Landing gear to the F/A-18 Hornet and E-2/C-2 aircraft will be re-worked and returned to the airframes much faster and at a lower cost thanks to an initiative by Fleet Readiness Center Southwest (FRCSW) and the Defense Logistics Agency Aviation (DLA) to establish a Flexible Manufacturing Cell (FMC).
The FMC is an automated system comprised of six, 5-axis machines and a palletizing system that will be installed in the existing landing gear shop in Building 472.
5-axis machines are computer numerically controlled (CNC) equipment that use multi-axis tooling to rotate around one or more axis to manufacture metallic parts and components.
The pallet system will move the landing gear through the repair process, automatically performing required set ups, and manage the parts inventory.
An all-in-one device, the FMC is programmable for milling, turning, and inside diameter (ID) and outside diameter (OD) grinding. FMC use almost eliminates human interaction with components, reducing the potential of error.
Re-manufacturing of the F/A-18 main landing gear trunnion (the pivoting point where landing gear move for landing and stow for flight), for example, requires 11 different machining applications totaling more than 80 hours of setup and operational time. The versatility of the FMC significantly reduces that to only six hours, saving more than $17,000 in labor costs per trunnion.
The manufacturing of other landing gear components will realize similar costs reductions.
To maintain continuity with existing CNC systems, the FMC features a compatible standard, central control system eliminating user-training requirements and eliminates the need to develop new software interface programs.
The move will save more than $1.3 million annually in related manpower and programming costs.
Furthermore, the system is equipped with a timer to perform automatic warmup and shutdown procedures.
Machines currently need a warming period requiring a machinist to devote two hours daily in early overtime. With the FMC timer, the warming period overseen by personnel is eliminated, saving approximately $219,000 annually.
The FMC palletizing system will be fully enclosed with a sliding door roof, able to accommodate the placement and removal of large parts. Assembly of the palletizing system will follow the installation of the primary FMC components.
For tool changing, a standardized HSK-A spindle tool holder will replace the current CAT 40/50 holders. The HSK-A is not only more versatile but able to fit machines without the need to change pull studs, saving more than $102,000 annually in manhours devoted to that task.
Another $103,500 per year will be gained by use of the 3D quickset tool kit. The tool kit eliminates the weekly accuracy alignments necessary for 4/5 axis machines, reducing setup time for machining.
Because of its ability to share data with other computing and manufacturing systems and technologies like cloud and cognitive computing, the FMC will help with planning and managing schedules and costs.
The system will also feature two manufacturing options: ultrasonic machining and a blown powder/laser ablation for additive manufacturing.
Ultrasonic machining will enable the FMC to machine thin coatings to hard alloys that require separate grinding.
The blown powder/laser ablation for additive manufacturing allows the re-building of surfaces damaged by corrosion, reducing the number of scrapped components.
In addition to F/A-18 and E-2/C-2, the FMC will be adaptable to service F-35 landing gear, as well. Furthermore, it may be used in the machining other components made of steel, aluminum and titanium.
Costing about $17 million, the FMC is designed and manufactured in Germany by DMG-Mori, USA. Installation is scheduled for March 2022.