Complete Production Equipment e

Production Equipment

Aerostructures

Issue 20082© RUAG Aerospace

Summary of core competencesHigh speed, high performance five-axis milling:- Material: Steel, titanium & aluminum- Dimension of aluminum parts up to: 2.00 m x 10.00 m x 0.60 m- Dimension of steel & titanium parts up to: 3.00 m x 4.00 m x 1.00 m

Turning machines:- Diameter up to 2.00 m

Five-axis stretch form press:- Dimension of parts: 3.00 m x 4.20 m x 1.10 m- Stretching capacity: 400 metric tons

Chemical milling:- Dimension of parts up to: 3.00 m

Circular Hydroform press:- Max. blank diameter: 1.00 m

Welding:- TIG- & MIG welding- Spot welding: aluminum, titanium & steel- Seam welding: steel & titanium

Surface treatment:- Chromic acid anodizing- Alodine treatment- Etching

Metal bonding facilities- Steel, titanium & aluminum structures including honeycomb applications

Autoclaves- Dimension of parts up to: Ø 1.85 m x 4.20 m

Resin Transfer Molding (RTM)- Experienced Development Team & Know-How

Testing & Measuring- NDT Testing & CMM

Assembly Jigs/Tooling- Automatic CNC riveting


Milling & Turning Machines 4 Henri Liné Powermill 260 V HS/5-2 (Aluminum, HSC) 5Henri Liné Macbormill 240 LS/3-2 (Steel & Titanium) 6Henri Liné Macbormill 245 HS/5 (Routing Machine) 7Makino MAG3 (Aluminum, HSC) Milling Center 8Starragheckert STC 1000, Milling Center 9Starrag + Heckert ZS-500 (Aluminum, HSC) 10Deckel Maho Gildemeister DMF 300 linear (Steel & Aluminum) 11Deckel Maho DMU100 monoBlock 12Deckel Maho Gildemeister DMC-200 FD, Turn & Milling Center 13MCM Clock Five, Milling Center 14MCM Jet Five, Milling Center 15Kitamura HX630i, Milling Center 16Forest Line V1250 & Flexiax 510, Milling Center 17Wissner Witec 4015, Sheet Milling Machine 18Pietro Carnaghi AC20 TM/1600, Turning Center 19WFL M60-1000 / M65-2000 / M65-3000, Milling & Turning Center 20Sheet Metal- & Welding Shop 21 QUINTUS QFL Hydroform Press 22 ACB Nantes (ALSTOM) Loire FET 400, Stretch Forming Press 23Chemical Milling Bath 24Jetline LWP120, Welding Machine 25Vacuum Chamber for Inert Gas Welding 26Metal Bonding & Composite Facilities 27 Bonding Shop Pretreatment 28 Cleanroom Area 29 Scholz Autoclave 30 Dopag Resin Mixing & Injection Unit 31 Isojet injection System 32Heat- & Surface Treatment Facilities 33 Heat Treatment Facility, Ripoche Furnace 34 Heat Treatment Facility, Schmitz und Apelt Furnace 35 Surface Treatment Area 36 Shot Peening Facility (Steel shots) 37Shot Peening Facility (Glass shots) 38Paint Shop for Assemblies 39 Paint Shop for Assemblies & Large Aircraft 40 Paint Shop for Detail Parts 41 Paint Shop for Assemblies 42 Paint Shop for Assemblies & Large Aircraft 43Testing & Measuring Equipment 44 ALSTOM US – 1000, Scanner 45Cegelec US – 2006, Scanner 46Wenzel CMM Machine LH 2015 47 Microtecnica MM Cyclop 48 Assembly Jigs/Tooling 49 Güdel CNC Drilling Machine 50 Brötje CNC Riveting Machine 51 Brötje C-Frame Riveting Machine 52Brötje IPAC Riveter 53

Location of Equipment see corresponding page


Milling & Turning Machines


Powermill 260 (Aluminum, HSC) Supplier: Henri Liné Machines Outils, S.A. Type: Powermill 260 V HS/5-2, CNC machine for

aluminum parts

Axis: 5, two-spindle Table size: 4.20 m x 10.00 mTravel per axis: X = 11.00 m, Y = 3.25 m, Z = 1.20 m

