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Aerospace/Defense

A solid way to

overcome micro defects Tests with improved-design carbide drill open new possibilities in hole quality

“Measure twice and cut once” may be a common expression in manufacturing, but it’s easier said than done when machining difficult materials. That’s why, when a leading global aerospace manufacturer sought to eliminate an entire second stage from its drilling processes — while also improving the hole quality in its aerospace components — it turned to Sandvik Coromant, for its expertise in metal cutting. James Thorpe, global product manager at Sandvik Coromant, explained how a drill’s design is integral to producing holes with better quality.

Hole making is the most common of all machining processes, but it is also the one most often taken for granted. Many machine shops see little reason to change or upgrade their existing hole-making setup and have been using the same tools and cutting parameters for years. But as the unpredictable effects of COVID-19 continue, this is all set to change.

Many manufacturers are exploring new vendor bases and products. Thus, machine shops that once specialized in a certain area of production are now opening their CNC lathes and mills to a wider variety of tough and challenging materials. At the same time, manufacturers must explore new ways to increase profits and reduce cycle times without sacrificing product quality.

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The white stuff Hole surface integrity is a real concern for aerospace manufacturers or general engineering companies that want to diversify into aerospace. Better hole quality is vital for preventing component failure — and is very much determined by the manufacturing processes used for machining or finishing the holes.

Tooling solutions and cuttingedge geometries in drills are continually evolving to meet the highest standards of manufacturing and part quality. Coolant is also being used more effectively for reducing heat buildup in the tool. And tests have found that each of these factors can control the so-called “white layer” effect on workpiece materials.

The term was coined by a leading global manufacturer in aerospace.

It refers to a thin, ultra-fine grain structure that is observed after component drilling, caused by the heat of the drill. Not only can the white layer change the surface properties of the material, but it was also deemed unacceptable in the customer’s quality management processes.

The manufacturer applies a strict hole-finishing process to drilled holes in aerospace components, including turbine discs, compressors, drums and shafts. That’s why it chose to partner with Sandvik Coromant to investigate why the white layer forms and how to control it.

It’s important to note that the tests were not only motivated by quality management. At the senior management level, the customer wanted to reduce its overall operational time and increase profits by eliminating an entire secondary machining process.

Second act The secondary process happens after a hole has been created with the carbide drill, and it can involve reaming, plunge or end milling to

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finish the component. The secondary stage occurs mainly to meet surface integrity demands and reduce issues like the white layer, rather than for dimensional accuracy, except when machining holes with tight tolerances.

The tests assessed drilling with two solid carbide drills, the CoroDrill R840 and CoroDrill R846. Each was run at two different sets of cutting parameters, 58 mm/min and 98 mm/ min, respectively, and spin speeds of 829 rev/min and 757 rev/min, respectively. Cutting force and torque data were measured throughout the tests, as was the white layer thickness.

Since these tests, R840 has been

Another Sandvik Coromant customer, an Italian general engineering manufacturer, achieved a productivity increase of more than 45% using the CD860-GM when machining the strong steel alloy 34CrNiMo6, compared to using a competitor’s drill.

From an overall cost perspective, the secondary process is even more expensive than maintaining low cutting data, which is the other way to preserve surface integrity.

That is why the customer wanted to investigate doing away with the process altogether. A supplier with a product that produces a conforming hole to size, without any secondary processes, is in a strong business position to significantly reduce cost per part.

The investigation into causes and possible ways to prevent the white layer involved four tests of drilling the high-strength, nickel chromium material Inconel 718, a popular aerospace material. It was the first time any such investigation had been carried out by the customer. www.designworldonline.com

superseded by the CoroDrill 860 with -GM geometry, and R846 has been superseded by the CoroDrill 860 with -SM geometry. Each of these next-generation tools is designed to further enhance tool life without compromising hole quality.

The results provided valuable insights into what causes white layer thickness. Particularly of note was that the R846 generated less of a white layer, due to the preparation of its curved and radial cutting edges.

Meanwhile, the straight cutting edges and chamfer imposed on the cutting edge of the R840 are believed to be linked with the increase in cutting force, torque and white layer thickness. Therefore, the drill’s design determines whether high hole quality with a reduced white layer can be April 2021

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achieved without sacrificing cutting data.

Not only did the manufacturer’s tests reveal a thing or two about the white layer, but the company has also been able to eliminate some secondary processes, like reaming and plunge milling, which resulted in time and cost benefits. What’s more, the results have also validated the design of the CoroDrill 860 range of carbide drills.

Better by design The range includes the aforementioned CoroDrill 860 with -GM (CD860-GM) geometry, designed to be a good all-rounder for drilling challenging ISO P, M, K and H materials across all industry sectors.

