sts industry’ sto ‘The rapid evolution of the global market we provide to our customers. achieving cost saving: place makes partnerships more important than ever. Choose a tooling partner that With the achievement of over $80 With these tools at our disposal, our is fully dedicated to your success million in documented customer cost Productivity Engineers use their expertise savings, 2006 was a very successful to maximize customer profitabilty Choose Sandvik Coromant Talk manufacturing economies with Sandvik Coromant. We look forward to discussing the many ways that we can work improve your bottom tin gether to .SANDVIK (1:800726:3845 ww coromant sandvik.com/us Your Productivity PartnerAVIATIONAPPRECIATION Aerospace Manufacturing and Design welcomes all aircraft enthusiasts to join in the fun and NAME THAT PLANE! Each issue, a new aircraft will be featured in the Aviation Appreciation section. Given a photo and a clue box, readers are encouraged to guess which plane is being described ‘and send in their answers to the AMD staff Prizes include: Astplace ‘A high-quality model of the featured airplane complete with desk stand and winner's certificate Runners-up (2rd through 5th place) ‘An Aerospace Manufacturing and Design consolation prize. These may be hats, pens, T-shirts, or other exciting products for your enjoyment, Please send your answers via email to: Heather Tunstall, assistant editor, htunstall@gie.net, with “Aviation Appreci tion” in the subject line. Only email entries ‘The entry deadline for the lanuaryFebriary Aviation ‘Appreciation contest willbe February 28, 2008, Have fun and good luck! ‘rove tan one hose uton piss one pu carder year Oue othe wl be een’ by lancom craving Safcaie poeta Phim fegptuanenmicras Sas Santas nal cae Ce egi ast Tae vemets in Austral , Great Britain, Somes oI ER Oe nal ay EStion a eae ene rei ete a) ete td peretin ree re ent on ent Ste ean SM ec ce rs me cur) PECIFICATIONS Height: 1Oft 3° Empty Weight: 2,770 Ib Wingspan: 32ft 9.5" Top Speed: 203mph Length: 26ft 5" ‘ower: One 640hp Bristol Mercury wis2 Engine/Horsep Co es ution, eh ey Ss rier a ea uch roms eg pian once a craedgecam Ze =i, m es) aw xclacodmue ule: of Edgecam... ..and the Yom Ker) Radan & Edgecam fulfilling your CAD/CAM needs together planit PlMAZAK'S INVESTMENT. IN.PEOPLE,, TECHNOLOGY DELIVERING. SOCIALLY-RESPONSIBLE MACHINE TOOLS. Led by muli-taskin integration strategies, axis, and process Mazak ‘Corporationiscontinuingglobalexpansion at a steady pace. Mazak’s philosophy has always been to manufacture machine Yamazaki tools in the major markets of the world and develop a closer relationship with local cuscomers. Supporting the commitment «0 people and manufacturing technology is Mazak's commitment to the industry During a three-day event this past December, “Manufscruring Technologies for Global Muzak announced an industry first. Relocation Competiviveness,” derectors are being installed on all Mazak machine tools being produced ~ detectors will prevent the resale of Mazak machines into countries that are prohibited under ‘export laws of the United States and Japanese governments, “Installation of chese detectors will be on every machine Yamazaki Mazak manufactures,” says Brian Papke, Mazak Corporation president. “We recognize that some potential customers may be reluctant to buy our machines with these detectors in place, but we believe chis industry-leading. action is the right thing to do.” In order for a machine to operate once its been moved or installed, when lives depend on it unique password must be entered. Each time the ‘mach reissued by Mazak, While this technology has been available for a while, this is the first implementation +o prevent violation of expore restrictions. According to Papke, this initiative was launched by Temohisa Yamazaki, president of Yamazaki Mazak Corp., and will apply vo all machines sold by Mazak, no exceptions. InKentucky, Mazak’sU.S. manufacturing is constancly changing under the direction of Ben presidenc of manufacturing. "Right now, we're looking ¢ is moved, the password must be Schawe, vice The AMAMCO Tool Double Margin Drill Peter makes the holes to install aircraft Dishants, Plant Manager engines, landing gear, and door fixtures. Everyone at AMAMCO Tool understands the need to get it right. Every time, Let us develop a tool for your critical drilling application. The state-of-the-art AS/RS is capable of handling up 10 50,000 rpair part numbers. The part cll conor has been strengthened with an integrated order entry system and additional parts specialists.Mazak ven nea assombly: Modular assembly speeds completion of Nex vertical machining cen ters at Mazak’s Florence, KY manufacturing plant. to increase production,” Schawe says. “We already have _Production-On-Demand, our pull-through manufacturing system. Were evolving On-Demand. Our goal is to maintain the same excellent quality, the same efficiency, ‘now to High Production- yet increase the number of machines wee producing in Kentucky for U.S. customers and for export.” The newest investment in production equipment is the massive double-column Mazak Versarech 140. N wich a 122" x 393" table — improving machining productivity for bases, columns, and other large machine members. Wich a nutati head that includes B- and C-axis positioning ‘ona 50hp spindle, the machine will increase processing productivity 50%, GROWING TECHNOLOGY Impacted by installed machines as well as regular Mazak’s North Pares Center in Florence received an everinereasing base of product introductions, Americ new investments as well. The heart of the Parts Centeris the state-of-the-art $2 million automated storage and retrieval system (AS/ RS) capable of handling up to 50,000 repair part numbers. The parts eall center has been strengthened with an integrated order entry system and additional parts specialists. And the module exchange program bas expanded ip news you can use A to not only include remanufactured spindles, but ATC, cool turrets, and more. With a centtally-located inventory of more than $50 million in parts, Mazale can continue to ship 97% of parts orders within 24 hours for every Mazak machine ever installed in North America, Mazak maincainsa domesticinvencory in excess of 46,000 parc numbers including everything from ballscrews, linear guides, motors, and spindles to the smallest non-critical items including commercial parts. A. + Bee Machine Sold Moding and Machining + MTs Machining + Tomttone Machinng + Wire EDM Easier Than RCD Surface models Solid models. Figuring cut how to program complex part eomecry-ike 2 wheel for the Mars exploration Rover-can be challenging Figuring out your CAM system's interface shouldnt be rocket scence, though CGIbbECAM provides the capabities you need to program complex pare geometry with an ntlve, easy-to-use graphical usr interface. And GibbsCAM's data exchange capabilities ensure you can read in part data from just sbout any CAD system, ‘Are you vp forthe challenge of today’ part designe? Contact us and we'll show you how you canbe with GibbsCAM, the industry’sexse-obuse leader With GitbsCAM, you dont have tobe 2 rocket scentist..unlss you are one! GillisCAM Povetully Simple, Simpy Povert Mars Rover whee! machined by GibbsCAM customer Next Intent for NASA Jet Propulsion Laboratory Gibbs and Associates 1-000-654-9399 tp /amd.GibbscAM.com WESTEC See GibbsCAM 2¢ Booth #3268A news you can use MORI SEIKI ANNOUNCES PASSING. OF YUKIO. MORI ‘Yukio Mori former president of Mori Seiki, dustry for over five decades. Mt. Moris son, passed away on November 19, 2007 at the Dz. Masabiko Mori, currently serves as the age of 75. Mr, Mor leaves behind an im- president of Mori Sek presive legacy, having joined the company During his tenure at Most Seiki, Me in 1954 and served the manufacturing in- Mori was renowned for treating his employ- Innovations in Aerospace Machining HBZ AeroCell {© compact horizontal machining 1 palette changer 79 in x 158 in (2m x4 m) © 142 HP spindle power, 30,000 rpm ok PBZ HD IB flexible clamping system {® up to 550 in'/min chip removal [& flume chip evacuation systems | 60 HP spindle power, 30,000 rpm GANTRY TS 1m two independent spindles [© high rail design = 1 ac/dc acceleration up to 0.59 handtmann Handtmonn ENC Technologies, Ine Ideas forthe future. 