C-axis n x 360° , A-axis +/- 110°, 20 RPMCNC Control: SIEMENS 840 DSpindle power: 70 kW per spindleSpindle speed: 20 - 24‘000 RPMTools: 2 tool changers with 50 places (HSK63)

Remarks: Dual operation possible, video monitoring, scanning equipment,control system for tool length and diameter, prepared for chip removal system,linear drivers in X-axis & Y-axis

Location Emmen


Macbormill 240 (Steel & Titanium)

Supplier: Henri Liné Machines Outils, S.A. Type: Macbormill 240LS/3-2, CNC milling machine

Axis: 3 to 5, two-spindle

Table size: 3.00 m x 4.00 mTravel per axis: X = 4.00 m, Y = 1.75 m (2x), Z =1.00 m

C-axis n x 360° , B-axis +95°/-105°, 4 RPM

CNC Control: SIEMENS 840 D Spindle power: 50 kW each Spindle speed: 20 - 4‘000 RPM resp. 20 - 6’000 RPMTools: 2 tool changer with 60 places

Remarks: Dual operation possible,automated milling head exchange system, for3-axis, fixed and special milling heads

Location Emmen


Macbormill 245 (Routing Machine)

Supplier: Henri Liné Machines Outils, S.A. Type: Macbormill 245 HS/5, CNC routing machine

for sheet metal Axis: 6 Table size: 2.50 m x 9.00 mTravel per axis: X = 10.00 m, Y = 3.50 m, Z = 2.00 m

C-axis n x 360°, A-axis +/- 120°, 10 RPMCNC Control: SIEMENS 840DSpindle power: 20 kWSpindle speed: 20 - 24‘000 RPMTools: Tool changer with 20 places

Remarks: Dual operation possible, video monitoring, scanning equipment,control system for tool length and diameter, prepared for chip removal system,special countersink tool

Location Emmen


MAG3 (Aluminum, HSC)

Supplier: Makino Type: MAG3, 5-axis horizontal milling centre

Table size: 3.00 m x 1.50 mTravel per axis: X = 3.00 m, Y = 1.50 m, Z = 1.00 m

A = +/- 110° C = endless

CNC Control: Fanuc 300 iM incl. Professional 5Spindle power: 80 kWSpindle speed: 500 - 33‘000 RPMTools: 120 (HSK 63)

Remarks: Manufacturing Management System,linear pallet system with 6 pallets,laser based tool measurement system, integrated vacuum system

Location Emmen


Supplier: Starragheckert Type: STC 1000 Horizontal Precision Milling Centre

Axis: 5 Table size: 0.80 x 1.00 m Travel per axis: X = 1.70 m, Y = 1.60 m, Z = 1.95 mTable speed: X = 40 m/min, Y = 40 m/min, Z = 40 m/min

CNC Control: Siemens 840DSpindle power: 70 kW / 230 NmSpindle speed: 8’000 RPMTools: 315 (HSK-A100)

Remarks: 2 Palettes, 315 cutting toolsCapable of machining complex parts in aluminium or titanium in a 5 axis simultaneous mode.

STC 1000 Milling Center

Location Geneva


ZS 500 (Aluminum, HSC)

Supplier: Starrag + Heckert Type: ZS-500, 5-axis horizontal milling center


CNC Control: SINUMERIK 840DSpindle power: 40 kWSpindle speed: 20 - 12‘000 RPMTools: 198 (HSK 63)

Remarks: Manufacturing management system,pallet pool with 6 pallets,laser based tool measurement system, scan tracking system

Location Emmen


DMF 300 (Aluminum)

Supplier: Deckel Maho Gildemeister Type: DMF 300 linear

Travel per axis: X = 3.00 m, Y = 0.56 m, Z = 0.72 m

CNC Control: SINUMERIK 840DSpindle power: 35 kWFast motor spindle: 18’000 RPMTools: 100 HSK 63

