Design of a specialised flowdrilling and tapping machine for the assembly of attachments on to exhaust pipes.

Requirement / Assembly of components on tubes.

Treatment of exhaust tubes to allow additional components to be attached.

Solution / Specialised flowdrilling machine.

Custom manufacture of a linear transfer drilling and tapping machine. The hole is created by pushing back and deforming the stainless steel (flowdrilling). This process allows components to be attached without the need for additional inserts.

Performance of the specialised flowdrilling machine /

• Automated manual loading and unloading station
• Digitally-controlled part transfer cart
• Component referencing
• Precise machining of materials by deformation
• Smoke extraction
• Dual drilling and tapping operation takes less than 90 seconds

Standard SMED rapid tool change-out interface integrated in to an aircraft part machining cell. The integration of a false platform designed by Lormac creates a unique and standardised interface for all manufacturing machines, minimising machine down-time.

Requirement / Speed up manufacturing rotation.

During machining operations, manufacturing changeovers are an indirect cause of down-time. There are three advantages to using a specialised rapid SMED change-out interface for part pick-up and assembly :

• speeding up change-outs,
• improving repeatability when repositioning tools,
• meeting needs in terms of multiple interface / tool “pairs”.

Solution / A single rapid change-out interface.

Development and integration of a false platform creating a standard rapid change-out interface common to all machines. The supplied tool was standardised through the use of zero point mandrels. Positive CAD locking components, these elements are released using hydraulic mechanisms. Lormac designed and installed a comprehensive rapid tool change-out solution for the customer’s application including the supply of a hydraulic release unit, positioning control and a blower.

Characteristics /

• Ø 1600 mm capacity
• 9 false platforms or identical interfaces,
• 8 dedicated tools.

Further information.

Dedicated machining fixture for working vehicle parts on a palletized machine (2 palettes) two spindles. The design of this custom clamping unit made sure that a maximum number of parts could be machined on each pallet rotation and that the cycle time was optimised.

Requirement / Custom part pick-up and clamping.

Custom clamping solution adapted to the geometry of the vehicle parts and meeting constraints in terms of productivity and customer quality :

• part positioning accuracy (two spindles),
• effective clamping,
• maximum size constraints,
• machining in 5 axes with access to multiple tools.

Solutions / Dedicated machining fixture.

Design, manufacture and optimisation of dedicated machining installations for custom clamping and positioning of parts to be machined :

• 2 x 1st OP 4 position installations, both handling 4 axis machining operations: clamping and positioning of 4 parts per tool with holes in the baseplate for pass-through machining.
• 4 x 2nd OP 2 position installations, all handling 5 axis machining operations: clamping of 2 parts per tool.

Further information.

Study, design, manufacture and optimisation of a machining fixture with hydraulic grip and holding. The installation is designed to machine the front and back faces of an aircraft casing in a single operation. Clamping is performed automatically to save time when positioning the part.

Requirement / Clamping adapted to the geometry of the part.

The customer’s specifications included several constraints requiring a dedicated machining installation with a custom grip system. The adaptation of gripping to the particular geometry of the part met the following requirements :

• Machining of the front and back faces in a single operation using the same tool,
• Part had “arms” which were not connected by a casing, causing problems when turning,
• Multiple areas to be clamped,
• Need for precise positioning.

Solution / Hydraulic machining fixture.

The fact that all skill-sets are available internally means that Lormac is autonomous and has limitless capabilities in meeting the most complex needs. The solution designed by Lormac, which was proposed and approved by the customer, was a machining fixture with hydraulic gripping and holding. The double-platform structure allows pipes to be placed between two plates so preventing retention of chips which may affect the precision of machining.The design of this custom machining installation allows stress to be placed on the arms without constraints or defamation. Internal safety system for the clamping system.

Further information.