Category Archive: Machining

Boosting Precision with New Machining Equipment for Spin Testing

As an industry leader in spin testing, Test Devices by SCHENCK is a one-stop shop for even the most demanding projects. Recently, we’ve expanded our machining capabilities by investing in advanced turning equipment. Precision turning is a crucial aspect of spin testing procedures and our new machine, the OKUMA V760EX vertical lathe, allows us to refine large aerospace components with enhanced efficiency and precision. 

At Test Devices by SCHENCK, we go beyond ordinary spin testing services by also offering CNC pre-spin machining and semi-finish machining. Combining these capabilities enables us to provide superior-quality components for customers in the aerospace industry. With our new machining equipment, we can deliver even greater precision in machining aerospace alloys. Below, you can learn more about how CNC machining services fit into the spin testing process and the new capabilities our OKUMA CNC lathe offers. 

OKUMA V760EX Vertical Lathe 

The OKUMA V760EX vertical lathe was designed with the needs of large part turning in mind, making it an ideal option for aerospace component manufacturing. It features massive construction and the high power capabilities needed to handle large-diameter workpieces.

The vertical configuration of the OKUMA V760EX provides the advantages of natural part handling and excellent chip fall. Additionally, its larger work envelope allows for easier workpiece handling and faster access to tools, while taking up minimum floor space.

How Our New OKUMA Vertical Lathe Levels Up Our Spin Testing Capabilities

By enhancing our in-house spin testing services with CNC machining capabilities, our clients can obtain higher quality parts more efficiently than ever before. In the aerospace industry, every component must meet its required dimensions precisely. Even a small deviation can have catastrophic consequences. CNC machining is the ideal manufacturing method for these needs since it achieves extreme accuracy and precision. 

The materials used in aerospace component manufacturing can be challenging to machine without specialized equipment. Aerospace alloys are often high-strength and uniquely formulated for extreme temperature resistance, creep resistance, and other demanding characteristics. Our new OKUMA vertical lathe features a rigid machine structure and a high-response positioning system for handling even the most challenging materials and geometries with ease. 

The OKUMA V760EX achieves the following accuracies:

• X-axis: 0.00059 in. (0.015 mm) over any 3.93 in. (100 mm) of stroke
• Z-axis: 0.00098 in. (0.025mm) over any 11.81 in. (300 mm) of stroke

Its repeatabilities include: 

• X-axis: +/-0.00020 in. (+/-0.005 mm)
• Z-axis: +/-0.00020 in. (+/-0.005 mm)

The OKUMA V760EX vertical lathe features a maximum turning diameter of 29.92 in. and a maximum turning height of 30.31 in. It performs powerful, heavy-duty cuts while its vertical orientation is well-suited for creating thin-walled parts without distortion. In addition, it offers a milling function for added flexibility. Its box-type base and column provide a highly rigid and dependable structure, and its headstock with flange construction reduces the effects of vibration and thermal deformation for accurate, stable cutting. 

Contact Test Devices by SCHENCK: Experts in Pre-Spin Machining Services and Spin Testing

Test Devices by SCHENCK delivers industry-leading pre-spin machining and spin testing services. From our state-of-the-art facility in Hudson, Massachusetts, we meet the needs of a global customer base. We are AS9100 and ISO9001 certified to ensure you receive the best possible quality components, every time. Contact us to learn more about our CNC machining capabilities. If you’re ready to get started on your next project, request a quote today. 

Top 3 Reasons to Choose Us for Precision Machining Services

In modern manufacturing operations that create critical rotating parts, each step, from forging to finish machining to final inspection, contributes to the overall quality of the finished pieces. To ensure the highest level of precision and reliability of your parts, it is essential that your semi-finish machining service provider has robust manufacturing processes in places relative to producing critical rotating parts. Look for full-service shops that offer high-quality, reliable, and consistent machining services.

One-Stop Shop Full Service Manufacturing

Rough and semi-finish machining for the aerospace sector requires precision equipment and experienced, knowledgeable engineers and operators that can navigate difficult or unexpected challenges during machining operations.

At Test Devices by SCHENCK, we have a highly skilled and experienced staff with the expertise in machining safety critical rotating parts from the most challenging aerospace alloys. We observe strict adherence to AS9100 and ISO9001 standards. Our talented team of engineers and machinists, combined with our suite of on-site resources, allows us to provide a full-service approach to manufacturing that is unique in our industry, combining machining, inspection, and spin testing operations under one roof.

High-Quality Expertise in Precision Machining

The customers we serve demand the highest levels of quality, accuracy, and compliance with industry standards. We are the premier provider of precision machining services for aerospace OEMs, operating in strict compliance with the AS9100/ISO9001 standards. Throughout our over 40 years of experience in working with critical aerospace rotating hardware for testing and production, the Test Devices team has continued to provide unparalleled precision and reliability in sonic, rough, semi-finish, and pre-weld machining services.