Remarks: 2 Machines,Traverse speed of travelling columnin X-direction: 100m/min (short idle times),short tool changeover time < 5 seconds

Location Emmen


Deckel Maho DMU100 monoBlock

Supplier: Deckel MahoType: DMU100 mono Block

Table size: 1.50 m x 0.795 mTravel per axis: X = 1.15 m, Y = 0.71 mm, Z = 0.71 m

B-Axis -120°/ +30C-Axis n x 360°

CNC Control: Heidenhain iTNC530; Shop-MillSpindle power: 26 kW Spindle speed: 0 – 24’000 U/minTools: Tool changer with 32 places

Location Emmen


Milling Center (2 Machines)

Supplier: Deckel Maho Gildemeister Type: Turn / Milling Center DMC-200 FD

Table size: Ø 1.85 mTravel per axis: X = 1.80 m, Y = 2.00 m, Z = 1.00 m

C = endless, B = 0° /-90°Table speed: X = 60 m/min, Y = 40 m/min, Z = 40 m/minCNC Control: Siemens 840D-Powerline FDSpindle power: 44 kW / 288 NmSpindle speed: until 10’000 RPMTable power: 200 RPMTools: 120 (HSK-A100)

Remarks: 2 linear pallets, laser based tool measurement system, Tool identification by Balluff

Location Emmen



Supplier: MCM Type: Clock Five

Axis: 5Dimensions of rotary table: 0.63 m x 0.63 mTravel per axis: X = 0.80 m, Y = 0.90 m, Z = 0.85 m

CNC Control: Siemens 840DSpindle power: 30 kWTools: per 2 machines; 334 tools HSK 100

Remarks: 12 rotary pallets

Location Geneva



Supplier: MCM Type: Jet Five

Axis: 5Travel per axis: X = 3.00 m, Y = 2.00 m, Z = 2.00 mDimensions of rotary table: 1.25 m x 1.25 m

CNC Control: Siemens 840DSpindle power: 50 kW at 6000 RPMTools: per 2 machines: 640 tools HSK 100

Remarks: 8 rotary pallets

Location Geneva


Milling Center

Supplier: Kitamura Type: HX630i

Axis: 4Travel per axis: X = 1.00 m, Y = 0.56 m, Z = 0.56 mDimensions of rotary table: 0.63 m x 0.63 m

CNC Control: Fanuc 18iSpindle power: 40 kW at 5000 RPMTools: 100 tools ISO 50

Remarks: 2 pallets

Location Geneva



Supplier: Forest LineType: V1250 & Flexiax 510

Axis: 5Travel per axis: X = 2.00 m, Y = 2.00 m, Z = 1.80 m &

X = 2.00 m, Y = 1.25 m, Z = 1.80 m

CNC Control: NUM 760FSpindle power: 23 kW at 4000 RPMTools: 136

Remarks: 3 pallets

Location Geneva


Witec 4015 Single Sheet Milling Machines

Supplier: WissnerType: Witec 4015 Economic, CNC single sheet high

speed milling machines


CNC Control: Alpha CAMSpindle power: 3 kWSpindle speed: 5 - 40‘000 RPMTools: Tool changer with 10 places (HSK 25 E)

Remarks: Vacuum clamping technique for aluminumplates up to 6 mm thickness.

Location Emmen


Turning Center

Supplier: Pietro Carnaghi Type: AC20 TM/1600

Axis: 4Turntable: Ø 1.60 mCapacity: max. Ø 2.00 m x 1.00 m

CNC Control: Siemens 840DSpindle power: 60 kWTools: 100 tools HSK 100

High pressure coolant: 350 bars

Remarks: milling spindle 37 kW2 pallets

Location Geneva


WFL Milling & Turning Center (3 Machines)

Supplier: WFLType: M60-1000 / M65-2000 / M65-3000

Axis: 5Capacity: max. Ø 0.82 x 3.00 m

CNC Control: Siemens 840CSpindle Power: 60 kWTools: 90 per machine

Location Geneva


Sheet Metal & Welding Shop


Hydroform Press

Supplier: Avure Technologies Type: QUINTUS QFL

1.1- 800 Flexform press

Press force: 800 barTables: 2Table size: ∅ 1.10 mTool height: max. 0.21 mWork piece dimensions: max. 0.98 m x 0.98 mCycle time: 60 seconds