205 Prore Lake Rd, Unit 8. East Dundee, Il 60118 Ph: 847-844-3300 . Fax: 847-844-3303 info@handtmanncne.com . www.handtmannenc.com ees with the utmost respect. At a ceremony in 1983, he stated, “Just as all living things will pass away eventually, so companies will also die. So what should we do to extend our life for as long as possible? We always keep this thought in mind while we are managing the company: Imagine that you are managers to0, and stare from what you can do. IF you do that, then this unsinkable aircraft carrier will always remain unsinkable, Ifyou don’t, ie will be destroyed from the inside, and will finally go down. Even in che face ofthe extreme evonomic downturn, Mr. Mori embraced his em ployees and refused to allow any layofs. In 2002, he explained, “We hold the mana ‘ment philosophy of ‘lifetime employment: However, this does not mean the seniority system. This s because people are our assets, to make the company grow: For this reason, ‘we will not reduce our personnel, in spite of the current recession.” ‘A company fune were held on Saturday, December 15, 2007... and memorial sevice MHI PURCHASES ADDITIONAL FLOW COMPOSITE WATERJETS Mitsubishi Heavy Industries (MHI) has awarded Flow International Corporation a second round multi-million dollar contract to supply MHI with Flow’s Composite Wa- terjer machine tool to cut the carbon fiber wing components for a major commercial jer aircraft program. Flows Composite Waterjet machining, system will measure 80f long. It will be utilized for cueting the composite string- ers, which are part of the composite wing structure. As a result of breakthrough de- velopment work, i¢ will be equipped wich multiple “sde-fire” nozzles. The system will be built and tested in Jeffersonville, IN. The UHP pumps that provide the ulrahigh- pressure water will be made in Kene, WA. “The second round award of Flows com- ‘mercial wing structure machining. system proves the effectiveness of Flows waterjet technology and its ability to create ‘sae of the ar aircraft parts ina cost-effective man- nes.” says Charley Brown, Flow's president and CEO. Tiaditionally, conventional cutting tools = handheld diamond or catbide-tippedee VLU MS UP 39 diferent models, all designed for maximum praduetity From twa-axis to twelve-axis tuning From 05" to 25° stock Q\iyano := The World Leader in Precision Pee ee ay Pee ence Re de aay Adional Branch Offices ~ Shanghai, China | Rizal, Philippines | Kowloon, Hong Kang | Bangkok Thailandrouters, bandsaws, cutoff saws, and abra- sive wheels — were used to cut composites However, due to the composition and fi ber orientation of advanced composites, these traditional cutting tools can dam- age the composites either by overheat SUCCESS GUARANTEED! Carr Lane Roemheld knows your power workholding system needs to be of the highest quality. That’s why, if you work with us, you'll get the best top quality results. We stand behind our products, and provide you with the excellent service you need to remain competitive in today’s manufacturing environment. Find out the advantages of the SWIFTSURE quality guarantee when you work with ust Clamping EEE Elements Clams Push Clamps Loc eas 4 Piston c a 1s Sina ao" URE. CARR LANE ROEMHELD MFG. CO. 16345 Westwoods Business Park Dr. + Elisvlle, MO 63021 (636) 386-8022 + Fax (636) 386-8034 For Technical Support Call (800) 827-2526 Block Oplinde a Valves tor by leaving frayed or delaminated edges. Frequent delamination and fraying requires ‘costly rework, Waterjets climinace cutting problems associaced with advanced aerospace com- posites because abrasive waterjets cut by stem, and Work Supports 1 Sources ONTiNE™ bet sa SHIPPING > erosive action rather than friction and shearing, To cut carbon composite air- craft parts, a thin stream of water moving a three times the speed of sound is emi ted fiom a tiny, jeweled orifice in the tool head of Flows machine. The one gallon- pereminute water flow draws in a separate stream of fine garnet particles that slice into the surface being cut. They produce exceptional edge quality, free of frayed or delaminated areas, which minimizes costly secondary finishing. A _——_— ee Aircraft EXPO ET interiors AIRCRAFT INTERIORS TO BE SHOWCASED IN HAMBURG Aircraft Interiors Expo, the largest dedicated alraft interiors event in the would, takes place from April 1-3, 2008 at the Hamburg Messe in Geernany: All sectors ofthe interiors industry will be Feacured, including seacin lighting, windows, in- flighe covertainment, fastening cechnology, power supply, and galley products. Major companies such as B/E Aerospace, Airbus KID Systeme GmbH, and Hanse Aerospace will be presenting their larest technologies This highly popular event attracts visicors -haul and regional airlines, a well as business-class and other specialise operators ‘The VIP and business jt sector is also taking, soft. furnishings, safery and socutity, from lo an increasing interest in the show One of the highlights of Airerafé Interiors Expo will be the Crystal Cabin avvard for excellence in aircraft interior innovation, Entries for the 2008 award have been received ftom companies representing 10 different nations. The starus of the scheme is evidenced by the fact that major players such as Airbus Embraer, Airlines, Lufthansa, and Air France have all Boi Tontinental agreed to join the jud to attend the expo, visi aircratinteriorsexpo. com/Registration, Anews you can use A AULEBMOSITE LEONE FOR BLACK HANK MER CH Are nel ih Sly A cb of hr re el ee sak fmf en eer Eee dred Sth emp i or TCHS ny om Te aes mee mt be yA emma Ooh Pc ee TS ee Gr BACK HAS, og tm femme ee 5 ‘cal goals in reduced weight, parts count, tooling ys ooh cetortadnce nis FLT ENUM MRED OS hhas employed an improved manufaccuring ap- proach through the use of a Reduced Tooling ‘Concepe that has cut che number of wols by more than 70% over traditional methods while producing a highly repeatable, close tolerance steuccure. Costs have also been reduced through the use of auromated fiber placement in the manufacture ofthe raleone skins, The CTC uses the advanced, lightweight material X-Cor throughout the details of the assembly. This is an enginecred material thar replaces traditional honeycomb in sand wich structures. The design also incorporates a paintless finish, which integrates the color into the skin laminate at the lay-up stage Jim Gibson, vice president, sales and mar- keting at GKN Aerospace, comments: “This pioneering program for the BLACK HAWK helicopter has employed a range of new tech- niques and materials, creating a valuable da tabase of knowledge and understanding for all involved in the team. We belive this will support Sikorsky and the U.S. government as they bring the considerable benefits these ‘Making the jump to multi-axis ‘machining? Using your new 5-axis ‘machine like it's a 3-axis? VERICUTs vitual manutacturing environment Simulates and optimizes ne entre CNC ‘machining provers. With VERICUT, you can: VERICUT isthe worl’ lacing CNC : : simulation software ~ueegin al systems to simulate CNC code whether eliminate prove-ots Boos CNC aicency UH-SOM BLACK HAWK Pico castes ShorhyR news you can use Pratt & Whitney, a division of Jet, and the 23,000 Ib thrust United Technologies Corp,, class Geared “Turbofan engine and MTU Aero Engines have for the Bombardier CScrcs. agreed to collaborate on Pratt The company will also provide & Whitney's next generation research and development product family, including che invesement for each of the new Geared Turbofan engine, programs, Financial and The agreement, which issubject manufacturing details of the to the launch of the aircrafe agreement were not disclosed, ives MTU Acro. “We are pleased to continue Engines abour a 15% stake in our long-time partnership key furure engine programs with MTU Aero Engines with with Prate & Whitney and Prate this agreement on the Next & Whitney Ca Under the agreement, MTU says Pratt & Whitney President will share in the design and Steve Finger. "MTU has been manufacturing of the Prat involved in the development & Whitney Canada’s 10,000 of key technologies for these Tb thrust class engine, the products for years and we are 5,000 Ib ~ 17,000 Ib thrust excited to share 4 collective programs, gi ada Generation Product Family class Geared Tusrbofin engine stake inthe future of these for the Micsubishi Regional programs.” A Proposed Bombardier Series plane ho cota Boba eam ee Beene ene esd Oem ested * Quality System is 1509001:2000 rT BI: BRUSH Pee Cee eer) 800-441-2751 + FAX: 717-692-2120 Ramee eenes ener rer en iin eke fecal olor acs (a i asaig DT ete en Pe aaron slope slg ec eka Teer yet Ps eee en ea alfa cp SS ee a ae eee Cape ea UWA eH BCU PORE ey FOR THE TOUGHEST NS Ts MACHINING NY Tarte ae ms Een eed teeny LR CR LLIN Dee ae ier| y\ News you can According ta a the recently released AIA Aerospace Research Center's Analysis, for the Fourth year in a row, U.S, aerospace sales increased in almost every industry sec tor in 2007, AIA expects that 2008 will ex USE tend this trend. In 2007, otal sales wil reach nearly $200 billion, and next year will cer nthe $200 billion mark by approximately $11 billion, Whil saioly punch ceo ales in 2007 increased across the board for nearly all SPEED IS MONEY. MACHINE YOUR PARTS FASTER! ORC nC i Stee cree eee ith te late ay Te eet cee) ieee rr ee et ners) Cy Coty Machine Tool Co. Oia Cee a PE i ras sei Cee) eens Can) vwewnnlagun.com MODELS NOW IN-STOCK AND AVAILABLE FOR FAST DELIVERY! product and customer categories, most ota bile was the surge in the civil aircraft sector of 166. Once again, the aerospace industry was a major contributor to the nation’s trade bal: ance, with exports jumpi In spite of a jump in imports of 18%, the net trade surplus for the sector should grove