On the surface, aerospace machining is pretty straightforward: precision operations done a step at a time. Although exacting, it’s frequently left-brain work that’s comfortably predictable. It’s mostly pocket milling, process monitoring and prescribed recordkeeping. Or is it?

Arguably, no other sphere of manufacturing attracts so many imaginative thinkers – big-picture types who ignore trivia, but are passionate about essential details. They’re innovators like Edvaldo Antonio da Rosa, the founder of a cutting-edge Brazilian aerospace shop with a name that evokes Japan – Toyo Matic.

Located in the southern city of Bragança Paulista, about 85 km north of São Paulo, Toyo Matic serves prominent clients in the Americas, Europe and Asia. According to its customers, Toyo Matic helps put Brazil on the map as a center for modern precision machining. “That’s been our ambition since day one,” says da Rosa, with a smile. “We love to hear people say: ‘You can’t do that in Brazil!’”

The 20-year-old company earned its reputation by routinely doing the nearly impossible. Although it boasts a crew of 75 skilled machinists, operators, engineers and office staff, Toyo Matic’s success reflects the drive and technical talent of its energetic founder. With typical Brazilian humor, associates declare that if da Rosa stepped into a revolving door one space behind them, no one would be surprised to see him exit first!

Not So Simple

As prime aerospace manufactures strive to build with weight-saving monolithic components, the “nearly impossible” has become a common request. When Brazilian aircraft manufacturer Embraer recently combined several hydraulic control components for their popular ERJ-170/190 aircraft into a simpler monolithic unit, it proved to be anything but simple to make.

After eight companies in three countries failed to find a cost-effective way to manufacture the part, Embraer probably started having second thoughts. Fortunately, the design packet found its way back to Brazil – and Toyo Matic. “It’s now the most difficult part we make,” confides da Rosa. “It took many months of testing to develop the procedures.” The heavily milled 7075 aluminum block manifold has deep, intersecting blind holes, some as small as 2 mm diameter. Numerous other bores, recesses and curved surfaces often require 6-micron tolerances, and it requires 160 individual CMM checks to generate the final 61-page inspection report that accompanies each unit!

Toyo Matic solved many of the problems that baffled others by optimizing their tooling to reduce the major causes of inaccuracy: vibration, thermal growth and chip-induced tool runout. “We’ve distilled the manufacturing process down to only six operations,” da Rosa explains, “but we use 112 different tools!”

Finding the “technically sweet” tooling solution was a creative effort well suited to da Rosa’s talents. Before returning home in the 1980s to start Toyo Matic in Brazil, he worked in Toyokawa City, Japan, for the large international tool manufacturer, OSG Corporation. “I suppose,” he notes, “that’s one of our secrets.”

Secrets Too Numerous

Instead of searching tool catalogs for the perfect solution, da Rosa takes a more direct approach. “Whenever I have the time, I always build my own tools,” he explains. “The advantages are just too numerous to ignore.” By making his own, da Rosa can optimize each milling tool’s length-of-cut ratio for each operation – this usually means producing the shortest possible tool to do the job. Standard-reach tools are usable for a wide range of operations, but their longer shafts make them prone to axial runout, deflection and vibration. This is especially true when subjected to the heavy side loads of aggressive pocket milling – the most common scenario in an aerospace shop. The traditional way around these problems is to slow the feedrate. But that lengthens cycle time and can cause new problems, especially in hard materials like titanium, where a reduced feedrate can cause galling and work hardening. Also, with the reduced chip load, heat can quickly build up at the cutting edges, significantly shortening tool life. “Changing to the proper length tool is the better solution,” offers da Rosa, “even though the better solution isn’t always the obvious one.”

What about deep-reach situations where a longer tool is required? Again, da Rosa’s optimized approach pays off. He makes exact-length tools with an integral 40- or 50-taper base that allows direct mounting in the machine spindle. By eliminating the toolholder altogether, he bypasses a major source of runout error. It is this kind of ingenuity motivation toward precision that gives a shop the innovate edge in the CNC business.

Economic activity in the manufacturing sector expanded in April for the 21st consecutive month, and the overall economy grew for the 23rd consecutive month, say the nation’s supply executives in the latest Manufacturing ISM Report On Business®.

Of the 18 manufacturing industries, 17 are reporting growth in April. Several of the fastest growing industries related to machining are:

• #2 – Plastics & Rubber Products
• #3 – Primary Metals
• #5 – Fabricated Metal Products
• #9 – Machinery
• #15 – Miscellaneous Manufacturing

The report was issued today by Norbert J. Ore, CPSM, C.P.M., chair of the Institute for Supply Management™ Manufacturing Business Survey Committee. “The recent trend of rapid growth in the manufacturing sector continued in April as the PMI registered above 60 percent for the fourth consecutive month. The New Orders and Production Indexes continue to drive the PMI, as they have both exceeded 60 percent for five consecutive months. Manufacturing employment appears to have developed significant momentum, as the Employment Index readings for the first four months of 2011 are the highest readings in the last 38 years. Inventory growth also took place in April after two months of destocking; however, the inventory restocking would appear to be necessitated by the strong performance in new orders. While the manufacturing sector is definitely performing above most expectations so far in 2011, manufacturers are experiencing significant cost pressures from commodities and other inputs.”

