The Rocket Propulsion Division, part of AFRL’s Aerospace Systems Directorate, recently modernised its fabrication shop in California with five new CNC machine, including a wire EDM machine, a die-sink EDM machine, a small-hole EDM, CNC milling machines and three CNC lathes.

“The recently upgraded machines provide AFRL with an increased capability to fabricate components of higher complexity and provide customers the benefit of being able to keep more of their work on-site, reducing program costs and turnaround time,” says Ben Gleason, lead fabrication technician. “The machines are equipped with similar CNC control units to lessen operator training. More accurate spindles and electronic part probing reduce set-up time and increase precision.”

Specifically, the new equipment will increase accuracy on multi-sided and complex parts, while improving operator safety and allowing for a cleaner, safer working environment.

“The unique skills of these devices allow them to machine tight tolerances with exotic materials such as superalloys, additively manufactured metals, polymers and composites,” says Lt Col Ammy Cardona, AFRL branch chief and materiel leader for the Experimental Demonstration Branch.

AFRL’s Rocket Propulsion Division designs and manufactures components for liquid rocket engines and solid rocket motors. The newly upgraded fabrication shop allows the laboratory to manufacture unique, one-of-a-kind rocket components that scientists and engineers can test in experiments, such as proof of concepts for new technologies.

The automation of the new machines will also ensure product quality and timeliness, which helps the team make accurate decisions of scheduling and production to meet the demand of AFRL’s test schedule.

“The new machines support highly precise cuts which eliminates waste and saves money on material and human error in the fabrication process,” says Gleason.
For further information www.afrl.af.mil

From ONA’s passion for EDM comes its obsession with incorporating constant improvements into the company’s machines that optimise production processes and improve finish quality.An example of this is ONA’s‘Script Programming’ tool. A high-grade programming language that allows for the creation of smart programs. It is possible to modify projects during the process to react to changing conditions, thereby guaranteeing piece quality.

All of the company’s models have the option of including an additional package with its Script Programming smart program creation tool. What advantages does this provide to customers’ production processes? Mainly improving production in terms of time and, above all, improving piece-part manufacturing quality.

ONA’s adaptive machining concept is based on the ability to react to changing conditions. Script Programming benefits from the application’s knowledge and experience, and translates that into dynamic programs capable of addressing changing conditions, rules and variables. The more knowledge it has about the manufacturing process, the more competitive it will be. The possibilities offered by Script Programming are infinite.None of this is possible with conventional programming, which is appropriate for pre-planned, static procedures where no changes are expected.

There are many advantages of Script Programming, including the ability to create personalised set-up cycles. Another benefit is the ability to execute actions conditioned by a series of premises.Without this option, the piece machining instructions are defined beforehand and cannot be changed. Thanks to Script Programming, it becomes possible to redefine the rules, adapting them to the process’s variable conditions during its execution.
For further information www.onaedm.co.uk

Carl Hirschmann GmbH is supporting activities at Rheinisch-Westfälische Technische Hochschule (RWTH), auniversity in Aachen with a co-operative project together with machine tool manufacturer GF Machining Solution and the study group EAK (Erosiver Arbeitskreis). In mid-November, Dominik Gotthelf and Bernd Reiner, sales manager at Carl Hirschmann, visited the university in Aachen, where they handed over an FJR80NCYA30A rotating and indexing spindle.

This spindle is used in an AgieCharmilles CUT P 350wire EDM machine from GF Machining Solutions to profile grinding wheels.

“For us as initiator of the project, it was important to train the research project group in the use of our rotary spindle and the associated control system,” says Reiner.

Manufacturing on an EDM equipped with Hirschmann high-speed rotating and indexing spindles is an efficient alternative to hard turning or superfinishing for rotationally symmetric parts. Even smallest parts in stainless steel, hard metal or even conductive ceramics, which cannot be made by conventional processes like turning or grinding, can be manufactured efficiently, reports the company.

Besides high-speed rotation, the application of rotating and indexing spindles allows precise indexing and simultaneous machining (via the machine control). It is thus possible to machine the finest rotationally symmetric structures and precise surfaces and contours.

In addition to the training, the meeting focused on a transfer of knowledge between the students and the two companies on technology and parameter settings. This is the basis for a further common research project and further investigations. The students receive additional support from grinding wheel manufacturer Tyrolit.

Hirschmannis pleased regarding this project with university RWTH Aachen and is looking forward to the results.
For further information www.carlhirschmann.de