Also, the CoroDrill 860 with -SM geometry (CD860-SM) is designed for machining ISO S grades like super alloys (HRSAs), titanium and Inconel.

The latter drill has proven especially popular in aerospace.

With the CD860-GM and CD860SM, Sandvik Coromant’s engineers applied the ethos that longer tool life and better hole quality come down to the design of the drill. The CD860-GM has an innovative polished flute design that improves the evacuation of chips and yields high core strength and reduced cutting forces while drilling.

The CD860-SM, meanwhile, has a new grade and optimized and refined point geometry, which further enhances tool life when working with difficult-to-machine HRSA materials.

The result is greater hole quality.

The CoroDrill 860 has already been proven in pre-market tests in a range of sectors. A mechanical engineering company in France put the CD860-GM to work on AISI 4140 structural steel. It was able to achieve quality hole making with both concave and convex entries of the drill, with good straightness and tolerance.

Another Sandvik Coromant customer, an Italian general engineering manufacturer, achieved a productivity increase of more than 45% using the CD860-GM when machining the strong steel alloy 34CrNiMo6, compared to using a competitor’s drill. It also achieved 100% longer tool life. Elsewhere, the CD860-SM has yielded impressive results in machining Inconel 718.

In particular, testing undertaken in Katowice, Poland, was able to achieve 180% improved tool life with the CD860-SM versus the use of the CoroDrill R840. AD Sandvik Coromant sandvik.coromant.com

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Aerospace/Defense

Figure 3.

Autonomous Electric Vertical Takeoff and Landing (eVTOL) Aircraft.

Applying Artificial Intelligence in rugged GPGPU-based military embedded systems Military equipment must be designed to face harsh environments. Artificial intelligence can help.

Dan Mor | Director | GPGPU and Video Product Line

In addition to supporting crucial, lifesaving and securityfocused applications, system designers of military applications need to build computing platforms that are subjected to extreme shock and vibration as well as severe and expansive temperature and humidity fluctuations, ranging from sub-zero to triple digits.

Artificial intelligence (AI) has joined the ranks of the advanced computing capabilities being integrated into rugged systems throughout military and defense applications, helping to facilitate high performance embedded computing (HPEC) systems in harsh environments. It’s AI’s intuitive processing that has served to propel modern military systems into this new realm of high intensity computing using real time data. AI in military systems is fueled by GPU (graphics processing unit) accelerated computing, which uses parallel processing versus serial, to enable the handling of thousands of data points simultaneously.

Knowing how to move today’s data processing technologies, like AI, into the realm of harsh environments can be accomplished by applying the same principles of ruggedization

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employed in developing other harsh environment systems.

Using this approach, you are employing GPU accelerated computing in the way that is best for the specific defense, military or mission-critical application at hand.

Define your application challenges As designers know, thoroughly understanding system requirements is a good place to start. Today’s military systems are using more resources in a much smaller footprint, typically referred to as optimized SWaP— size, weight and power—while needing to keep costs low. In addition, these applications function in harsh environments, and carry with them the need to operate reliably all the time, every time. This dichotomy has challenged many electronic engineers developing critical military, defense and space systems for decades, but, as history has shown, these challenges can not only be mitigated, but met, as well.

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Figure 1. Deeper data insights are fueling developments in military systems.

To reap the benefits of HPEC systems using GPU accelerated computing in military and defense operations, reliability is key, because all that advanced processing won’t mean a thing if the system is unable to withstand harsh environmental factors and provide stable, long term operation. Working together with today’s design innovations, like power efficiencies, SWaP-optimization, and enhanced ruggedization, real-time data processing has expanded the number of applications that can use embedded systems in harsh environments.

Increased system abilities through AI disciplines As AI matured, it expanded into a new discipline--machine learning, where systems can learn from data inputs without being explicitly programmed. A logical component applied to actions the system deems appropriate enables an action to be executed by the system. Take this one step further and you arrive at where we are today: deep learning...classified

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as a subset of machine learning. (Figure 1) When working with military and defense systems, ruggedizing electronics is important as designers encounter a growing number of remote, mobile and unmanned military applications. AI-based systems are using this GPU accelerated computing, and just like many parts and components used in a harsh environment, the GPGPUs (general purpose graphic processing units) themselves, most of the time, aren’t rugged at manufacture. In fact, they were brought over from the gaming industry, where graphics and data processing continue to set new limits, but is not a rugged environment by any means.

