Machining parts for aerospace applications is often complicated by the necessity of maintaining tight tolerances during short production runs. At Duotech, reverse engineering and fabricating one-of-a-kind machined parts from aircraft grade 6061 or 7075 aluminum alloy is a daily requirement. In order to meet the requirements of AS9100, meticulous attention to accuracy and precision is required.

To ensure the highest quality work, Duotech Services exclusively uses Haas Machining Centers equipped with integrated Renishaw Machine Tool Probes. While each part produced has its own unique requirements, below are helpful guidelines we use at our facility to meet our requirements:

6 Guidelines for Maintaining Tight Tolerances During Short Run Productions

  1. Ensure that the workholding setup is rigid: If the part is not rigidly held, there is no possibility of accurate results. Duotech Services uses six inch Glacern precision CNC vises because of their precision and strength. When necessary to rigidly hold irregularly shaped parts, machinable aluminum soft jaws are used to prepare unique fixtures for workholding. Additionally, especially for thin walled parts with high precision requirements, vacuum workholding with customized fixture is used to maintain tight tolerances.
  2. Check work probe and tool setter calibration: To ensure the best possible results, verify work probe and tool setter calibration. While the Renishaw system is exceptionally stable in normal operation, it is wise to verify calibration periodically.
  3. Ensure that tooling is properly seated and as rigid as possible for the job: Make sure that your tooling is held as securely as possible and that the seating surfaces are cleaned of any debris. Use the shortest tool as possible for the job for maximum rigidity.
  4. Turn on cutter compensation: Enable cutter compensation and measure the tool immediately before the job and periodically as the job runs.
  5. Warm up the spindle: As the machine runs, the spindle lengthens or “grows.” To ensure accurate depth when machining, make sure that the spindle is sufficiently warmed up prior to beginning the job.
  6. Test and verify coolant flow: Make sure that your coolant system is delivering plenty of coolant to keep the tool cool and to flush chips out of cavities being machined.

With meticulous attention to the guidelines listed, it is possible to maintain the tight tolerances needed to produce high quality aerospace parts.

From concept to implementation, Duotech’s capabilities encompass your entire project. On-site machining and fabrication shortens design cycles. Our staff puts time on your side. Whether J.I.T. or build-to-print, send us your requirements for aerospace quality work.

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