1. SUMMARY BOYER COMPANY figures, activities, cutomers and positioning machining of exotic materials microdrilling and ultraprecision measurement services HIGH GRADIENT RF COMPONENTS past and present activities results on the test part technical developments (control and machining) comments machining of a complete structure

2. BOYER COMPANY SOME FIGURES 30 years of existence 47 people 2800 M2 5 Meuros of turnover ACTIVITIES AND CUSTOMERS Nuclear weapons(CEA/DAM) Civilian nuclear(AREVA NP services nucléaires, CERN) Defense (THALES UNDERWATER SYSTEMS) Energy (S2M) Aeronautics and space sector (SNECMA) Optical sector (ESSILOR) Automotive (HONEYWELL, DELPHI) POSITIONING Precision machining and ultraprecision from prototype to medium production runs. Manufacturing, assembly and measurement services

3. Machining of exotic materials EXPERIENCE An important know-how acquired in the field of Civilian and Military nuclear sector as well as in research An established team accustomed to machining new materials Materials: tantalum, titanium, copper, molybdenum, vespel, aluminum, graphite, steel, Inconel, Maraging, AlSi MMC etc...

4. Microdrilling Microdrilling of cylindrical holes from diam. 0.1 mm to 0.25 mm in a gold plate 0.05 mm thick. Required tolerances for diameters, spacings and positions: 0.01 mm. Result: less than 0.005 mm. Without deformation at the entry Machining of a grid composed of square holes of 0.10 mm x 0.10 mm ± 0.02 Result: 0.01 mm in size and radius angle 0.01 to 0.015 mm Micromachining was carried out without deformation or alteration of the material. Holes compared with a pen tip The required accuracy is guaranteed by our means of measurement of three-dimensional machine WERTH

5. ULTRA PRECISION machining NANOFORM 250 ULTRAGRIND diamond turning and milling of ultra precision Three axes (X, Z, C) X and Z: 220 mm Position 0.2 m, Ra <10 nm, Tolerance of form <0.5 microns Gobal deformity of 5 µm Ra 50 nm Milling in H of a tin part Micro drilling of a pure aluminum part

6. MEASURING SERVICES equipment 1 optical measurement WERTH device 750x405x410mm 4th axis 3D measurement by laser optical system and high precision controls fragile parts, deformable or too small and can not be by conventional means. 1 ZEISS Prismo 7 (integrated rotary 4th axis, measuring head) 1500 x 900 x 700 mm 1 ZEISS Prismo 5 Super ACC (added rotary 4th axis, measuring head) 700 * 900 * 500 mm 1 ZEISS UMM 850 (integrated rotary 4th axis, measuring head) 850 * 1200 * 600 mm 1 Machine ZEISS MC 850 (added rotary 4th axis ) 850 * 1200 * 600 mm 1 FORM TALYSURF Série 2 Taylor Hobson

7. - Three-dimensional control of the first part (development of the range of control, the control program and analysis of results) - Provision of control programs and start on site - Load shedding control 3D standard parts - Dimensional inspection and sampling of three-dimensional quality Analysis of the results includes a chart, listing machine with gaps identified and popularized a summary containing the information from the protocol defined with the customer. MEASURING SERVICES Screen copy of a part machined on EDM SARIX machine Drawing of a blade section

8. ACTIVITIES ON HIGH GRADIENT RF COMPONENTS PAST ACTIVITIES machining of a test part delivered in june 2011 CURRENT ACTVITIES machining of a complete structure

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14. TECHNICAL DEVELOPMENTS CONTROL - fitting tool to maintain the part without deforming it - minimum of contact to avoid to mark the part - use of the super ACC ZEISS machine to get the precision MACHINING - fitting tool to get the 1µm flatness - setting of the tool (diameter, radius, position in X and Y) - milling strategy to get the best roughness possible - feedrate, cutting speed - good speed to obtain the good following of the axis

15. COMMENTS We know now that it is feasable in the precision asked but it has required : - a lot of developments to get the precision and the roughness required - a lot of time to machine the standard part Any change in the design implies changes in the process and development of the manufacturing

16. MACHINING OF A COMPLETE STRUCTURE PROBLEMATIC - the aim is to manage to produce parts according to the drawings in a limited time - It implies to have a reliable process DIFFICULTIES - It is necessary to reduce the number of operations at the minimum - It will be necessary to monitor the tool wear for a complete structure - The design of the milling has changed. The radius at the bottom decreased from 3,15 mm to 0,5 mm, thus the type of milling tool is different. The milling strategy has to be reviewed to get the good roughness Example : the path of milling to mill the cross should be divided by 2,5 to get the same roughness

17. STATE OF PROGRESS - The milling operation is validated in term of roughness - The turning operations are validated - The flatness in milling and turning is validated -We are in a process of validation of the exact position of the milling tool (X, Y) This is the last point to be able to launch the machining of a complete part.

18. Test part for the complete structure