to more chan $56 billion, Overall, AIA expects robust growth co continue though 2008, g to $92.5 billion, Acrospace industry sales are projected to grow nearly $12 billion co $211 billion next yeat, spurred by civil aircraft sales and engines and parts deliveries, which are likely to jump an- other 13% ORDERS AND BACKLOG Total orders will rise by $21.7 billion, of 9%, to $261 billion in 2007. With shipments to- raling $184.9 billion, the order backlog will inceease by $57 billion co $360 billion. The backlog is primarily driven by the sharp in- crease in orders for com of September 30, a total of 3,019 commer: ial transport aircraft remained in the unfilled order backlog. Foreign customers held orders for 2,214 of those aitliners amounting to over three-quarters of the value of che backlog. This obviously reflects the face rhat the ma jor US. placing sig Aeets since the post ial jedliners. As acy carriers have stil noe begun ficant orders to apitalize ther downeurn, 2008 FORECAST AIA forecasts that U.S. aerospace industry sales will grow 6%, oF $12 billion, toa record $210.6 billion in 2008. The increase will be riven primarily by increased delivery of civil aireraft, engines, and related parts and compo: nents. Deliveries of civil transports will likely cop 480 aircraft, for a value of $33.5 billion and general aviation jets — will add another $12.8 billion to sales. Looking beyond 2008, che current backlog of commercial aircraft orders gives us confidence particularly business that che civil airerae sector will continue on. an upward trajectory for atleast an additional three or four yeats. A P<Gibbs and Associates and Inf matic have entered into a world wide strategic: partnership. key component in the relation- ship is Infimatie offering Gibbs SEP (Shop Floor Programming) with the new line of Infimatic ‘open architeccure controls “We are extremely. pleased sd by Infi- matic as their control-resident programming solution,” states Robb Weinstein, Gibbs’ senior to have been speci vice-president of sales and sera tegie planning. “Though Gibbs has worked closely with MAG Fadal (Fadal Machining Cencers) and MAG Cincinnati (Cincin- nati Machine) for many swe did not take Infimatic’s selec~ tion for granted, Infimatic has worked diligently to develop a uunique control, and ie was only after an extensive evaluation that Gibbs SEP was selecred.” Gibbs SEP’ exse of use, ase of learning, and recognition as the industry standard for shop floor programming systems were key factors in its selection. Able o support programming wire frame gcometry, the Gibbs SEP version bundled with the Infi- matic Freedom NC200 can be upgraded to support program- ming more complex pars in- cluding surface and solid mod- cls, A key advantage of Gibbs SFP is ies compleve compatibil: ity with the GibbsCAM product line, Programs developed offine using GibbsCAM ean be directly transferred to Gibbs SEP on the controller for review and easy q | news you can use A modification. Changes made to the part program on the Froe- dom NC200 using Gibbs SFP ‘can then be transferred back to GibbsCAM and referenced as shop-peoven processes. A Gibbs SFP version bundled with the In imatic Freedom HC200 can be upgraded to support program: ming more complex parts including surface and solid models. ISIS WHERE IMAGINATION | EVERY PLANE IN HISTORY took fist fightin somaones imagination. At Boeing, wo envision the most remarkable Engnwors nthe Puget Sound rea of Washington state ‘You wil app your engnoenng we manutactoneg sks to area processes and matonals, clad fabaton, assembly snd Yoong which regia knowledge of manufacturing bet practices, compose andor ascemblytoohng experience, and an understanding of CADICAM software. ‘An AA degree in a related discipine and 3 to § years of evant ‘ho Boning elansfetion sina for anginners a type ny 508 years IME positon. Relocation i avaiable. [To view detated job descriptions and apply onne please visit: ww.boeing.con/carees and cick onthe Mandfactuing Planners & Manufactutig | Engineer Featured Opportunites buon. wil rect yout ou Manufacturing Planners & ManuacurngEngheers Fauued Opportaes | splash page where you san ea more an apply onine. boeing.com/careers tags, and ascomble the people ake them take shape. That's why wove here, Boeing has inmate openings for Manutacung Planners and Manwfecting 12° I prefered for the NP pesition. Educational credentials meeting !Seenan nan engineering lassifetion ie raquled otheiE Curtiss-Wright Corporation's Mecal Treatment segment has been awarded! a contract from The Boeing Company to estab- lish a ser peen forming pro- duction cell inside of Boving’s The laser peening cell is planned co be in production during the sec- cond quarter of 2008 and would initially be utilized for shaping the complex curvatures of some of the wing seetions of ehe new Boeing 747-8 Curis Wright’ laser_peen ing technology is based on a [Neodymium glass laser cechnol- gy; which was originally devel- coped at che Lawrence Livermore National Laboratory. Te has the ability co impart deep compres sive sereses on the surfice of news you can use metal pars, which can then be used t0 precisely form metal panels into their desited shape. Corts Wrights Metal mene segmet peening facilities in Livermore, CA and Barby, UK. and. also has mobile laser peening systems with the capability wo go on-site anywhere in che world “We ae very pleased co be providing Bocing with our state foftheart laser peen eechnology for their most advanced aircraft design,” says Marin R. Benance, chairman and CEO of Curtis: Wright. “This award isa cant milestone in bringing our proprietary laser peening tech- nology to the market. A number of industry leaders, such as Rolls Royce and Siemens, have also “Teeat- operates laser recognized the benefits of this process and we see a strong out: look for additional production onders.” ‘The Boeing 747-8 Ince new high-capacity aierafe based fon Boeing’ proven 747 family. The 747-8 offers the advancage of improved aerodynamics and reduced operating costs over cur- tinental and 747-8 Freighter are rent 747-400. A. See ey ‘ies from 3 mm to 100 mm in diameter, made from all certified Ce Cn od Ct you access to features and performance figures ‘to successfully master your development goals. Steinmeyer rg www.steinmeyer.com Pee ercr) NT Tha ag een Sisal ShyinkFt Technology-Critical for high precision and high speed cutting applications No two applications are the same. That's why Briney Shrnk-Fittoolholdars are rica to every cut. With Shrink-Fit technology you get + bet poesia Tt intr Reig ‘trated 6002 or beter ECan ntiry + est inl repos power + beat pore bance Increase ol 8 spice ie snegemoan — *Dasgn bud eus- tome ry 0 Tesi Systems | sain Ce artes an ing.comParker Aerospace has been se lected by Airbus to supply both the fuel and hydraulic: syseems for its new A350 extr- widebody (XWB) aircraft. Parker will pro vide che entire fuel system equip ment package, including che in certing system, fuel measurement and-management system, uid mechanical equipment, and en gine feed and ransfer fuel pumps The contract will generate more than US. SI billion over the life of the program for Parker The fuel tank inesting system uses aie separation modules with parenred fibers. The air separa- tion modules generate nitrogen- entiched aby removing the oxy gen molecules from ies air source and distributing the nierogen to the fammabilty of fuel vapors in the fuel rank and inceeasing che aircraft safe The fuel measurement 5 tem gages the fuel the tanks located in an aicrafés ‘wings and fuselage aswell as che fuel management sytem, which monitors the distribution of fuel ‘while commanding pumps and valves in the fuel system co pro- vide fuel eansfe and refuel. The fluid mechanical equip- ment and the engine feed and transfer fuel pumps are new product wins for Parker Acro- space on Airbus aircraft. These produets will provide muliple fanetions for the sircrf, ine cluding refueling and defucting, sransfer, engine feed, and fuel tank venting. During aircraft news you can use ‘operation, the pumps eransfer fuel from tank to tank and sup- ply fuel co the engine. The Patk- ce fluid mechanical equipment will provide the control valves for fuel shucof, isolation, emer: ‘gency shutoff, and venting air in and out ofthe tanks, Parker Aerospace has also won che hydraulic power gen eration and distibucion system fon the new A350 XWB. This ‘complex bill of material is com prised of seven individual work packages including pumps, res. cervoirs, manifolds, accumula- rots, thermal contol, isolation, and software, Together, these produets provide the hydraulic system functions necessary 10 power and control the air This system expands Parkers ca srcra GK pability and product offering to the aerospace industry, including a newly designed enginedriven pump, an electric motor-driven ppump with control and protec- tion functions, an automatic air bleeding bootstrap reservoir, and hydraulic stem control and health monitoring software © DO-178 Level