Since 2006, thousands of amateur scientists, artists and hobbyists alike have attended the annual Maker Faire (http://makerfaire.com/), a large-scale science exhibition that showcases technology and engineering creations, and provides a chance for attendees to share their expertise and inventions. The event— to be located in New York, the Bay Area, Detroit and the UK this year— was started and organized by MAKE Magazine’s Dale Dougherty, who has described the attendees as experimentalists. “Essentially these are people that are playing [with] the technology. They don’t necessarily know what they’re doing and why they’re doing it. They’re playing to discover what the technology can do and probably to discover what they can do themselves, what their own capabilities are,” he said at a conference.

Technology Showcases

While there have been hundreds of exhibits since the show’s inception, the showcases have highlighted technological products that are available through large-scale manufacturers, including 3-D printers. The 3-D open-source printer exhibited at the show enables its users to participate in personal manufacturing without the costly result. Other 3-D technology showcased has included motion capture display technology, which has been increasingly used in film production. Devices that incorporate LED technology  screens have also been featured at the show.

Creative Tech

Some creative devices featured at the Maker Faire have included electric “muffin mobiles,” and two giant constructed neurons that mimic how brain cells function using lights. Also featured at the show: a “rain swing set” featuring a controller at the top of the swing set that automatically shuts off water when a person swings. Another “maker” invention is a radar speed detector constructed from a Hot Wheels toy.

Robot Devices

DIY devices constructed from recycled items at past shows include robots constructed from old devices, such as computer monitors, that can be operated from remote locations. One attendee from the R2 Builders Club, (a group that builds homemade “Star Wars” inspired R2-D2 androids) demonstrated his personal R2 robot creation, which was constructed from aluminum and featured a compact flash reader that controls the sound. Other past creations include a giant robotic spider, a robotically maneuvered chess game and a robotic giraffe.

To see more show highlights, what the video below:

Laser, Waterjet and Plasma Cutting Basics

In order to fabricate a variety of intricate part designs, appliance pieces and tools, manufacturers commonly use cutting technologies including waterjet, laser, and plasma processes. Each of these standard cutting methods employs different application tools; they are not always compatible with the same type of materials. Plasma cutting involves melting material surfaces via a high speed gas process. Another heat-centric process, laser cutting, involves using high temperature to melt materials while a gas jet propels excess materials out of the cuts. Waterjet cutting, which is used as an alternative to both aforementioned processes, does not involve heat treatment and employs jet streams to cut materials.

Here is an overview of the three cutting processes:

The Waterjet Cutting Process and Applications

Waterjet cutting—also known as pure waterjet cutting—was first available for commercial manufacturing use in the 1970s. The process, which is often used instead of plasma and laser technologies, incorporates a high-pressure stream of water that cuts a wide volume of materials. The process is commonly used for replacing milling operations. During the process, an orifice ejects a jet stream at speeds which exceed the speed of sound. This cutting technique is distinguishable for its ability to create precision cuts and is an efficient process for timely jobs that require intricate detail.

Another form of this process, abrasive waterjet cutting, involves incorporating an additional abrasive, such as garnet or aluminum oxide. Once these abrasive materials are added to a small chamber in the cutting tool, harder materials, such as concrete and steel, can be cut. Standard materials compatible with the water process include metal, foam, foods, rubber, plastics and glass, and flammable materials. Common applications associated with this process include parts for the automotive and shoe industry and standard products fabricated with this process include tissue paper and diapers. The process is also distinctive because it does not involve heat treatment and cause deformations as with other cutting technologies.

Some Advantages of Waterjet Cutting

• Detailed, precision cuts result in material savings;
• Minimal material loss in the pure cutting process;
• No thermal distortion;
• Short set-up time;
• Good to use in hazardous zones where heat is restricted;
• May be used for flammable materials;
• Cuts a wide variety of thick and thin materials

Waterjet Cutting Considerations

Although the waterjet cutting process is compatible with a vast amount of materials, there are limitations to consider. Experts note that the pure cutting process should not be applied to diamonds, which are too dense, or tempered glass, which will crack when under pressure. Additionally, the process is not efficient when it is used for fabric or material bundles, as the jet stream loses power after cutting through the first several layers of material. It is also helpful to note that water jet may be slower than the speed of a laser cut component.

Laser Cutting Process and Applications

The laser cutting process is a thermal method that employs energy to melt material. Typically, this process is used to melt material in a localized area, and lasers are able to achieve extremely thin cuts. An assist gas, typically CO2, is transmitted through a beam that treats the material. The gas jet is typically co-axial to the beam and works by blowing the excess metals out of a cut slit. As with flame cutting, laser treatment involves cutting work pieces along lines and curves. The process is sometimes used complementary to CNC/Turret cutting.

Overall, laser cutting is efficient for its precision and the ability to cut numerous materials such as precious and non-ferrous metals, (excluding reflective metals) wood, glass and plastics. The process is often used as an alternative to plasma and oxyfuel cutting, as it is distinctive for accuracy and heat input control and the ability to produce high-quality cuts without additional finishing.

