Preview of the exhibitors at Farnborough Airshow 2018

Simulation space for aerospace

CGTech’s Vericut is widely used in aerospace and defence to improve the efficiency of all types of CNC machine tools. Vericut is CNC machine simulation, verification and optimisation software that enables users to eliminate the process of manually proving-out NC programs.

The software simulates all types of CNC machining, including multi-axis milling, drilling and trimming of composite parts, waterjet cutting, robotic machining and mill/turn, additive and hybrid machining processes. Vericut runs standalone but can also be integrated with all leading CAM systems used in aerospace.

Throughout the show, CGTech will be demonstrating Vericut’s optimisation capabilities, which have recently been enhanced with the introduction of the new Force module.

Force is a physics-based optimisation method that determines the maximum reliable feed rate for a given cutting condition based on four key factors: force on the cutter, spindle power, maximum chip thickness, and maximum allowable feed rate. It calculates ideal feed rates by analysing tool geometry and parameters, material properties of the stock and cutting tool, detailed cutting tool geometry, and Vericut cut-by-cut contact conditions.

Force interpolates cutting conditions using a proprietary set of material coefficients to account for the strength of material and the effects of friction and temperature. The materials data is generated by actual machining tests and does not rely on extrapolating from finite element analysis results. According to CGTech, the bespoke cutting coefficients used by Force result in the most accurate cutting force calculations available today.

The company will also demonstrate Composites 8.1, the latest versions of Vericut Composite Programming (VCP) and Vericut Composite Simulation (VCS). CGTech’s Composites 8.1 release of VCP and VCS features a completely redefined Graphical User Interface (GUI), enhanced suite of programming and analysis tools, and redefined methodology through the use of the powerful new Laminate Manager.

This helps users easily manage files, processes, and batch actions for the entire composite laminate. Internal refinements ensure that large projects are now able to be programmed and simulated in a fraction of the previous time.

CGTech www.cgtech.co.uk
Hall 2, Stand 1120, booth 2

Mini gears, major growth

AS9100 registered, the company claims to have saved its customers over £4.5 million over the last four years through innovation and continual investment in new machine tools as it believes in offering a fair price for aerospace components.

Mini Gears will be showcasing the seating mechanisms manufactured at its 35,000ft² factory in the UK, together with a range of precision machined parts including aluminium profiles for privacy screens, table plate support hinges, brackets, seat supports, handles and door release mechanisms. The team looks forward to welcoming visitors onto the stand.

Mini Gears www.minigears.co.uk
Hall 1, Stand 1522

End-to-end heat treatment

In the two years since the last show, the company has added new prime approvals, made a company acquisition and invested heavily in new vacuum brazing and plasma nitriding processes and equipment.

“Providing a high quality and rapid service to aerospace component manufacturers is key to our success and continuing growth. With a dedicated transport fleet of over 50 commercial vehicles, we take end-to-end responsibility. Acquiring the business of Metaltech in Newcastle, last October, not only added extra production capacity but with part of the fleet now based there it also allows even faster access to our services for customers in the North East and Scotland,” explains CEO, Peter Carpenter.

Two new vacuum brazing units have been established, one at the company’s Manchester site the other at Cambridge. Further to their commissioning, both units have achieved Rolls-Royce approvals. In addition, the company also carries approvals from BAE Systems, Airbus, Safran, Bombardier, Moog and many others, for specific heat treatment and plasma nitriding processes.

Wallwork Cambridge was one the first companies to achieve AS9100 revision D. With its expanding order book there is major investment at the site in a further vacuum brazing furnace and two additional plasma nitriders.

The company has also developed Nitron CA coatings that provide an environmentally safe alternative to hard chromium plating (HCP). Applied by physical vapour deposition (PVD), under vacuum conditions at low process temperature, Nitron CA coatings will help manufactures comply with REACH regulations in the EU and OSHA legislation in the USA.

As well as a full range of heat treatment services, the company also provides Nadcap approved processing of complex aluminium and magnesium components, typically used in satellite and aircraft parts.

“Our range and quality of services aimed and developed specifically for aerospace component manufacturers has never been stronger. This reflects our growing order book and confidence in the future,” Mr Carpenter concludes.