B. “These are exciting wins for Parker and reflect chee years of dedicated work from many Park cr divisions and team members says Bob Barkes, president of Parker Aerospace. “We are pleased obeaparcaf this echoologically advanced aircraft program.” Parker supports many Airbus aircrai platforms, including the ‘A300, A310, A320, A330, A340, .A340-500/600, and A380. A DISCOVER NEW HORIZONS 7 ee eer eee =A SCHUNK Re ee COLL ac}By Kelsey Higginbotham Assistant Editor He United States is seeing a dramatic drop in available and perent workers withisy the country fices shortage of workers Whe pases basic carer skills and a strong work ethic for filling aivanced manufacraring jobs: In 2003, / a survey conducted by the U.S. Department of Labor (Dol) revealed thar 80% of US. manufacturing employers had a serious problem finding qualified candidates for the highly technical world oF mod em manufacturing,While participating in an Aerospace Mant facturing and Design Roundsable discussion at the 2007 WESTEC show, Francois Gat, global segment manager at Kennametal, Inc spoke out on the lack of skilled labor in the Us. “What I find when I goto visit my custom= cers is che lack of available valent, We, as an in dustry have to work toward fixing this. There arc numbers, published inthe pres, chat show ‘ase the imbalance of mechanical e graduates out of the U.S. versus th ; ar ofihe Sold isan astronomical dference. The Dos addressing the etal work force needs of the advanced manufactur industry. The Dol. holds forums with employ cers, representatives fiom industry associations, and others involved in the advanced manufic turing industry to learn about thee biting and training needs. In 2004, the U.S. Secreeary of Labor annotinced a series of investments rtal- ing more than $43 million o support compre- hensive partnerships that include employers, educators, the public workforce system, and other enti nise behind this investment was to address the needs of the manufacturing busi ness, while also assisting workers in finding good jobs with good wages and promising ca reer pathways. Some ofthe ideas from this ini- tiatve were: expanding the pipeline of youth helping alternative labor pools gain industry defined skills and competencies: developi new traini developing tools and ccurriculs for enhancing skill sets; enhanc the capacity of educational institutions; devel- ‘oping industry-defined career ladders and lar. tices; developing strategies co retain and retrain incumbent workers: and asisting transitioning, individuals from declining induscries to high covith industries. *The National Association of Manufictur cers (NAM) is aso doing their part to keep the long-time tradition of greae U.S. manufactur ing alive and well. NAM has a Manufaceurin Institute dedicated to facing the challenge of finding skilled manufacturers head on. Under ants from che Charles Stewart Mort, the Ford, and the Lumina Foundations, NAMs Center For Workforce Success has catalyzed business leadership in suppore of polices that promote accountability, affordability, acces, and suc ‘cess of students in community colleges, as well as fulfilling the need for business champions This Center for Workforce Success, which is the education arm of NAM's Manufaceri Institute, has been working on manufactur solutions for 10 years. TI ission of the c ter is wo find and to promote workforce solu tions for manufacturers in a global cconom als, provides manufaccusing solucions through access to highly-skilled workers; education with decision makers on a company’s issues involvement in making local chan Another good idea brought up during the WESTEC roundsable came from Trace at Iscar Metals ims, at the shop disappeared Slowly, we are beginning, to see chem come Jacobs, product man “Apprenticeship prog 2 the customer level, ha i and hese practices to keep compa- le nies in the know How LASERDYNE Makes Satisfied Customers Into More Successful Customers LASEROYNE work side-by-side with customers to develop laser system hardware find software thet makes them more ‘Shocesstl The many unigue operating features ofthe 450 and 790 systems re the result of partnering wih customers to solve ‘pect laser processing needs and increase ‘Productivity and quality. The new 450i 2 cost efective replacement for older NBYAG laser deiling systems Used for processing turbine blades, vanes, shrouds and other “small” components. Woking wih Inading turbine engine manufacturers, ardwaro and software features contin 10 be ine-tuned to reduce cycle tine while improving part quality and consisteny. ‘The new 700i avaiable in multiple sizes and snow avaiable wth automated part oad /unioad a8 well 3 enhanced ail-on-ne-y" Toate. The S94P laser process control, avaliable on both systoms, features an architecture that provides improved performance and usblity, ‘The capabiies of ts contr alow LASERDYNE engineers to provide new processing toos that are beyond what was possible inthe pas. When you become a Laserdyne customer, you tap ito experience anda culture of Cooperation that has been proven though Customer relationships as long as 25 years. In the aerospace industy alone, the customer Net is a Who's Who of engine manufacture, airtame manulacturer, and contrat ‘manufacturers as LASERDYNE technology has become the inustry standard for laser processing systoms 70D 0p tote test PRIMA NORTH AMERICA www.prima-na.comSS CIleeRIOa) back ~ in a very limited manner ~ but they are making 2 comeback,” he said. Jacobs continued, “Some of the bigger companies are opening up their training labs again and fextending invitations for apprenticeships Many of us are starting to realize that we Cn] th Automation Burnishing ee ee Engineored aoe have 1o do something, we have to rally rain cour workers. | feel education isa great place tostare, but i has to evolve into a place where they can gee rallife experience as well.” NAM® “Dream Ie: Do Te paign is a step in the right direction toward Fore Internal Whirling Caan rine ~ Power Section » cae) apprenticeships. This campaign’ focus is 10 ‘make manufacturing a prefered career choice by 2010, reaching out to young adults, their parents, their educators, their communities, And their policy makers. “Dream Ie. Da Ie will form strong and committed coalitions with local, political, educational and business entities. Through the promotion, «focused ad vertsing campaign wil be launched: a websive providing highly-paid manulaccuring jobs will be created and partnerships with community colleges echnical schools, and local univers ties responding to the interest of studying for a career in manufacturing will be formed. ‘The Information Technology Industry ‘Council is forming methods o ensurea bright fucure for U.S. manufacturers. The council stands by the idea that Ametican competitive: ness will drive the development of a highly shilled workforce. In onder to obtain and maintain the best and che brightest employ- ces, American businesses must compere with companies from around the world, Highly-ed. tucated workers add value to che bor force by strengthening research capabilities, inereasing, productivity, and developing innovative parts. There is, of course, & chllenge to sustain ing this well-educated, strong workfor. rmanuficrurers need access to the indivi ‘who will help develop romorrow’s technolo cal innovations and keep our economy grow: ing. The U.S. needs both long- and shore term solutions to help strengthen the U workforce. In the long-term, the U.S. needs a strategy to expand the education pipeline for American students studying science, technol- ‘gs engineering and math. In the short-term, the U.S. needs a commonsense approach to immigration policy that creates incentives for both USS. and foreign workers to develop val able skill sets that will contribute to Americ: ‘economic growth, Even sith all the negativity surrounding USS. manufacturing, there is a way of pusting positive spin on it. Let look at the fact that 7286 of the manufacturing job loss in the U.S. ‘over che past five years, isa direct result of pro- ductivity improvement. In the past five yeas, nine of the 10 hgest industrialized economics in the world, inchiding China, have lose mans facturing jobs. So, we are not alone, and this loss results from mechanization and autom With these improvements comes the dire ced for skilled workers. erospace Manufacur- ing and Design will be showcasing manuficto- ing companies who are stepping up and doing their page « maintain and improve a strong, competent workforce, Because in rely, the US. sy far the largest manufacturing econo: sy inthe world; les keep it that way. Aefficiency 7 made by MAG INDUSTRIAL AUTOMATION SYSTEMSBy Rod Jones, Chiet Learning Of- at ficer, Mori Seiki University eA product that very few of ts employ stand, Mori Seiki finds ths to be an uns able possibly, and has taken drama tweensure that it does noc occur Seiki University cd maximum kno MSU t ach 10 p~ We make precision more productive.skilled worke dlisionally, Maslow Kaabach was named vice generate