Reducing Turnaround Time with Advanced Manufacturing

Shown with a recently purchased Laserdyne 795 BeamDirector system are (left to right) Kurt Magedanz, process engineer, and Ed Magedanz, senior manufacturing engineer, Ace Precision Machining Corp.

Multi-axis laser processing is one of the complete spectrums of precision manufacturing services provided by Ace Precision Machining Corp., Oconomowoc, WI, What sets this one-stop contract manufacturer apart from others is the depth of its laser processing operations along with large-scale capabilities in metal joining, CNC machining, metal forming, thermal processing, and much more.

Ace Precision is a strategic manufacturing partner with leading aerospace, power generation, and defense manufacturers. By doing all operations in-house without dependence on outside subcontractors, Ace Precision reduces turnaround time on projects, eliminating issues that might occur when using a third party supplier.

“Almost nothing is outsourced,” states Ed Magedanz, senior manufacturing engineer, Ace Precision. “Because our facilities and trained people encompass all areas of metal forming, fabrication, and testing, the company maintains process control from start to finish. We work on large projects that involve prototype development over many months before actual quantity manufacturing takes place. When the project ramp-up occurs, we are ready with the right equipment and trained personnel to deliver as required. Our track record with multi-axis laser processing is a great example of how we provide all of our contract services to the benefit of our many customers.”

Expansion
Ace Precision laser processes a wide range of materials, capitalizing on the growth opportunities within industries that have seen a rapidly expanding need for the latest in laser system processing. Among these are long time OEM customers Honeywell, Rolls Royce, and Siemens, as well as other global manufacturers who require components and assemblies processed with multi-axis laser systems.

“The aerospace and turbine industry has made a large move to cooling combustion components with effusion holes,” Magedanz says. “These are small holes drilled through the part at steep angles. In many cases, where parts are thermal barrier coated, our Nd:YAG lasers are the only way of providing these steep angled holes efficiently, and accurately. We continue to grow our laser department by acquiring the latest technology to take advantage of these new industry trends, which provides the versatility with different laser system models to handle the growing range of projects.”

Ace Precision's dedication to Laserdyne systems goes back to its beginnings and now includes four CO2 systems with up to 8-axes of motion, five multi-axis BeamDirector drilling systems with Nd:YAG lasers, and a shuttle-equipped 2D cutting system. Together, these systems give Ace Precision the capacity, flexibility, and precision required to produce highly complex combustion chambers, liners, turbine plenums, compressor housing, tailpipe, and heat shield assemblies along with other precision engine components.

The materials for these components and assemblies include cobalt, nickel, stainless steels, and aluminum, ranging in thickness from 0.005" to 0.500". The nickel and cobalt based high temperature alloys are especially challenging, and include Haynes 625, 188, 230, and 718.

The Right Assets
With seven Laserdyne multi-axis laser systems already in house, Ace Precision recently added the two new 795XL systems to process complex parts needed for a military project. In developmental and through prototype stages during a two-year period, when the project went into quantity production, Ace Precision was ready with the newest Laserdyne systems. “This is how we handle major projects and use our broad range of precision processes,” Magedanz states. “It gives us the advantage of faster turnaround because we are using the very latest, high-speed laser systems with the highest repeatable quality level established during the prototype stages of the project.”

The motion required for a multi-axis laser is very complex. Laserdyne's AFC features make trepanning, percussion drilling, and drilling on the fly a fast, precise, and high quality process.

“One of the best things about working with Laserdyne equipment is that even though the technology has evolved during the years, their program structure is still the same,” states Kurt Magedanz, process engineer, Ace Precision, and son of Ed Magedanz. “We can take a program from one of our older laser systems and put it into one of the newest laser systems, and it will operate with no changes, even with a completely different laser source and a controller that is two generations newer. We accomplished that by taking the part programs from the older lasers for the prototype work and then moving them to the newer, faster systems when we move into volume production. It is a real time-saver and our system operators like it because it requires minimal learning to operate the newer systems.”

The latest two Laserdyne 795XL systems at Ace Precision are capable of 7-axes of motion with 2m x 1m x 1m (80" x 40" x 40") work envelope that includes two high-accuracy rotary tables. The structure of these laser systems allows for the processing of small to large part configurations in all seven axes giving Ace Precision the needed flexibility to handle a wide range of projects with repeatable precision.

“Our Nd:YAG lasers are capable of drilling effusion cooled holes in very dense patterns at shallow angle holes with diameter tolerances of less than 0.002". Methods of achieving these effusion-cooled holes are: deep hole drilling, percussion drilling, trepan drilling, and drilling on the fly,” Ed states.

Maintaining High Accuracy
Achieving a high level of accuracy from prototype to production stages and from one job to another is possible because of how Laserdyne designs and integrates its system features. Everything works perfectly together – the controller, software, motion system, laser, process sensors – because everything is Laserdyne’s design and manufacture.

A good example is Laserdyne’s Automatic Focus Control (AFC), a feature Laserdyne engineers continue to refine. AFC guides the motion system, maintaining critical focus position and following the contour of the part regardless of slight surface irregularities. With AFC, all machine axes react to sensing of the part surface, creating unlimited R-axis correction with high-speed and unmatched sensitivity. AFC allows top machine speeds, maximizing productivity without downtime or scrapped parts. Ace Precision uses AFC for trepanning, percussion drilling, and drilling on the fly.

Trepanning is a process for creating holes where the part is held stationary and the laser beam is moved with simultaneous multiple action motion, creating a round hole or any feature by cutting the periphery of the shape. Laserdyne's extremely accurate and repeatable laser positioning allows for unique, tight tolerance trepanned features.

In contrast, percussion drilling delivers one or more pulses from the laser to a part while the laser beam and part are stationary. More than one pulse may be required depending on the material type and thickness.

With nine Laserdyne multi-axis laser systems in house, Ace Precision is experienced with the most complex projects requiring laser processing. An example includes drilling effusion cooling holes in very dense patterns at shallow angles while holding hole diameter tolerances of less than 0.002".

A variation of percussion drilling is drill-on-the-fly where pulses are delivered to the part by the stationary laser while the part rotates. The hole placement is a function of rotational speed and laser pulse frequency. If multiple pulses are required, utilization of drill-on-the-fly synchronizes the movement of the part to the laser pulses, ensuring delivery of multiple pulses to the exact location required. By changing the laser pulse energy, pulse count or lens focal length, the characteristics of the drilled hole-size and taper, can be controlled to meet the requirements of the part. Drill-on-the-fly software also allows changes of the pulse shape during the process to improve hole geometry.

“Repeatability (±0.0001") of the laser system really comes into play on our jobs,” Ed says. “Design of the Laserdyne BeamDirector allows us to maintain this accuracy, consistently through the entire work envelope.”

New Solutions
“The best thing about working with engineers from Laserdyne is their willingness to work with us to find a solution when we have a complex part that needs an outside-the-box approach to laser processing,” Ed states. “By doing so, we come away with a solution to our problem and they get to use the experience to develop new technology for integration into future systems.

“Our new Laserdyne systems – together with our other seven laser systems – show our capabilities, their depth, and how we use Laserdyne supplied systems to the benefit of our customers,” Magedanz says. “This also applies to our machining, metal forming, thermal processing, and other precision services. In the chip cutting area for example, we have more than 50 CNC machines – vertical mills, horizontal mills, turning centers, and more. We are positioned so our business ensures redundant capabilities in two separate facilities, managing risk and providing timely and reliable service to customers around the world.”

Ace Precision Machining Corp.
Oconomowoc, WI
www.aceprecision.com

Prima Power Laserdyne
Champlin, MN
www.primapower.com