Expanding ruggedization to GPGPU-based systems Real time response applications are requiring systems that can perform AI processing at the sensors for “AI at the Edge” and for autonomous operations, exponentially increasing computing requirements. Using a GPU instead

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Aerospace/Defense Figure 2. Rugged GPGPU-based systems, like the A176 and A178 from Aitech, combine powerful processing with SWaP-optimized performance.

of a CPU reduces development time and “squeezes” maximum performance per watt from the computation engine. The main reason this can happen is that GPUs use a parallel architecture, whereas CPUs are serial in nature.

GPU accelerated computing uses a GPU to accelerate the compute capabilities of a system by running compute intensive portions on the GPU, using less power and delivering higher performance over many CPUs that can provide equivalent performance results. GPUs serve as the heart of these computationintensive embedded systems. Through an increased power-to-performance ratio, GPU-based systems can meet the exorbitant calculation demands these applications now require.

(Figure 2)

By applying the ruggedization expertise of board and system manufacturers to products based on GPU accelerated computing, advanced processing systems can reliably operate in remote, mobile and harsh environments, from industrial environments such as down-hole well monitoring and autonomous robotics systems to unmanned aircraft and ground vehicles as well as persistent video surveillance throughout military and defense operations.

Rugged GPGPU in action Below are some documented use cases of rugged, SWaP-optimized systems that need to capture and process data and graphics from several inputs simultaneously and manage it all from I/O interfaces.

Proper system ruggedization

made it possible to use AI-based technology in mission-critical, harsh environments, both manned and unmanned.

Air: Autonomous Electric Vertical Takeoff and Landing (eVTOL) Aircraft Prototypes of pilotless eVTOLS are being rapidly developed, with many using platforms that already exist, such as drones or unmanned helicopters, then integrating leading edge technologies to achieve the needed function of these air transport vehicles. Rugged GPU accelerated computing is at this forefront. In fact, the technology is advancing so quickly that systems are moving to next gen architectures as development is taking place.

In this instance, accommodating the increased sensor processing

Figure 4. Ground mobile platform.

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Aerospace/Defense integrated into the unit is cause for the upgrade to replace typical CPU-based embedded computing architectures.

Land: Ground Mobile Platform Relied upon to send mission-critical data from the battlefield to a forward battle command, or directly to the soldiers on the ground themselves, tanks and other ground vehicles incorporate several onboard cameras and data collection points to aid in the decision-making process. In one instance, a rugged GPGPU system is capturing images from six cameras— four composite and two HD-SDI— then performing simultaneous image processing applied to object recognition and classification as well as situation awareness. The system is using CUDA for image and video processing and saves this sensitive data on internal fast NVME SSD

that can be transmitted back to the command center instantly and when needed. The multiple video inputs are processed simultaneously in a low-power, small form factor (SFF), rugged system, which provides a performance-per-watt (PPW) factor that is critical in determining a go/no go for program deployment.

Enhanced military intelligence How to design reliable systems for harsh environments is critical and includes even more specific technical considerations, such as which techniques will best mitigate the effects of things like environmental hazards as well as ensure that systems meet designated application requirements. At Aitech, for example, GPGPU-based boards and small form factor (SFF) systems are qualified for, and survive in, several avionics, naval, ground and mobile

applications, thanks to the decades of ruggedization expertise that is applied to system development.

For defense and military applications, AI has a unique opportunity to provide significant benefits across a range of activities.

While industrial environments may garner financial and productivity benefits from implementing an AI-based strategy, mission-critical applications that protect human life and require extreme precision and accuracy are a different category altogether. Up-to-date, reliable operational intelligence is paramount to the success and safety of modern defense initiatives, and enabling ruggedization across these systems is the key to mission success. AD Aitech | aitechsystems.com

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The Perseverance, with Adaptive Caching Assembly.

Space-rate force/torque

sensor for Mars 2020 Rover Edited by Mike Santora ATI Industrial Automation worked with NASA’s Jet Propulsion Laboratories (JPL) to develop a custom force/torque sensor for Perseverance, the latest Mars 2020 Rover project. JPL is the leading US research entity for robotic exploration of our solar system and manages NASA’s Deep Space Network, the hardest-working telecommunications system on the planet. The Mars 2020 mission is a collaborative effort undertaken by NASA, JPL, and many other organizations commissioned to develop new technology to explore the surface of Mars.

JPL needed an automated system for collecting and handling space material, and moving it through the indexing process. To accomplish this, engineers developed the Adaptive Caching Assembly, an application that resembles a pick and place operation commonly found on a factory floor. Developing the systems and components that would perform in the Rover mission was a huge challenge to overcome.