At Test Devices, our operation not only conforms to the AS9100/ISO9001 standards, but we comply with various QPRs for leading jet engine OEMs. Our quality assurance team is staffed with the most experienced professionals, including on-site quality process experts, designated quality representatives, and dimensional inspection and CMM experts. From forging state to completed semi-finish machined conditions, we are committed to providing the highest levels of quality, dependability, and precision by employing controlled manufacturing processes, including:

• Component specific CNC/CMM programs
• Detailed operation sheets
• Inspection plans
• In-process control
• Dedicated and accessible operations management
• Direct and frequent communication with customers

Customer Focus

Being flexible and responsive to the customers’ needs and constantly changes is a necessary capabilities in the today’s manufacturing world. Whether it is a change in requirements or specifications, schedules, test criteria, or delivery times, providing exceptional customer service requires a commitment to communication. Frequent personal contact with each customer ensures that we are aligned on expectations and are meeting their needs.

All our customers are confident in our ability to respond quickly to urgent changes that could impact the manufacturing or delivery schedule. Our production manager maintains close working relationships with our customers, as well as coordinates with all departments daily on customer requirements. From machining to inspection, spin testing, balancing to shipping, every department is in lock-step throughout each step of the project.

Choose Test Devices for Your Precision Machining Services

Though Test Devices specializes in rough and semi-finishing of rotating parts in aerospace, the same high standard in the quality of work, and operational excellence could serve many other industries and customers with similar needs. Through our reputation for quality and professionalism, as well as our four decades-long history of success, our customer base continues to expand across sectors such as automotive, energy storage and generation, electronics, and medical devices.

Our dedicated and seamless production management team combined with our highly skilled and experienced team allow us to provide machining, balancing, and spin testing operations under one roof. For more information on our precision CNC machining or alloy machining services, please contact us today. To learn more about our precision machining tools or processes, please download our eBook.

Machining in the Aerospace Industry

The success or failure of aerospace operations is dependent on the accuracy, precision, and quality of the components employed. For this reason, aerospace companies utilize advanced manufacturing technologies and techniques to ensure their components fully meet their needs. While new manufacturing methods such as 3D printing are quickly gaining popularity among industry professionals, traditional manufacturing methods such as machining continue to play a critical role in the production of parts and products for aerospace applications.

Recent advancements in machining techniques and technologies—such as better CAM programs, application-specific machine tools, enhanced materials and coatings, and improved chip control and vibration dampening properties—have significantly changed how aerospace companies manufacture critical aerospace components. However, sophisticated equipment alone is not enough. Manufacturers must have the expertise to overcome the challenges of machining materials for the aerospace industry.

The following blog post discusses what aerospace component machining processes encompass and what machining challenges aerospace component manufacturers face.

What Does Aerospace Component Machining Involve?

In concept, machining raw material into aerospace parts and products seems simple. However, turning materials into functional components that fully meet the specifications and standards of the application necessitates extensive engineering and operational expertise.

Aerospace manufacturers often invest in CAD/CAM software and automation components to achieve better part quality, process control, and production efficiency. However, while these cutting-edge technologies help deliver consistent and dependable output, company employees must have the proper knowledge and skills to use them to machine components effectively and efficiently.

What Are the Challenges of Machining Nickel-Based Superalloys?

Many critical aerospace components, such as hot sections of jet engines, are made from nickel-based superalloys, which are aerospace materials characterized by their ability to offer superior performance in demanding environments. This quality stems from their excellent strength at high temperature, toughness, hardness, oxidation/chemical resistance, creep resistance, and thermal insulation properties. While these properties make these materials an excellent choice for such components, they also make them difficult to machine. Some of the challenges faced by machinists working with nickel-based superalloys include:

• High cutting force requirements. The high dynamic shear strength of nickel-based superalloys necessitates the application of significant cutting forces to machine the material into the desired part or product.
• Poor thermal conductivity. Since nickel-based superalloys do not readily conduct thermal energy, the heat generated by the cutting operations migrates to the tooling rather than the chip. As a result, machine tools experience greater wear in these machining operations than the machining operations for other materials.
• Susceptibility to work hardening. Superalloys are prone to work hardening, which leads to a greater risk of notch wear.

Given the proper engineering and operational expertise, machinists should be able to overcome these challenges and produce machined components suitable for use in aerospace applications.

Why Partner With Test Devices for Your Aerospace Machining Needs?

At Test Devices (a business unit of SCHENCK USA CORP.), we’ve produced critical rotating components for customers across a wide range of industries for over 40 years. This extensive experience, combined with our full-service manufacturing capabilities (semi-finish machining, inspection, and testing all under one roof), allows us to provide expert and reliable product solutions for major aerospace propulsion suppliers, automotive manufacturers, industrial power generation manufacturers, and numerous other industrial companies.

To learn more about our products and services and how they can benefit your aerospace application, contact us today. To discuss your requirements with one of our experts, request a quote.