Location Emmen


Stretch Forming Press

Supplier: ACB Nantes (ALSTOM)Type: Loire FET 400

Stretching capacity per jaw: max. 200 metric tonsStretching stroke: 2.10 mDistance between jaws: min. 20 mm

max. 4.20 mJaw length: 3.00 mPress power: max. 400 tPlane orientation of the carriage: 0 - 15°

Size / Sheet thickness: 3.00 m: up to 1.50 mm (e.g. for aluminum) 2.00 m: up to 2.50 mm

1.50 m: up to 3.20 mm 1.00 m: up to 4.00 mm

Location Emmen


Chemical Milling of Aluminum Alloys

Bath dimensions: 3.50 m x 2.20 m x 0.80 m

Chemical milling masking: Alkaline type II (sulfide) solutionLacquer: Toluene based masking,

spraying and dipping

Location Emmen


Jetline LWP 120 Precision Welding Machine

Welding length: 3.05 mPart diameter: min. 0.23 m

max. 1.01 mMaterial thickness: min. 0.4 mm

max. 6.0 mm

Guidance accuracy: ± 0.13 mm

Clamping force: 17.9 kg/cm2

Rotating device: CWZ 600Length capacity: 12.00 mPart diameter: 1.22 mRotation: 0.03 – 6.0 PRM/min.Part weight: 1 tRotating plane tilting: 135°

Location Emmen


Vacuum Chamber for Inert Gas Welding

Stainless steel chamber

Internal length: max. 1.70 mInternal diameter: max. 0.70 m

Material thickness: min. 0.5 mmmax. 6.0 mm

Guidance accuracy: ± 0.13 mm

Vacuum achieved: max. 1 . 10-3 Torr.Vacuum required: max. 5 . 10-3 Torr.

Location Emmen


Metal Bonding & Composite Facilities


Bonding Shop Pretreatment

Bath dimensions 3.00 m x 1.70 m x 0.60 m

Specifications:Vapor degreasing: TrichlorethyleneCleaning of aluminum: Turco 4215Pickling of aluminum: Sodiumdichromate/Sulfuric acidPhosphoric acid anodizing: Phosphoric acidCleaning of titanium: Turco ARR 4181Pickling of titanium: Acti 107 CXPickling of stainless steels: Sodiumhydrogensulfate/Sulfuric acidRinsing: Deionized water RT, dipping and

sprayingDrying oven: Temperature max. 70°C

Location Emmen


Cleanroom

U.S. Federal Standard 209 B Class 100‘000/VDI 2083-6

Cleanroom size: 30.00 m x 18.50 m

Spray-booth for adhesive primer: Size: 3.50 m x 3.00 m x 2.50 m

Drying oven: Size: 3.00 m x 2.00 m x 2.50 m Temperature: max. 150°C

Curing oven: Size: 1.20 m x 1.20 m x 2.00 m

Location Emmen


Autoclave

2 Autoclaves of same type and size available

Type: Scholz

Dimensions, chamber size: ∅ 2.00 m x 4.50 m

Pressure range: Atmospheric up to 16 bar

Temperature range: 20°C to 320°C

Location Emmen


Resin Transfer Molding (RTM)

Type: DOPAGResin Mixing and Injection Unit

Temperature control & data registration unit: STANGE SE-502

Electrical heating system: 16 kW / max. 250°C

Hydraulic circuit heating equipment: 16 kW / max. 250°C

Vacuum and pressure equipment: 20 mbar absolute up to 7 bar

Experienced development team

Location Emmen


Resin Transfer Molding (RTM)

Type: IsojetInjection system for 1- and 2-component thermosets

Thermosets: 180° C curing systems

Max Volume: 40 liters in one shot

Remarks: Degassing of resin before injection

Location Emmen


Heat- & Surface Treatment Facilities


Ripoche Oven (Aluminum & Titanium)