demand from customers, but we had president of Mori Seiki University, ensuring no idea of how immediate and overwhelmin that our brightest minds would be wholly fo- those requests would be. Upon the opening of caused on improving and refining our erain- the MSU facility, customers flooded us with We ki es, inquiries ae ro when they could W that MSU would eventually courses offered. Opening. these three acronyms Say it all See Cat) Soe ee ey Ee een Bren ee ee ee SER oe ot ed jon't lose money. time, engines or your job. Now that is what in the world ee Cy 1.888.419.1399 of our classes helped to meet some ofthis need, but further accion was required MSU's Education On Demand represents a completely new and unique approach to pro viding education. Delivered through an on interactive experience, operators ean learn the intricacies of machining, processes by work with vie his, emulating the a cit real life counecrparts, 3 periences during the courses mirror what hey would encounter on the shop floor. By hamessing advanced compu controlling a machine has be programming, recreated in an sc manufacturers, e-learning. pro vides significanc benefit over a craditiona room model. Cla ime, 24 hours per day, This shops thar cannot afford the reduced capacity ‘comes with sending an employee off-site vides a welcome level oF for as much as a week for classroom-based «classroom environment, With traditional courses, the student with the least experience is often cither lef behind or slows the pace of the entire ass, When completing a course online he material is covered as quickly ot as slowly as the individual student equires. Rather chan bbe embarrassed by asking a question infront of peers, a student can thoroug area that he or she finds diffcule vo understand. With MSU Education On Demand, students, ourse by scoring 100% fon a comprehensive rest of the mater ing maximum retention for each individual ‘Whae differentiates Education On De mand fi er online learning, is the realism created by the graphics. Alvhotigh the Education On Demand courses are designed co be effective standalone modules, we are also classroom instruction as well. We find that our students appreciate the captivating. instruc ion aids while benefiting in terms of increased ultof the blended learn chension sa ing experience. he results obtained since launching MSU have surpassed our expectations. The division has overseen more than 10,000 hours of tai ing, with more than 1,000 students partic. pating, While many of chese were Mori Seiki employees and diseriburors, roughly 25% Mori Sciki customers, and we expect that per eat, The de stronger and the esablishmenc of MSU came atthe periee ime to help mece this growing need. ADREAM CUTTER MEGA FLUTE PLUNGE ROUGHER RAPTOR MILL “[rectnicur NEL Tae) UTA MAG Cutting Tools are the highest performing tools in the aerospace industry, the most precise, with the most versatility. MAG Rotary Cutting Tools are positioned to meet the needs of all titanium, composite and aluminum aerospace part manufacturers, delivering the highest metal removal rates per hour.HYDRAULIC COUPLING TESTING ACCOMPLISHES QUALITY GOALS Frater Acoiacesarched fan ime The scope ofthe poet was wo pero {or to partner with co implement im- a ydraulie leak tests four parts of six parts provements to their leak testing machines. at a time, on. quiel Finishing Needs! When performance and productivity are the issue - M.A. Ford® has Kiweme Solutions - MLA. FORD High Performance Cutting Tools ‘Contact your local distributor or contact M.A. Ford at 800-553-8024 or 563-391-6220 1.com * www.maford.com Eaton and QFSI were abe o develop a hydraulic test system that metal their defined objective. in che hydraulic control circuits aboard an aircrale, The pares had to be cested as individual halves both in a coupled and a 0 plant control er for government track- record keeping: nalog gages, remov- crepancy’ visual leak inspection: + More pars b tested 16 improve elliciencys + Reduced operator contact with machine oils (Skydeol + Aucomatie pare coupling and de- coupling wth preion engi + A filly enclosed, safer machine Quality Fise Systems Ine (QESD was selected to work hand-in-hand with Eston Aerospace to develop a hydraulic test sys- tem to. accomplish their abjcrives The fine cask was to find the hard- ware 10 use i this projec, which would be capable of standing up co the stingent equited test concurrently\ / ol www.visioneng.com/us/measurement Tel: 800.644.7264 ENGINEERING “Jack of all trades” ...master of one " Optical measurement = Video measurement Combined optical and video measurement The best of both worlds... Vision Engineering's Hawk family of non-contact measuring systems have been designed for companies who demand the highest levels of manufacturing quality, Hawk systems range from simple optical measuring microscopes, to combined cptical and video edge detection measuring platforms, all delivering high accuracy, repeatable measurements So now you can really have the best of both worlds. info@visioneng.com See us at Westec 2008, Booth 2144Oe at MWe iol Nels re] technology*is Cee) KURT standard workholding, custom fixtures and gaging systems excel in today’s tough opplications ku Toll Free 877-226-7823 worn kartworkldng.om wo hurtletonis. Working cogether, Eaton and QEST were able to identify the different materials 26 ‘quired to stand up to the various uid used ia the testing. Wich this aspect resolved, the me chanical section of the system was designed to greatly reduce the operators handling of the test pares, which has substantially improved the dhroughpuc of the testin ‘The vse parts are coupled and un-coupled by auromaced fixture manifolds thar position vertically within 0.005", utilizing a ground, square-form, 3” diameter lead serew coupled roan Allen Bradley servo system. The assem bly is capable of withstanding up ro 47,000 Ib cof backpressure that is developed internally to the parts during esting, Previously, an opera ‘or performed this coupling and decoupling manually and ic was very time consuming, The new systems produce product at bet ter than three times the previous through pat, Cleanliness and oil carryover from the tested parts was significantly improved by adding a laid purging cycle to the new test system chat automatically removes excess fuid from che parts atthe end of che est With the mechanical concept of the ma chine well along, the team earned its atten tion to the design of the automatic controls system for the test machine This system uses the latest, state-of-the- are Allen Bradley compact logix PLC wich a Panelview Plus color touch screen human machine interface (HMI). HMI sereens were designed and developed to ensure the conerol Tayouts were functionally correct and easy to use forthe associates. Arrention was given to developing a stan- dard interface that could be used across mult proces plemachine eypesand muleiple global facilities, This allowed associates from different work cells the ability to “flex” from outside of thee normal working area with little to no learning ceurve. The machines all fl” similar in their ‘operation thanks to ths controls concept IT groups agreed on the Ethemet com Aa technically speaking ‘The leak testing system, improved by Eaton ‘Aerospace and OFS G produces product at 2 bottor than three times J the previous throughput Test pars are coupled and un-coupled by auto~ mated fature manifolds that position vertically within 0.05", utilizing a ground, square-form, 3° Aiametor lad serow coupled to an Allon Brady servo system, munication protocol and standards, to en sure remote access to the machines over the Internet and host daca exchange for accu rate record keepi These machines formed the basis of a plant-wide network co which all cese ma chines will eventually be connected. The nctwork will also use bar code scannts at cach machine to identify the product to be ested, recall the test parameters from the server, and upload the test data and results (co the server fle ac the end of testin The amoune of hand-generated paper work used co gather this information has been greatly reduced, and has made it much less prone to entry errors during data gathering, With several thousand pare numbers and derivatives, just in aeronautical hydraulic Firings, the ease of adding additional pare riimbers and theit parameters to the testerOne small part in a very big world, but at every IMTS, OTe Nanuet a tu enue ec (Neuter ecto. ocr ee ERC ‘of 200 and from lilinois to North Carolina, Mexico, and Poland, Teking key Pe ae ee eRe eas GUE i WRLC Le Se ed Nee kee ea ea Incraasein productivity, Show after show, IMTS playé a big partin growing Coen a nae ger ee er ec REM Cec Col Meola Laem ol @aelt-LF IMTS nL Ta ea LL OCC Tae aa Ce LETT Register to attend IMTS 2008 at IMTS com today!Aa technically speaking has added greater lexiility Fine resolution, high quality pressure eransducers are utilized 10 re- cord che pressure differentials during the esting, resulring in very accu rate, real-time eesults thar surpass any