Cover shots

Tabletop ECT module for jet engines

In response to customer interest in a lower-cost, limited-feature, eddy current testing (ECT) system for jet engine components weighing up to 30 lb, UniWest, has developed a new tabletop, 3-axis, semi-automatic ECT inspection system. The ES-1000 provides precision ECT for rotationally symmetric parts, such as engine disk bores and webs.

The new unit enables capacity utilization efficiencies for global OEMs and places semi-automated ECT within the financial reach of smaller regional jet engine maintenance facilities.

Organizations that already own a full-scale ETC-2000 system can share existing components with the ES-1000, such as probes, part-mounts, and signal processing instruments as well as computers and monitors. All of UniWest’s eddy current instrument series, such as the US-454, US-454A, and the EddyView Pro and Premium can be used with the ES-1000.

The modular ES-1000 system comprises four operationally independent components: 1) turntable and gantry module; 2) eddy current generation and processing instrument; 3) eddy current probe, and 4) computer and display, running Windows 7 or higher.

The system’s essential component is the 24in2 turntable that is compatible with UniWest mounting mechanisms. The turntable and extendable gantry accepts parts up to 30" in diameter and 12" tall. For inspection of larger parts, custom gantry and probe-arm configurations can be fabricated.

The turntable module’s 32"-wide gantry rail and attached probe arm are fitted with servo-driven lead screws for horizontal and vertical placement of the probe. Any of UniWest’s eddy current probes may be attached to the probe arm by means of appropriate holders.

System setup involves placing a part on the turntable, positioning the probe-head at the scan initiation point, and pressing the software start button. The system then automatically scans the part using a pre-programmable routine.

In addition to the cost efficiencies associated with component interchangeability, the ES-1000 is subject to less downtime because components are swappable from one system to another. Although the ES-1000 system is not designed for multi-dimensional motion at this time, minor contour following is afforded by spring compliance of the probes.
 

UniWest
www.uniwest.com

Omega end mills

Omega M726 and M725 end mills are designed to overcome the challenges of machining in hardened steels, even up to 58-62 HRC, running wet or dry. Increases in tool life – and corresponding savings in tool costs – have been achieved by applying advanced understanding of cutting technology. That process resulted in changes to corner geometries, a 50° helix angle, improved cutting edges, and a more advanced AlTiNX coating to protect those cutting edges from heat generated in the cutting zone.

Six flutes provide more cutting edge engagement per rotation for more inches per minutes in hardened steels, and extra strength for longer tool life. Running dry requires use of modern, high-speed, high-efficiency machining techniques and continuous toolpaths.

Tested in A2 steel at HRC 60 using 1/4" diameter end mill at 0.250" axial DOC and 0.015" radial DOC, the Omega M726 end mill lasted more than three times longer than comparable competitors’ tools and the original M706. In addition, the M726 end mill provides superior finishes in a wide range of non-hardened materials.

The new Omega M7 line is available in sizes from 1/8" to 3/4" and in a variety of lengths with neck relief and corner radii as standard options. Sizes 1/8" to 3/16" are designated the M725 series and have five flutes for maximum chip evacuation. All other geometries on M725 end mills are the same as those on M726 end mills.
 

IMCO Carbide Tool Inc.
imcousa.com

High-rigidity profile grinder

The Micron Macro’s rigid design enables speed and precision for high rates of stock removal and part finish quality. This unit is rigid enough that 100 lb of load force to the spindle results in only 1µm of deflection.

Most components are rooted to the machine frame. The worktable is stationary, with the wheel head traveling on axes within the housing during grinding, which improves accuracy, optimizes force distribution, and minimizes thermal variation. The stationary table makes the machine footprint one-half to two-thirds smaller than competitive models.

Ball screws are oversized by a factor of three for rigidity, and the torque tube is mounted in the base of the machine and filled with insulation to provide harmonic damping and thermal stability.
 

Peter Wolters of America
www.peter-wolters.com

IMTS 2014 booth #N7333