The Sample Caching Subsystem consists of the Adaptive Caching Assembly, a large robotic arm with a drill, and an assortment of drill bits used to collect samples from designated areas on the surface of Mars. Once collected, a small robotic arm,

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ATI’s Space Rated Force Torque Sensor. known as the Sample Handling Assembly or SHA, inspects and seals the samples in the Rover’s onboard laboratory.

An ATI Force/Torque (F/T) sensor integrated within the SHA end effector assembly provides enhanced responsiveness. With force-sensing from ATI, the SHA is equipped to maneuver easily through the tight workspace, performing demanding tasks with acute accuracy.

To deliver a robust force-sensing solution for the Perseverance project, ATI adapted their Force/Torque Sensor technology to offset the wide range of environmental conditions. The SpaceRated Force/Torque Sensor from ATI boasts a new design that provides signal redundancy and compensates for temperature variation, ensuring accurate resolution of forces and torques throughout the mission.

This sensor is thermally calibrated and proven to operate optimally in a spectrum of extreme temperatures. To develop and test these breakthrough features, the ATI engineering team designed specialized calibration equipment and conducted 24-hour surveillance of product trials.

planet from firsthand experience. This project has a full agenda that includes searching for signs of ancient microbial life, categorizing climate

Components made of thermally and geology to identify potentially stable, low-outgassing materials were inhabitable conditions, recovering added to fortify the sensor against the samples from the planet’s surface, and drastic environmental fluctuations.

— arguably the most exciting objective These materials also prevent crossof this mission — preparing for human contamination of samples during the exploration of Mars. mission, which is one of the most

The Perseverance Rover is an important considerations of the Mars unmanned robotic vehicle about the 2020 Rover project. size of a car; during its exploration, it

After years of development, the will collect and index small samples highly anticipated Mars 2020 Rover is of rock and soil from prime locations. fully assembled and ready to begin its Once on-board, sample tubes are mission. Perseverance is set to launch on July 30, 2020, from Cape Canaveral, cached inside the Rover for eventual return to earth.

Florida, and will arrive at Mars in

This subsystem emulates February of 2021. automated processes found in the agriculture and manufacturing More on Mars 2020 industries, where robots are used The purpose of this particular mission, to make repetitive operations more part of NASA’s Mars Exploration precise. Certain application settings Program, is to learn about the red such as foundries and refineries require unusual environmental considerations for which ATI has developed specialized sensors. However, nothing quite compares to the conditions expected from the Mars 2020 mission, where subzero surface temperatures and rugged terrain are typical. Before landing on Mars, the rover and its subsystems have to survive the initial Atlas 5 rocket launch.

NASA scientists inspect the Adaptive Caching Assembly.

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Aerospace/Defense Beyond outer space applications, ATI’s Space-Rated Force/Torque sensor provides active force control for applications where repair opportunities are limited or in situations with high vacuum or extreme temperature variability.

Through this project, ATI developed new technology that will be a part of NASA history and provide robust and reliable force sensing to applications here on earth.

The temperature compensation, thermally stable components, and additional signal redundancy benefit users in industries such as radioactive decommissioning, oil and gas, metal casting and foundries, and other applications where conditions dictate continuous use in extreme environments. ATI looks forward to following Perseverance, the Mars

2020 Rover, during its mission and to the new applications that will feature this space-rated force/torque sensor.

These force/torque sensors are often used with robots in similar applications for greater process control and provide process verification, such as indicating that a pin is inserted properly into a fixture.

Beyond outer space applications, the space-rated force/torque sensor provides active force control for applications where repair opportunities are limited or in situations with high vacuum or extreme temperature variability. AD ATI Industrial Automation ati-ia.com

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CS Hyde Company Adhesive Tapes Ideal for Aerospace Manufacturing CS Hyde is your source for high temperature adhesive tapes slit to custom widths with little to no minimums. Types of tapes ideal for aerospace applications include: Fiberglass cloth tapes for glassing seams, corners, edges, or common repair jobs. D-Wrap Polyester tapes for masking anodized metal components. Anti-Chafe tapes like skived PTFE, UHMW, or PTFE Coated Fiberglass tapes for use on engine cowlings to reduce abrasion on cowl hoods or flap components.

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The Lee Company High Pressure Dual Metering Flow Control The Lee Company’s High Pressure Dual Metering Flow Control valve is a two way restrictor that allows a designer to specify a different metered flow rate in each direction. This valve is ideal for high pressure hydraulic applications with system pressures up to 5000 psi. It features all stainless steel construction for durability and long life and it is available in .187 and .281 diameter models. Each Lee Dual Metering Flow Control is 100% tested in both flow directions to ensure reliable, consistent performance.

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