previous machines capabilities The results in turn are instantancously displayed on the HMI, wi buile-in associate warning messages. Tes constrains can be entered di recy into the HMI with user acess level control. The machine aso tracks the numberof parts tested, che number of good parts, numberof reject parts during a pre-selected ime frame allowing Eaton to pinpoint areas of inefficiencies in the manufacturing process (Optional features available on the machines include: low fluid ‘warning system; controlled fluid temperature systems fluid column, test accommodation fr swivel couplings and rorque measurement and explosion proof designs for Scoddaid solvents or alcohol. Working as a team, Eaton Azrospace and QESI were able to bring a level of quality testing to the process never before achieved. ‘The testing process is now accurate, sensitive, and repeatable. A Eaton Aerospace Irvine, CA ‘aerospace.eaton.com Quality First Systems, Inc. Davisbure, Mi afsi.com Give ws our iedback at onlneamd comifeedbacHt for a chance twin a prize ‘Gleanliness and oil carryover from the tested pats was significantly improved by adding a uid purging cele tothe new test systom that automatically removes exces fi from the pars atthe end ofthe test. EDGE WELDED BELLOWS ¥, tg IT'S NOT ROCKET SCIENCE...OR IS IT? BellowsTech has perfected the manufacturing of edge- welded bellows, delivering ulta-precse, reliable, high periormance preduct to meet custom requirements foe almost any application and industry. For more information, Y BellowsTech uc Media@Weblink Connecting Your Business ‘Media Weblink provides internet and non-intesnet soliions forall ypes of businesses. As a multi-media ‘agency, we offer a wide varity of services which link together offering maximum results. ManufacturingInfo.com Machine Shop Web.com DieShop Web.com FabShopWeb.com MoldShopWeb.com ProductionShop Web.com MFGvideos.com MachineShopVideos.com For Marketing Solutions call 866-449-0442 Media Weblinktechnically speaking ain By Earl Dunlap PE., Par3 Technology ulki-wal carbon mano tubes are be terial fo create specie. geomerie for engineered composite applications: This research and development named Cote Tempering MWWCNT and engineered application methods co enhance engineer compos ite, For example: carbon fiber Berga apolcations, The research for some materials ike potopeljmuer powders nad woe resin metciiation with this technology has reiched the rapid. promgping. and. SF industry in the form of RP Tempering technologies wrth carbon fbr ly-upe This materiale proces il work with forh autoclave and ompresion-molding proceses. No goom- cary vo da has been roo simple or complex: when applying the Compose Tempeting Shapes he expected range of result fom Standard sero carbon fier lay-up sere applod Ch Comper Temportng + Reduce chances for catastrophic break fom impact Composite Tempering™ Strands (Alternating) + Compression mode ile mode + Marerial reduction, (CP) reducing cost + Weight reduction and avoidance by reducing CF + Increase torsion durability during physical application use + Increacethree- and four-point flex strength ‘+ Do nor change tensile strengeh, clongation or flecural modulus + Reduce vibration signatures + Damping enhancements + Does not change the useable physical design of part geometry + No delimitation will ‘caus form this process BASIC THEORY These pre-manufactured shapes from Par3 Tesinlogy replaced or betwes the by eft ofthe carbon Biber lay-up. The mano Composite materials will not delaminate the peopeg carbon fiber lay-up. The shape shown fr for round stands of compose tempering mars with MWCNT. Other ‘Raps an being reerched and vated Tn hs partdarepplicron the cand are und shout 0.0005" in dame They ate placed in between cach layer of carbon fiber prepreg in altemating paren. Oth- er detigns and parerns could be used to Achieve spectcrevul, om far osphet Gil [See Compose Tempering Suands A meh) oe‘TEMPERED VS. NON-TEMPERED When the tempering technique and mace- Fials are applied initial resules show prom- ising results in compression mode, The stress, shown below in the before and af ter pictures, redistributes considerably in comparison on a tempered pat. This will Aa technically speaking reduce the chances of a catastrophic break in compression mode, On the tensile side rss all goes to the ouside rap corner ich side, FEA compared to the actual test results, in a photopolymer, showed re sults where within 5%, (See Before Temper ing and After Tempering Screen Shots The Future of ETT TM TE TTC Our in-house, state-of-the-art, ‘computerized system isthe most advanced inthe industry. Usizing Finite Element and ther leading edge software, we offer our customers numerous benefits, inctuding a significant increase of load capacty 6=— =-— ‘Toleam more about this technology, ‘and why we are the “Go To Guys" for spiral ‘bevel gear design, please visit our Website or ‘contact our design engineering department. Committed to Being the Best (ag ARROW NG GEAR COMPANY 2001 artis Sent Doers Gre 5 Te (6 08-7640 npering technique and ma: terials are applied initial results show prom ising resules in three-point flex and torsion strength, The sereen shots on the following, page, of a tensile bar being Rexed, demon swate that the tempered parts has higher sength verses a non-tempered part. In the three-point flex picture the stress sccm to move away form the mass inthe center where a fracture normally happens and redistrib ates ourward, We seein the Torsion piccures the stresses stay at the end of the tempered parc where he force is being applied. On the rnon-tempered part the mass consolidates to ward center of the part faster fracturing long befare the non-tempered part. When this was tested in actual photopolymer parts the results where within 10%, REDUCING VIBRATION In order to reduce structure-borne vibration, several methods are available. Sometimes juse changing the system’ stiffness and for mass will alter the resonant Frequencies, This, in tucn, will reduce the unwanted vi bration as long as che excitation frequencies do not change. But in most cases, the ampli- tude of the vibration needs eo be isolaced or dissipated by using an isolator or by applying camping materials, Dampi rial dampi comes in two forms mate ig and system damping. Material damping isi ial of choice while system damping can be controlled at the boundaries and interfaces. rent in the mate Dd esinto of onto a structure is commonly. used today in automorive, aerospace, appliance, HVAC, and other applications. They can cither be applied as an unconstrained (free) layer of a constrained layer. Boch are highly dependant on placement on or in the struc- ture and the range of operating temperatures thac the structure will se, The unconstrained layer is che simplese way so apply damping, into a structure (.e. paines, cape, laminate, epoxy). The material is bonded to the outside layer ofthe structure. The unconstrained lay ct of material dissipaces energy as the struc- ture goes through eelic deformation ‘The constrained Composite Tempering geometry is onc of the most efficient ways Of introducing damping into structure ‘The material can be a single thin sheet oF a number of strands chat are placed within the material walls during. the manufactur ing process. The shear bond of the materials, dissipates energy as the seracture go through shear cyclic deformation This structure of tempering compound in this case is Smm diameter placed in evenly spaced straight lines becween each layer of carbon fiber prepreg. These strands will al ternate between each layer in a isotropic pat- tern, We can do this seamlessly and should perform berter during a high impact sirua- tion holding the geometry together. By forming a composite mul tunneled shapes alternating direct tween each layer will form a substantially 3D tunneled structure. The infrastructure of en- gineered tempering strands will have a pre- determined cross-sectional shape technically speaking am Mach more testing will have to be done in the earbon fiber and other engineered ma- terials This phoropelymer and many other materials have completed materials testing and the results are proven, Par 3 Technology is currently testing thei tempering technol- ogy in multiple macerals and designs, Par 3 Technology Cookeville, TN par3technology.com Give us your feedback at onlineamd.comt Fedhathfere tent winapi Profit from . our precision Measure your profits to millionths of an inch MHighest accuracy in the world 0.0001" to 0.00001" (.254y) Sizes from 3” to 18” in diameter Fast changeover for reduced set up time NORTHFIELD @ on... PRECISION INSTRUMENT CORP. (santas eb {antes vemstozee, Print sen3837-98 8873-5 763873-65 83671588888367-09 ———" reference guide ad Jolas, president of ZTM Ine, worked at Boeing when he cided ro sear his own busines. Coming from a family fll of Boeing employees, i was a daunting idea to leave a big company with acretirement plan and insurance ad sare frm seratch, But in 1996, he did jus ha. TM manufictre airfame parts and