From traditional hand-held tools to electrical discharge machining (EMD), Fleet Readiness Center Southwest (FRCSW) uses a variety of instruments and machines to help ensure it delivers the best possible products to the fleet.
Computer-based/assisted tooling is computer numerically controlled (CNC) and multi-axis CNC tooling.
Developed in the early 1950s, CNC tooling has been in use at FRCSW for some time in its manufacturing processes. Examples include lasers for cuts and patterns from minimally thick pieces of steel and aluminum; the waterjet tool that uses high-pressure water and an 80-grit garnet abrasive to cut through steel, titanium, and other materials; and EMD that creates an electric arc to erode metals like titanium.
Multi-axis machining uses CNC tools to rotate around one or more axis to manufacture metallic parts and components. The number of axis varies from four to nine.
FRCSW uses 5-axis machining. A 5-axis machine can mill material on a plane of two coordinates (x and y or back and forth, and left and right), as well as space, or top to bottom (z). The other two axis, a and b, apply to the rotation and tilting of the part, respectively.
Many of the commands 5-axis machines are located in Building 472 and designed for smaller, aluminum-based manufacturing.
About six years ago, the command purchased a larger, higher capacity machine made by Gruppo Parpas for $3.5 million that can handle a variety of metals including titanium, stainless steel and aluminum.
The inside manufacturing table is roughly 20 by 40 feet, enabling FRCSW to manufacture larger components like formers and longerons.
With both low and high-torque heads, the model also has the capability to mill carbon fibers, a primary ingredient of aircraft skins.
A significant feature of the Parpas machine is its ability to measure. The software uses a probe to verify the dimensions of the part either during or after the manufacturing process. Afterward, the operator receives a printout of the dimensions. The feature potentially saves artisans hundreds of manhours in the verification process.
Artisans also save time in setup procedures because the Parpas machine uses a tilted plane or angle variation that is uncommon in 5-axis CNC tools, machining all axis in one path. With other 5-axis machines, the manufacturing table moves in a back and forth motion, or the x and y-axis, while up and down is the a, c, and z.
Ordinarily care must be taken that when a part is machined, it is perfectly square to the machine, but parts need not be square to the Parpas as it will pick up the parts corners and compensate for any tilt.