Composite alignment

Today, the majority of composite parts are made to an approximate size and then manually trimmed to their final dimensions. Composite parts require the same high accuracy as metals and alloys, especially within aerospace. As well as the extra time it takes to create a composite, like carbon fiber, if it’s inaccurate it will cost your company thousands if not millions over the lifetime of the process.

Before NC-PerfectPart

We were contacted by a precision CNC machining company who were experiencing complicated, time-consuming processes. They were machining composite parts involving multiple setups. Despite all efforts, the counterbores that were being drilled did not line up during assembly. This was a big problem as they were wasting time and money machining parts they could not use.

The fixture changeover and setup are critical to the company’s production scheduling, therefore they had to find a way to streamline their existing process.

After NC-PerfectPart

After a detailed study, we designed a new process that seamlessly integrated with the customer’s existing methods. NC-PerfectPart was used to accurately identify the part’s actual location, once it had been placed in the machine fixture. It then identified the part’s surface to ensure the drill holes met the required depth and absolute tolerances.

We were able to orientate and clamp the part, allowing all the machining operations to be completed in one setting. We were also able to compensate for any twist in the material.

Not only has NC-PerfectPart reduced the setup time, it has removed the need for manual intervention, the requirement for complex fixtures and multiple machine setups.

Since our customer began using NC-PerfectPart, they have seen a threefold reduction in the time taken to produce the part from the initial estimate. The process is now producing parts not only in a timely manner but also on a consistent basis.

Demonstration

 

The process