slookingineo growing their assembly woe: curren they have a stall bench-top assembly sector, ‘working mainly on bushings, bearings, and small assembbes. Although Bocing was the only company they supplied in the begining, they now make pare for Spirit, and they are looking coward other customers in the near fucre “ln che beginning, | worked at Bocing for almost 18 years. When 1 ef there and had the opportunity to stare working for thers as 3 vendor Iwas file with thei drawings and pars, 50 ie was an cay thing to make happen,” says Julius. "But now is the time to expand out horizons, and were excited about i From the beginning, Julius wanted ZTM 0 be “lighss ou’. Automation isan important pare of helping companies grove in a be labor market. With the shortage of skied workers cis important beable to run cycles efficiently wih low operator intervention. In 1997, Julius bought his fst Toyoda machine, a-axis horizontal 630, and within year a second one was purchased. The machines worked so wel, Julius knew where to turn wher he needed more. 7es-0094 “In 2002, we stated buying the high-speed machines with the thought of putting them on one of the RGVs and ral systems,” Julius explains. “We bought wo more Toyoda 630s fairly close wogether, Slang withthe nil system, and hooked those Rist fou together.” Two Toyoda G30sarefor machininghard metals che other two ae for machining aluminum In 2004 we de ; les people to draw from and the demands fom the ster induscry boeing so high, we had to really sare moving with the technology,” Julius notes, “Thats when we bought the eo el systems, and about nine of 10 Toyodas prety quick ~ we were bringing them in evry couple of months.” Five of those machines are Toyoda 550 horizontal machining centers that are now automated with a ehrce-level, 90-pllet RGV spec Feo he 850 wren te a thei of 2006, wih the ith delivered in July 2007. Prior tothe ith machine, she ft four were stand-alone, waiting for the rl system. ‘The new system consists of thce load stations and dramatically reduces eye time “es realy slick, says Vincent Pray, director of operations at TM IF we filly load it, i€ could run about 89 hours. We gee it to run overnight the fll night almost every day of the week. ‘Over the course of thece shift, ie sakes three employes co run the system for 24 hours. The leading i done onthe fs shi, and |the machines ae still running the next morning when the second shift comes in. If ¢ machine is stopped, ies because not enough work has been loaded on them, explains Julius "We've basically got two people who load and unload parts and material,” Julius says, “and a third employee introduces new work to it constantly Its enabled us o run a lor more parts with es people. Hands down, is no doube that productivity is way up. ZIM racks its quality mainly to ensure their customers receive exceptional products, but also because scrap is very expensive and fobvaining material has been diffcule over che last several years. Z:TM racks scrap in opportunites: How many opporcnitics docs a workcell have to scrap par? In one month, the five Toyoda 550s hhad 4,200 opportunites © scrap a part, while the other half of the shop, with the stand-alone small vercal-type machines, had 6,000 opporeanitcs. On the Toyodas, we scrapped five parts, outof4.200 opportunities,” Julius says. “Now in cur, on the stand-alones, we scrapped 2.5% that’s 150 pares — wich the sime amount of spindles asthe Toyods. So, the qualcy i unbelievable." In addition co the 550s, Julius recendy purchased a Toyoda 1050 horizontal machining center to furnish their year-old. 37,000K2 building. The machine is the largest one on the premises, and 2 Second cone is planned to come in early 2008, The pair will bejoined by small Gepallec RGY system, also planned for early 2008, "We can ‘run a longer part on the 1050s,” Pray explains, “It can i ‘IM recently incorporated five Toyoda 550 horizontal machi ‘three-level, 0-pallt RGV system with tree load stations, dramatically, Feducin cyte time. SMT Rely get the Ae Dee ee EL ad Article Reprint Service provides a cost- Ce ee company’s roduts and services. Our profes Re eect Se eta Se ee ee ad See ec es See So Cree eae AS RO Ar iter tad Ce eee ROE eg eer to learn more. Improve your shi _bid-to-award ra trouble meeting RFQ deadlines? Adding a “fudge ‘quotes? If so, you're likely to be losing a substantial ‘of business. With Costimator® JS, the industry’ leading software, you can quote jobs with speed, accuracy to significantly increase your sales and profits. ‘to lear how other shops have benefited from. tor JS and view our FREE Demo. ystems.com 413-733-1972837-98 8873-5 763873-65 83671588888367-09 aus Feference guide run about a Gf part andl atypical window is usually 39° 10 40" Julius credits much of his success to his partnership with Toyoda, When he was fis starting out, Toyoda personnel helped him choose which options and which machines were right for what he needed. They were Poms ie4 [AND DEFLECTION GAD MODELS SAVE SPACE SEC ae runs SELES Duk ed Be delivered om time, set up, and he has had litle ‘orno trouble with any of his Toyoda machines to date think they see the long-term objectives like we do,” explains Julius. “They dont look at i af just one sale, then let’ go on to the next! They look at helping to: build Sys e FROM STOCK SPR etd Seu Roe Peer Oe ae Sarre Ponce at ry 7es-0094 ‘An overhead viw ofthe ZTM shop floor. Automation has assisted ZTM in reaching their goal of “lights out” machining. companies. Theyire very knowledgeable, and they'e customer-oriented people, They want their equipment to perform well, so theyre reat to work with, The partnership isenhanced by awillingness tw help each other g Julius. Now ZTM works with Toyoda on ideas to improve machines, making them better suited for the company as well as Toyoda ow in business, explains other customers They alvays willing to look at sofware changesand technology changes,” hesays."And wee proud if they wane 10 bring customers in to see their equipment — we dont feel like its a dhreat. There® work for everybody, and Tayorks always helped us, 50 we're always willing o shove off thet equipment. With the help of Tayoda, ZTM has become what it is codayy and there are plans for even more growth in the near facure. Julius is considering adding another building on an additional four acres of land in late 2008 oF tatly 2009. The growth pace for the company has been quick, and i scems co be continuing and I hope weve caleulaced eveeyehing sight,” says Julius. “L dhe ‘market cured quick, that would be an issue and if we cant get enough people, that would bbe an suc. Bue were definitely buying che right cqipment ~ it reliable and the uptime is g fn it~ so were doing that par right. The w ‘conomy, we cant control that, butwe can control the «ype of equipment and how we serie up.” A. ZIM Ine Toyoda Machinery USA Wichita, KS Arlington Heights, IL ztm.com toyedausa.com Give u you feedback atonlineamad comifedback! for a chiance to win a prizeSize is important. If you're under the impression that Hurco only —_standard—not add-ons that nickel and dime makes small machines, give us another look. _ you to death. We've been busy designing the right machines Additionally, they all come with WinMax® to fit nearly every application. Our current Control Software that takes machining to the MGs range from 24 inches to 84 inches and __next level. lathes from 6 to 10 inches. And they all come Contact Hurco or your local distributor to find with lots of Best In Class features that are the size that fits you. ote wget837-98 8873-5 763873-65 83671588888367-09 aue Feference guide 7e5-00%8 TOMBSTONES, PLATES AID INCREASED AERO PRODUCTIVITY I: the Wichita, KS facility a St Bombardier Aerospace, Bombardier Learjet Models 40, 45, and 60 business jets are produced, When Drew Hants, methods engineer, hada ‘project requiring creased" productiviny, be turned 10 Advanced Machine Engineering (AME) for assistance. Hey was already familiar with their products tnd hod previous eupeticnce with AME. Dietmar Goellner, CEO. of AME and Alvin Goellnes, fusing group Jim Patk, AMES representative = ‘in Wichita, visived Hanus gw Hanus purchase several li tanbstnes tobe ued with their alaized system log with tba, the Kansas facility components and precision dowel erevs, wih ean be ed for cating ire plates onto tombstones or thee pals Bombardier ‘was running frqukchangoer 240 diferent. pars through a cell comprised of four Grid tombstones and plates along horizontal, 4-axis machines . ‘with modular components, allow with a 28-paller system and —_usersto very accurately and quickly fone vertical, S-axis machine logate and align on a 2° precision swith an 8-pallee system, rid system, AME’s team of experts demonstrated. the advantages of sub-plares with hardened inspected with AME’s CMM precision bushings and machine. Calibration. blocks hardened threaded inserts ona were added to check the 2” grid system. Hanus needed probe for repeatability of the to change parts quickly from machines. At the