Schaeffler Aerospace Opts for WFL Millturn Technology to Master Complex Bearing Systems
Schaeffler Aerospace utilizes the Millturn machines for complete machining of aerospace bearing components, integrating multiple operations into a single setup. This approach -- combining turning, milling, and drilling -- has allowed the company to efficiently handle the stringent requirements in the aerospace industry.
Schaeffler Aerospace based in Schweinfurt, Germany.
With around 600 employees, Schaeffler Aerospace & Co., based in Schweinfurt, Germany, manufactures high-precision roller bearing systems for the aerospace industry. In addition to manufacturing, the company also specializes in developing, designing and rigorous testing of complex bearing systems, each one tailored to the unique demands of its intended application.
Roller bearings used in the aerospace sector must be able to withstand extreme temperatures, challenging load profiles and high speeds. The industry also requires over 70 years of traceability and documentation with the highest levels of component quality and reliability. What's more, production of the bearings must be guaranteed over the entire usage cycle spanning several decades.
At Schaeffler Aerospace, 75% of bearing components are used in engines for passenger and military aircraft and 25% are used in helicopters and aerospace applications. The materials used, such as Inconel 718, case-hardened steel M50Nil or Cronidur 30, are extremely tough and difficult to machine. At the same time, the tightest tolerances must be met during machining and thin-walled geometries created without causing any microstructural damage.
Efficiency through complete machining
Schaeffler Aerospace has been using WFL MILLTURN machines to meet these requirements since 2006. Prior to the purchase of these machines, many machining steps were carried out separately on classic 2-axis turning and 5-axis milling machines. Thanks to the MILLTURN, the company was able to achieve process-integrated complete machining for the first time.
Technology developer Thomas Memmel and WFL sales representative Andreas Lehner at Schaeffler Aerospace.
Machining steps such as turning, milling, drilling or measuring are now carried out on a single system, which reduces set-up times, prevents re-clamping errors and improves the machining quality. In the case of average batch sizes between 15 and 50 pieces, the number of set-up processes plays a decisive role.
"One of the particular advantages of the MILLTURN machines is the integrated B-axis. Thanks to swiveling tool positioning, complex component geometries can be created with a small number of tools in just one clamping operation," explains Thomas Memmel, Head of Technology Development at Schaeffler Aerospace.
Despite occasionally longer overall cycle times, combining the machining operations is economically advantageous, especially in regard to autonomous shifts or multiple machine operation.
Michael Koberstein (Turning-Milling Trainer), Thomas Memmel (Technology Development)
The MILLTURN machines also offer convenient CNC programming and are perfectly integrated in CAM environments, which means that machining strategies can be implemented efficiently alongside rapid adjustments and optimum planning of the machining steps. At Schaeffler Aerospace, this has reduced the programming time and maximized process stability, even for small batch sizes and variable geometries.
Fields of application
The finished bearings can be found in modern Rolls-Royce aircraft engines such as the Trent 1000, Trent XWB or Pearl 10X models used in the 787 Dreamliner and A350 airliners or business jets. Components from Schaeffler Aerospace are also installed in engines for the new A320neo and 737MAX short and medium-haul planes. These engine programs are of central importance to the aviation industry.
Demo of a bearing system on the Rolls Royce Trent 1000 engine.
Helicopter manufacturers also put their trust in bearing solutions from Schaeffler Aerospace. These bearings feature in gear units, transmission shafts and swashplates, where they ensure the ultimate in smooth running properties and reliability -- even under changing loads and difficult climatic conditions.
Another outstanding area of application lies in aerospace. Schaeffler bearings are used, for example, in the turbopumps of the RS-25 engine -- the high-performance engine used in the first stage of NASA's SLS (Space Launch System). These bearings must withstand incredible speeds and operate in unique environmental conditions. The bearings are lubricated with liquid water and oxygen at operating temperatures below -200° C: requirements that can only be met by absolutely reliable and precisely manufactured components.
Process reliability is supported by state-of-the-art measurement technology within the M50 MILLTURN.
The process reliability is supported by state-of-the-art measurement technology within the M50 MILLTURN, such as integrated scanning measuring probes, which enable exact process monitoring during machining. The tolerances required are in the range of 20 µm for turning and up to 10 µm for milling -- values which can only be achieved with consistent process control.
Digitalization and automation
Schaeffler Aerospace got on board with digitalization at an early stage to make processes more efficient and to ensure the high level of traceability that is essential for the aviation sector. "We develop our own software applications to gradually move towards a paperless production model and to develop a more consistent process chain. This proactive approach shows that we anticipate and set trends rather than merely respond to them," explains Thomas Memmel.
The M50 MILLTURN with automation cell is the latest addition at Schaeffler Aerospace.
When it comes to metal cutting, Schaeffler Aerospace relies on connectivity to drive process optimization or extend service life using data. Particularly noteworthy is the company's focus on the quality of high-performance components, which is always the utmost priority. These measures demonstrate a deep understanding of the industry and a clear alignment with future-proof, high-quality and production-related processes.
The company is also making headway in regard to automation. Thanks to robot-assisted loading and a largely unmanned third shift -- including at the weekend -- the company is able to compensate for shortages in skilled workers and reduce costs. The challenge lies in the sensitivity and high quality of the components; loading errors must be reliably detected and prevented. This requires intelligent process monitoring using sophisticated sensor systems, which have been developed by WFL itself.
The rapid pace of technological development means Schaeffler Aerospace has to be clever about selecting and integrating megatrends.
Outer ring of an engine bearing on a coordinate measuring machine.
In the field of automation, it is clear that there are challenges in regard to small batch sizes and changing geometries. Nonetheless, the company places great value on programming systems quickly and minimizing set-up times during type changeovers. Michael Both, Head of Industrial Engineering Aerospace, emphasizes the decisive role of automated and complex solutions when it comes to ensuring a competitive edge in a high-wage economy such as Germany. Efficiency and precision are essential in the aerospace industry, which is why advanced technology is used to reduce errors and increase production quality.
The use of MILLTURN technology is a strategic key for Schaeffler Aerospace in meeting stringent quality requirements -- both today and tomorrow. Combined with digitalization and automation, the company continues in its role as a reliable and innovative partner to the global aerospace industry.
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