High Speed Machining Using Makino MC1516 at Raytheon

Case Study 64 of Industrial Engineering ONLINE Course  -   Process Industrial Engineering FREE ONLINE Course (Module)

1999 |
High Speed Machining of  Bulkhead at Raytheon Aircraft

Raytheon Aircraft Company (Wichita, Kansas) does industrial engineering, that is continuous improvement in engineering. Attention is given to  maximize throughput and efficiency. 

Raytheon engineers came to know about high speed machining and  decided to use a Makino (Mason, Ohio) MC1516 high-speed horizontal machining center with a seven-pallet modular machining center (MMC) to machine  bulkhead.   MC1516's Jet 50 spindle provides up to  15,000 rpm. The 50 taper spindle provides horsepower at various ranges and brings a high level of rigidity.  

To machine the bulk heads,  end mills reach 12,500 rpm and achieve metal removal rates as high as 320 cubic inches per minute.  In two setups, the MC1516 machines thin wall tolerances under 0.00010 inch to near net shape. Roughing and finishing are conducted simultaneously using carbide end mills.

The seven-pallet MMC allows the spindle engagement for more than 90 percent of the time. The MMC allows setups offline and keeps the MC1516 constantly fed.

The new technology adoption had challenge of learning quickly. The team consisting  of people in every discipline involved in the process, from manufacturing engineers, programmers to the operator  worked with Makino to learn and optimize the new process. The planned learning paid off with production parts being machined immediately after installation. Raytheon quickly realized the efficiencies, such as reduction in machine and labor hours per part. The machine uses  universal vacuum fixturing also. While the larger bulkhead is machined on a dedicated fixture, vacuum fixtures allowed operators to set up smaller parts in one operation.

The successful process improvement using high speed machining  will be extended to more parts.

https://www.mmsonline.com/articles/high-speed-machining-helps-modernize-bulkhead-manufacturing