Supplier: Ripoche

Inside dimensions: 4.20 m x 1.50 m x 2.00 m

Temperature range: max. 700°C

Charge: max. 1’250 kg

Remarks: Heat treatment facility, used to release internal stresses and improve the condition of our aluminum and titanium parts

Location Emmen


Schmitz & Apelt Oven (Aluminum)

Supplier: Schmitz und Apelt

Loading space: 4.50 m x 2.00 m x 2.40 m

Temperature range: max. 620°C

Charge: max. 1’500 kg

Heat capacity: 330 kW

Remarks: Heat treatment facility, used to release internal stresses and improve the condition of our aluminium and titanium part

Location Emmen


Dimensions: 3.00 m x 1.70 m x 0.50 m- Aluminum Pickling Turco 4215, Smut-Go 1, Chromic-/

Sulfuric acid- Chromic Acid Anodizing MIL-A-8625 Type I Class I- Conversion Coating MIL-C-5541 Alodine 1200, Alodine 1500- Rinsing Deionized water RT, dipping and sprayingDimensions: 2.00 m x 1.20 m x 0.50 m- Titanium Pickling Nitric-Hydrofluoric acid- Magnesium Chromating Black chromating- Aluminum Pickling Tri-acid etching, Nitric-/Chromic-/

Hydrofluoric acidDimensions: 1.00 m x 1.20 m x 0.70 m- Steel Phosphating Manganese phosphating bonder 98Dimensions: 0.70 m x 0.55 m x 0.55 m- Cadmium Plating Steel, high strength steel, stainless steel,

Copper alloys

Surface Treatment Area

Location Emmen


Shot Peening Facility (Steel shots)

Supplier: USFType: MP1500TI

Axis: 6

CNC Control: NUM 1040

Table size: Ø 0.63 m

Capacity: Ø 1.50 m x 1.00 m

Location Geneva


Shot Peening Facility (Glass shots)

Supplier: USFType: MP1200

Axis: 3

CNC Control: Fanuc 18i

Table size: Ø 0.36 m

Capacity: Ø 1.20 m x 0.78 m

Location Geneva


Paint Shop for Assemblies

2 Spray Booths Temperature and humidity controlled

Dimensions: 3.50 m x 2.80 m x 2.40 m

1 Curing Oven Temperature max. 60°C(for forced curing)


Location Emmen


Paint Shop for Assemblies & Large Aircraft

Temperature and humidity controlled


Location Emmen


Paint Shop for Detail Parts

3 Spray Booths Temperature and humidity controlledDimensions: 3.00 m x 3.00 m x 2.00 m

3.00 m x 2.00 m x 2.40 m6.00 m x 3.00 m x 2.20 m

2 Curing Ovens Temperature max. 80°C(for forced curing) Dimensions: 4.00 m x 0.70 m x 1.40 m

5.00 m x 3.80 m x 2.00 m1 Baking Oven Temperature max. 250°CDimensions: 2.50 m x 1.80 m x 0.85 m

Location Emmen


Paint Shop for Assemblies

Temperature and humidity controlled

Dimensions: 8.00 m x 6.00 m 2.40 m

Location Emmen


Paint Shop for Assemblies & Large Aircraft

3 Cabins fully equipped


Painting and curing Temperature range20° to 60° C

2 Separate curing stations

1 Surface sanding station

3 mixing stations two-component paint application

Location Oberpfaffenhofen


Testing & Measuring Equipment


Ultrasonic Scanner

Supplier: ALSTOMType: US -1000

Motion Displacement VelocityBridge (Scan Axis);Squirter X 4.30 m 0.50 m/sTube Carriages Y 1.85 m 0.10 m/sVertical Squirter Z 1.80 m 0.10 m/sPitch Nozzles A 160 degrees 2 degrees/s

Data Diagnostic System:Graphic Output: Colour C- and D- Scan, various diagramsEvaluation Features: Divers, filters and histograms

Remarks: Non destructive testing of composite parts and assemblies.Scan profiles can be controlled in three dimensional space.

