1. CTMA Investment - $0.5M; Industry Cost Share - $1M
Airframe structural parts rarely truly precise due to difficulty of maintaining accuracy and repeatability over the full working envelope of very large 5-axis machine tools – results in excessive scrap and rework.
Integrate a “system of systems”
Tracker3 Laser tracking system from API
Calibration algorithm from Boeing
Optimization and real-time compensation software from API
840D CNC controller from Siemens Automation
System integration and lab testing by API and MAG – Cincinnati Machine
Pilot a system and process that can complete in two days machine calibration testing and real time position compensation to produce accuracy better than 0.005” over the full working envelope– current methods require 2-4 weeks
CTMA Investment - $0.5M; Industry Cost Share - $1M
Volumetric Accuracy For Large Machine Tools (VA4LMT) Minimize nonproductive time for calibration, reduce scrap and rework, improve part quality – translates to reduced part cost and reduced cycle time
DoD Benefits
Application by Armed Services:
CTMA Sponsored:
Navy/NFPC propeller machining
Air Force/WR-ALC aircraft structure machining
Activity Sponsored:
None yet
Potential:
Machining of very large parts for all services
Level 1 Benefits (projected):
Boeing – $1M/commercial aircraft
AF(WR-ALC) $320K to $727K/year
Navy $8K and 4 weeks cycle time/propeller
Level 2 Benefits (projected):
All Air Force – $842K to $2.8M/yr
All Navy – no extension pending Phase II
Level 3 Potential:
Maximum benefit to be enabled by Phase II results