beginning fone setup to the next. It was of each day, it shows where shown that grid tombstones adjustments are needed to and plates along with modular hold. 0.0002" accuracy. A components, would allow him rotary axis cheek is also done to locate and very accurately on the fourth axis rorary table and quickly align on a 2" ro ensure accuracy. precision grid system: Today, 800 different parts Hanus. purchased several are being run through two full-grid tombstones to be cells. Monolithie parts are run used with their pallerized on one setup. Bombardier is, system along with sub-plaes, enjoying a 91% savings on components, and precision setup time with a total saving dowel screws — which can be of 819 on cycle time over the used for locating fixt old dedicated system. fonco tombstones or “The new system played a pallets for quick changeover. major role in allowing us to Bombardier's pallets were achieve our Six Sigma goals for cienced Machine 4) Cane araies Aerospace pp y this segment abricat Rockford, Ik bombardier.com threaded inserts, and locating have improved setup time, we and mounting holes. A 2* are producing better quality grid system ‘was integrated parts,and wearesavingmoney Give us your feedback at onlineamd.comifeedbackl for a chance to into their pallets and all was in the long run,” A twin a prizeBree ecu ee Seren rarer seen etn eet rer net Leeann nee nr ere Seer ann rere eMart Daren pesoireetetipeontiyer ioieovennenienrr emer mere nt See ee eee et eee td pe ee ec?Clircons) Machines sau ion to long-part_ machin ing, particularly of elongated, small cross-section, composite, and aluminum parts, is che MAG Cincinnati E Mill E Mill performs contour machining, routing, drilling, and tapping to produce finished, complex 3D geometry parts up vo 12m (408) Tong in a single setup, reducing processing costs compared co machines with larger_ vertical placforms. The desiga combines a pro dluction-proven 500mm 3-axis horizontal machining center (HMC) with headstock and talcock adapred from horizon- tal lathes to provide fourth and fifth axis of motion, The part manipulation system allows A- axis programmable rotation and 360" infinite positioning, while supplying Veaxis linear’ travel pull-through for parcfeed. Work stock is loaded and unloaded from infeed and ourfeed tubes. The E Mill can be ordered with a choice of a 16,000rpm oF 24,000;pm_HSKG3A_ spindle Supporting single setup pro- cesing, a drum-seyle automatic tool changer accommo 12.tools up to Skg (17.6 Ib) weight, 200mm (7:8740") long, and 125mm (4.913") diameter, The E Mill comes standard with full enclosure guarding, vacuum filtration, and mise/dust extra tion for CEand OSHA compli- ance ~ especially important for machining composite materials. A pressurized way system pro- teeesagainse wear from abrasive composite dust. The headstocklailtock sys- tem feares rough hole chucks with powered jaws, allowing the work stock tobe advanced imentaly through the jaws The “live” headstock travels on Veaxis linear slides, letting move next © the stationary talswok, lock on the workpiece, then slide back, pulling the work stock along. The system pro- vides 1,089mm (42.9") of travel for incremental part indexing The fully programmable feed sytem can accommodate work stock from 300mm (14°) 10 12m (40f) in lengeh and up to 304,8mm (12") square in cross The headstock moves on par- allel_guideways 775mm (30") COMPLEX PARTS UP TO 40 FEET IN ONE SETUP apart, while the fixed ailstock offers «similar broad base. This gives exellent sabilty for coor- inated A-axis part rotation. Made from a tough industri al plastic, the infeed and oufeed tubes are clam-shell designs ‘The infeed opens from the top for loading work stock, with the outfeed bortom-opening for case of part removal. ‘The tubes vent abrasion and delamination ‘of composite: materials, while the enclosed design provides ad- fluids, pare chips, and dust. The E Mill machine design can be adapted ro larger machin- ing centers with more powerful spindles for processing of harder materials. Besides cost savings ‘over machining platforms with (Loft Designed for machining ‘ong parts up to 12m (4), the Cincinnati Mil combines 3 production-proven SOOmn S-axs horizontal machining center wth headstock and talstck that provide fourth and fith ans of ‘motion for programmable rotation and 360° infinite positioning. (Above View inside the MAG Cincinnati E Mil work area. The part manipulation system allows ‘ans programmable rotation and 360” infinite positioning, hile supplying Vex linear ‘travel pull-through for part eed. 12m Gof) travel or more the compact E Mill design saves valuable plant oor space, avoids fixcure costs, and enables faster secup for reduced WIP, MAG Cincinnati’ E. Mill is particularly well-suited for long Aecospace components such as stingers, spars and floor beams ina variety of materials including composites, aluminum and rita: nium, Capabilities expand be- yond aerospace to include other industies such as construction, ship building, and wind power that utilize long parts.KOMA BIG BORE TABLES Rotary Tables Angle Head: EXTRA LARGE In-Stock at Koma Precision: extra large| big bore rotary tables and extra large angle heads...Jon-demand models using very light jets (VLIs) or other small planes, supports the view that this technology and business model indeed have a long-term impact, as have other disruptive technologies such as steel mini-mills and express package delivery Business funding, mainly in the form of private equity financ- ing, continues to attract new entrants focused on building market demand, and production infrastructure for the new breed of light, jets and'small piston aircraft, which define this sector. Present and prospective U.S. on-demand air transport operators such as Day- Jet, Linear Air, SATSair and POGOJet are increasingly mirrored by European cousins such as JetBird and Blink. Altpert infrastructure upgrades are also underway to accommadate ‘on-demand services. Upgrades range from projects such as the large- scale transformation of Stewart International Airport in New York, to installation of Small Aviation Transportation System (SATS) technolo- fies for safe higher-volume, low visibility condition fight erations at focal, minimally-equipped ianding facilites nationwide. Orders and deliveries for technologically advanced VLIs and other ‘small aircraft for on-demand air travel services continue to increase 2 this new personal air travel paradigm emerges into being Business models, marketing strategies and client service success drivers are still in gestation and expected to be core priorties for industry players during 2008, Most providers are striving to deliver new levels of transparency, quality, responsiveness, and value to develop their markets effectively. In short, the industry continues to develop with more resources as it moves toward providing the varieties of on-demand air travel services. We are expecting more of the same in 2008, but also believe that we will see more evidence of how various marketing approaches and business models work in practice. ‘Two notable new players were funded in the European market JetBird and Blink. Each have their own similaities and differences versus the existing U.S. players. These deals do lay the foundation, and provide the means to begin offering service that can be used Oz ‘ongoing research into next-generation air travel, particularly De ee a 5.2 proof point for further investments Blink raised $30 milion to begin purchasing its first aircraft. Blink will be using the Cessna Mustang, four passenger jet to build ‘and operate a fet of 30 with a focus on the European market The company is offering a pay-per-use model as well as a pre-paid contract that fers discounts. Because Blink has partnered wath well-established operator in the charter industry (TAG Aviation, it will beable to start offering service in May 2008. Blink wil start out with a bit of an advantage, given the density ‘of continental Europe and the willy varying rte structure on short fights. One hour fights can be had for anywhere from $50 to $1,500. Efcient point to-pont options for business travelers area clear oppor tunity that will be reasonably e2sy to justify for many. Blink seems to be mostly aiming forthe corporate or business traveler with ts intial offering. Blink’ planes are positioned as a “boardroom inthe sky” and willbe sold on 2 per plane versus @ per-seat bass. Overall Blink fas removed a number of risks from the equation. Financial isk i limited thanks tothe funding round. Operating ramp risk i imited by the TAG partnership, an asset risk fs minimized by going with an already proven jet fom a longtime manufacturer. ‘We expect thatthe focus for 2008 will be managing the customer ‘experience and leaming more about the market. The good news for the industry is that Blink launches operations in May 2008, soit willbe biazing a trall very soon ‘We find the TAG partnership also interesting as a potential win-

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