Location Emmen


Ultrasonic Scanner

Supplier: Cegelec Type: US -2006

Motion Displacement VelocityBridge (Scan Axis);Squirter X 12 m 0.50 m/sTube Carriages Y 3 m 0.50 m/sVertical Squirter Z 3 m 0.50 m/sPitch Nozzles A 180 degrees 2 degrees/s

Data Diagnostic System:Graphic Output: Colour C- and D- Scan, various diagramsEvaluation Features: Divers, filters and histograms

Remarks: Non destructive testing of composite parts and assemblies. Scan profiles can be controlled in three dimensional space.

Location Emmen


Computerized Measuring Machine (2 Machines)

Supplier: WenzelType: CMM Machine LH 2015

Measuring range: X-axis 1.50 mY-axis 4.00 mZ-axis 1.20 m

Weight: max. 1’500 kgAccuracy: U3 = 3.2µm + (L/300 mm) µm

Remarks: Universal measuring program of curves and surfaces. Real scanning capability. Alignment by center of gravity.Statistical analysis software for geometric elements. Communication software CAD/CAQ: Network: CATIARotary table, Ø1.5 m

Location Emmen


Measuring Machine (Profile Projector)

Supplier: MicrotecnicaType: Cyclop

Soft: QC 400CNC

Capacity: 0.60 m x 0.40 m

Magnification: x 10, x 20, x 50

Remarks: Ø end shield 1000 mm

Location Geneva


Assembly Jigs/Tooling


Supplier: GüdelType: CMM Machine LH 2015

Spindle speed: up to 20’000 RPMAccuracy: ± 0.1 mmCNC-Control: Siemens 840DSafety: Safety area controlled by laser scanner

Measuring range: X-axis 18.00 mY-axis 1.00 mZ-axis 1.00 m

Swivelling tower: 180°

Dia. Tolerance: Hole: 0.05 mmSurface Tolerance: Hole: 0.8 µm

CNC Drilling Machine

Location Emmen


CNC Riveting Machine

Supplier: BrötjeArea of Application: Automatic assembly of pressure

bulkheads for widebody and narrowbody aircraft.

Longitudinal travel: X-axis 0.40 mCross travel: Y-axis 4.30 mVertical travel: Z-axis 1.00 mRotation: A-axis -10° / + 90°

C-axis -200° / + 200°Clamping force: min./max. 0.9 – 15 kNForce: min./max. 10 – 71 kNPositioning accuracy: ± 0.2 mm

Remarks: Technical data subject to change upon requirement.



C-Frame Riveting Machine

Supplier: BrötjeArea of Application: Manual assembly of panels (stringer

and frame) for wide- and narrowbodyaircraft.

Component length: X-axis 4.15 mComponents width: Y-axis 1.90 m

Clamping force: min./max. 0.6 – 10 kNForce: min./max. 7 – 60 kNSpindle speed: 300 - 15000 RPM



Integrated Panel Assy Cell Riveter

Supplier: BrötjeArea of Application: Multi-axis IPAC riveter with enhanced

manufacturing solution for skin panels and shell assembly.

Component length: X-axis 11.53 mComponents width: Y-axis 3.40 m

Rivet performance: up to 17 rivets per minuteClamping force: 50 – 1500 daNForge force: 1000 – 5.500 daNSpindle speed: 300 - 18000 RPM



RUAG Aerospace Ltd.Seetalstrasse 175CH-6032 Emmen, SwitzerlandPhone +41 (0)41 268 41 51Fax +41 (0)41 268 39 88E-Mail: [email protected]

RUAG Aerospace Structures GmbHP.O. Box 1253 D-82231 Wessling, GermanyPhone +49 (0)8153 30 43 01 Fax +49 (0)8153 30 44 54E-Mail: [email protected]

RUAG Aerospace Ltd. Geneva7, Chemin du Champ-des-Filles 1228 Plan-les-Ouates, SwitzerlandPhone +41 (0)22 884 19 50 Fax +41 (0)22 884 19 51E-Mail: [email protected]

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