Advantages of Laser Cutting

• Quick set up time;
• Ability to produce thin cut widths;
• Minimal waste clean-up;
• Low distortion rate;
• Applicable to small batches;
• Efficient alternative to mechanical processing

Laser Cutting Considerations

As with all cutting procedures, it is essential to consider safety precautions and wear appropriate gear when processing materials with laser tools. Although lasers work with a number of metals, they are not suitable for reflective materials, such as aluminum and copper alloys. In order to avoid partial burring on thin work pieces, a proper application distance must be applied when processing the material.

The Plasma-Arc Cutting Process

Materials processed with the plasma cutting process are treated with a high-temperature ionized gas arc. The gas content may be oxygen, nitrogen, argon. As the gas passes through nozzle, the restricted opening of the tool causes it to exit at a high speed, enabling it to cut through metals, and an electric arc ionizes the gas. Standard materials that can be treated using this process include aluminum, steel and stainless steel sheets. Typically, this process is used for heavier cuts, including processes such as welding and for cutting aluminum alloys and is commonly used as an alternative to mechanical saw cutting.

Advantages of Plasma-Arc Cutting

• Popular alternative to mechanical oxyfuel cutting;
• CNC is cost effective for thick metals;
• Ideal for cutting thin non-ferrous materials (up to 1 inch);
• Suitable for cutting various expanded materials;
• Efficient for producing non-linear cuts

Plasma Cutting Considerations

It is essential to consider plasma cutting limitations, specifically when compared to other processes. For example, plasma cutting machinery may cost more than other cutting methods such as oxyfuel cutting. In addition, keep in mind that the edges of the processed material may be rough, specifically with thicker materials. Professionals also note that warping may occur when processing intricate parts. Additionally, whereas laser and waterjet cutting may be used to achieve fine precision cuts, the CNC plasma cutting process is most effective for cutting 2D shapes that require less intricate details.

There are many different categories of lathes. Some of the major categories are listed below.

Woodworking Lathes: Woodworking lathes are the oldest variety. All other varieties are descended from these simple lathes. An adjustable horizontal metal rail – the tool rest – between the material and the operator accommodates the positioning of shaping tools, which are usually hand-held. With wood, it is common practice to press and slide sandpaper against the still-spinning object after shaping to smooth the surface made with the metal shaping tools.

Metalworking Lathes: In a metalworking lathe, metal is removed from the workpiece using a hardened cutting tool, which is usually fixed to a solid moveable mounting, either a toolpost or a turret, which is then moved against the workpiece using hand-wheels and/or computer controlled motors. These (cutting) tools come in a wide range of sizes and shapes depending upon their application.

Cue Lathes: Cue lathes function similar to turning and spinning lathes allowing for a perfectly radially-symmetrical cut for billiard cues. They can also be used to refinish cues that have been worn over the years.

Glassworking Lathes: Glassworking lathes are similar in design to other lathes, but differ markedly in how the workpiece is modified. Glassworking lathes slowly rotate a hollow glass vessel over a fixed or variable temperature flame. The source of the flame may be either hand-held, or mounted to a banjo/cross slide that can be moved along the lathe bed. The flame serves to soften the glass being worked, so that the glass in a specific area of the workpiece becomes malleable, and subject to forming either by inflation (“glassblowing”), or by deformation with a heat resistant tool. Such lathes usually have two headstocks with chucks holding the work, arranged so that they both rotate together in unison. Air can be introduced through the headstock chuck spindle for glassblowing. The tools to deform the glass and tubes to blow (inflate) the glass are usually handheld.

Metal Spinning Lathes: In metal spinning, a disk of sheet metal is held perpendicularly to the main axis of the lathe, and tools with polished tips (spoons) are hand held, but levered by hand against fixed posts, to develop large amounts of torque/pressure that deform the spinning sheet of metal. Metal spinning lathes are almost as simple as woodturning lathes (and, at this point, lathes being used for metal spinning almost always are woodworking lathes).

Ornamental turning Lathes: The ornamental turning lathe was developed around the same time as the industrial screw-cutting lathe in the nineteenth century. It was used not for making practical objects, but for decorative work – ornamental turning. By using accessories such as the horizontal and vertical cutting frames, eccentric chuck and elliptical chuck, solids of extraordinary complexity may be produced by various generative procedures.

Reducing Lathe: A reducing lathe is a specialized lathe that is designed with this feature, and which incorporates a mechanism similar to a pantograph, so that when the “reading” end of the arm reads a detail that measures one inch (for example), the cutting end of the arm creates an analogous detail that is (for example) one quarter of an inch.

Rotary Lathes: A lathe in which softwood, like spruce or pine, or hardwood, like birch, logs are turned against a very sharp blade and peeled off in one continuous or semi-continuous roll.

Watchmaker’s Lathe: Watchmakers lathes are delicate but precise metalworking lathes, usually without provision for screw-cutting, and are still used by horologists for work such as the turning of balance shafts. A handheld tool called a graver is often used in preference to a slide mounted tool.