Wallwork Group www.wallworkht.co.uk
Hall 2, Stand 2427

Machining that goes global

Underpinned by guaranteed uptimes (up to 96%) and lowest piece part costs, whether the need is for a large-capacity Ecospeed 5-axis machining centre or the smaller capacity 5-axis Heckert 500 X and STC 800 X machining centres – and including the dedicated blade (LX) and blisk (NB) machines – Starrag has expertise in meeting all machining demands in the most cost-effective and productive manner.

With a wide product range of machines available under the Starrag brand: Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP and Starrag – and a leading player in Industry 4.0 strategies, the machine tool builder’s stand will be manned by experts promoting Starrag’s maxim ‘Engineering precisely what you value’.

The Starrag Group is a global technology leader in manufacturing high-precision machine tools for milling, turning, boring and grinding workpieces of metallic, composite and ceramic materials.

Principle customers are internationally active companies in the aerospace, energy, transportation and industrial sectors. In addition to its portfolio of machine tools, the group provides integrated technology and maintenance services that significantly enhance customer productivity.

Starrag www.starrag.com
Hall 4, Stand 4163

Problem solving cleaning

Emphasis is placed on problem-solving to meet customers’ needs, especially for processing parts of complex geometry to a superior standard.

The Turbex product portfolio includes the Galvatek range of surface treatment lines, notably for chemical cleaning and anodising. More than 600 turnkey installations in over 35 countries have been designed, delivered and installed. The equipment is typically automated and uses modern technological developments that ensure efficiency, reliability and low emissions.

Galvatek is especially well known in the aerospace industry, as its multi-stage lines for chemical cleaning, anodising and etching are widely used. Continuous development ensures that technological advances create better and more efficient processes for industries where precision and fault-free operation are required.

Chemical surface treatment plants are built either for one specific purpose or as part of a larger package for preparing parts for other surface treatment phases. Turnkey solutions are regularly supplied, complete with waste water purification and recycling systems.

Non-destructive testing (NDT) and component cleaning are closely related. Through Turbex's experience of cleaning, it has developed an extensive knowledge of the FPI process and the systems required. Its FPI systems utilise expertise in automation and process control to provide consistency and traceability.

Precision cleaning machines with basket rotation and flood wash options will also be promoted. These machines use a world-patented system whereby rotation of the holding basket and spray jets is individually adjustable, allowing them to rotate in the same or opposite directions. Programs can be tailored, together with other movement options such as rocking of the basket, to clean even the most complex parts efficiently. Integral condensing eliminates the need for extraction.

This equipment is aimed primarily at high-precision cleaning applications in the aerospace sector with the possibility of simulated clean room conditions.

Another focus will also be modular and bespoke, high precision, ultrasonic cleaning machines with automation. A hallmark of their construction is multi-frequency ultrasonics, where a single transducer can generate two different ultrasonic frequencies. Consequently, dissimilar components and materials can be processed optimally in the same tank.

For processing larger parts such as casings, landing gear components as well as aerostructures, Turbex offers the ACV range of front-loading, spray washing and rinsing models. They are particularly popular for degreasing and precision cleaning prior to NDT. Standard sizes range from 1-3m in diameter, although larger machine sizes are available.

The PLC-controlled machines provide a high level of cleaning performance due to ingenious design principles combined with high spray pressures and liquid flow rates achieved by the powerful pump.

Turbex www.turbex.co.uk
Hall 4, Stand 4042

Tool management system that saves time

Displaying every group of tools in the smoothly sliding drawers of Bahco’s robust, lockable trolleys enables engineers to find whatever tool they need without delay. A ‘push’ device enables easy removal from the stain resisting foam inlays.

Using Bahco’s ‘Configurator’ software, customers can choose the size and colour of trolley they prefer, as well as the number of drawers and inlay format. Colour coding in each drawer shows where a tool has been removed, helping to combat the risk of foreign object damage.

For line maintenance engineers on the move Bahco offers a range of heavy-duty portable tool boxes, all with colour coded foam inlay drawers.

Specialised ergonomic tools, intended for working on engines or avionics, are designed to protect even the toughest hands from painful muscular-skeletal disorders.

Precision torque tools in the Bahco range include electronic torque angle wrenches and mechanical torque wrenches with adjustable head. Also available are electronic torque wrenches with a fixed or reversible ratchet head, torque screwdrivers with preset torque values and electronic torque and angle measuring adaptors.

Bahco www.bahco.com
Hall 4, Stand 4C/90 in Hall 4