Fast jets, fast machines!

The latest Ecospeed F 5-axis machining centre from DS Technology (UK) has been installed at BAE Systems, Samlesbury

Compared with using older production equipment, the high-speed cutting capabilities of modern machine tools can increase productivity considerably. A good example is the latest Ecospeed F 5-axis machining centre from DS Technology (UK). Since the first one was installed at BAE Systems, Samlesbury, it has been working around the clock manufacturing components for the Eurofighter Typhoon much more quickly and economically than other machines on site.

Compared with DS Technology's ‘ACM' machining centres originally purchased by BAE Systems to fulfil this and other work, the Ecospeed F is twice as productive, according to facilities engineer, Nigel Tuley.

Furthermore, the fixed column machine is 25% faster than the previous generation of Ecospeed moving column machines, three of which were installed at Samlesbury between 2003 and 2005. These machines form the basis of a flexible manufacturing system (FMS) that includes two load stations and a rail-guided vehicle for the transfer of six pallets to the three machining centres.

Two of the FMS machines are devoted to producing aluminium front fuselage sections (bulkheads, cockpit and instrument panels, etc) for the Eurofighter Typhoon, while the other machine produces aluminium details for the rear fuselage of the F-35 Lightning II.

By the middle of 2006, BAE Systems had won additional Eurofighter Typhoon work, namely the production of the centre fuselage frames. It became clear that the increased workload combined with the projected two thirds increase in Eurofighter Typhoon build rate to 60 aircraft per year within 12 months would require additional production capacity at Samlesbury.

So an order was placed for the latest generation Ecospeed F, which took over the finishing operations on the three types of centre fuselage frame, while two ACM machines were retained for rough-machining the castings.

Whereas roughing of the frames removes about half of the material by weight, finishing of the 2 m x 1.5m components removes only 2 to 3mm of material in cycles that are approximately eight hours per side, giving an indication of their complexity. Large apertures for the air intake and wing attachment lugs are finish milled, but the majority of the work is pocketing to remove weight. There is a lot of thin wall machining at 40:1 depth-to-thickness ratio and some at 60:1.

Tuley commented: “Not only is the Ecospeed F more productive, but accuracy and surface finish are better as well. This is partly due to the high dynamic stiffness of the machine, and partly due to the uprated control system with enhanced look-ahead capability.”

www.ds-technologie.de  

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