Aerospace patterns made on Rye CNC router

Aerospace patterns made on Rye CNC router

Keywords Aerospace industry, CAD, Rye Machinery, Software

The Aerospace Division of Cheltenham Tool Co. Ltd has bought a twin-table Rye Pentaxial 1710 TP CNC router(Plate 5) to increase the precision, repeatability and productivity of its subcontracting operations for the aerospace industry. Already a supplier of components to several major aerospace companies, Cheltenham Tool had been making patterns, jigs and fixtures by traditional methods on milling machines, jig borers and other machines, usually with substantial handwork by its workforce. Ever-increasing requirements for precision and fine tolerances made it essential that Cheltenham Tool acquired the latest CNC technology, both for pattern-making and for the making of aluminium components, many of them quite small.

A Cheltenham Tool purchasing team, led by Dave Marfell, drew up a detailed specification and researched the available machines thoroughly. The choice was somewhat limited by the fact that the company often needs to machine complex curves and shapes, and this made it essential that they bought a 5-axis CNC machine capable of working with the company's CAD/CAM system. The router had to be capable of handling small high-specification alloy components in volume, with edge finish quality in the 16 micron range, and large complex patterns, and it had to be able to deliver tolerances which are fine even by aircraft industry standards.

 Plate 5 The Rye Pentaxial 1710 TP twin-table CNC router in use at Cheltenham Tool Co. Ltd

After talking to several companies, the purchasing team went to Rye Machinery at High Wycombe and there found that the Rye Pentaxial could be supplied to meet their specification,which included a powerful 10kW ISO 40-spindle, complete with ceramic bearings and a 12-station toolchanger.

A major benefit to Cheltenham Tool is the fact that the Pentaxial 1710 TP, which the company purchased, has twin tables. These can be used either on a shuttle basis, so that the operator can unload and load one table while the components on the other are being machined, or synchronised together to provide a table 2m × 1.7m. In shuttle mode, the router achieves high productivity with maximum spindle-up time. With the tables locked together, the company has the working area for large components.

A further benefit of the Pentaxial 1710 TP is that, after the head has been tilted, there is automatic compensation for co-ordinate points which have been "taught in" with the head positioned vertically. The controller will also define a shape in the machine X, Y and Z axes and translate it through compound angles without any reprogramming.

These capabilities plus the benefits of downloading computer-aided design (CAD) data directly to the CNC controller of the Pentaxial at high baud rates enable Cheltenham Tool to manufacture even the most complex press tools and SAAB FluidForm tools on the Rye without reprogramming. Michael Nash, chief executive of Cheltenham Tool,explained that the ability to machine a design with complex curves using data already on the company's CAD system saves time, eliminates transcription errors and increases efficiency.

The Pentaxial also has the latest type of high-efficiency vacuum workholding, which greatly simplifies the positioning and holding of curved components while they are machined. This,coupled with some clever advice from Rye's applications engineers, made it possible for complex layouts to be held without difficulty.

The Pentaxial now spends much of its time machining aluminium tools and components, but at various times is required to deliver similar high standards of precision working in timber,laminates and various plastics. A new press about to be installed will make even larger tools necessary. and will make even better use of the large bed of the Rye Pentaxial.

"The key benefits of the Pentaxial are its large bed, its precision and repeatability and its high spindle speed", said Michael Nash. "We get reliable quality and far greater output than we ever did before".

For further details contact Rye Machinery Ltd. Tel: +44 (0) 1494 441211; Fax: +44 (0) 1494 440345.