1) What is Force?
VERICUT Force is a physics-based feedrate optimization program that analyzes and optimizes cutting conditions throughout NC program operations. VERICUT Force makes the most effective NC program for the given material, cutting tool, and machining conditions.
2) Who should be interested in Force?
All companies that do CNC machining and are interested in time savings and improved results should be interested in Force optimization. Any NC program using a cutting tool that makes a chip – including milling or turning – in any material, from superalloys to plastics and everything in between, should all be Force optimized.
3) What are the benefits of Force?
Force provides an optimal, balanced approach to feedrate optimization. A traditional non-Force-optimized program will fix the feedrate and vary the chip thickness while cutting. A Force optimized program will fix the chip thickness and vary the feedrate (a.k.a., feedrate scheduling) and produce an optimized NC program that will be faster and safer. The combination of VERICUT simulation/verification and Force optimization are ideal for non-attended and lights-out machining.
A Force optimized program will:
- Use cutting tools to their full potential (maximize chip thickness, keep it constant)
- Increase feedrates when chip thinning occurs, creating time savings
- Limit force or feedrates where excesses are occurring for a safer NC program
- Gain substantial time savings, improved tool life
4) What makes Force different from other optimization products?
VERICUT Force offers the best solution for true, constant chip-thickness machining with proven results in aerospace and other manufacturing industries.
VERICUT Force is neither CAM system nor machine specific, so Force can optimize any CNC program from any CAM system. Force optimizes any CAM system, any CNC machine, any material, any cutting tool, and any part, large or small.
Force allows for fast iterations. Often optimization involves testing different settings to find the optimal desired results. With VERICUT Force, these parameter changes can be made easily and quickly.
VERICUT Force is designed by NC programmers for NC programmers. It makes sense to them – NC programmers get it without getting confused or frustrated.
Force Charts along with VERICUT NC program review give excellent visual tools that provide the NC programmer with valuable information to make data-driven decisions based on facts, not guesses, opinions, theories, or past experiences. Force charts provide real visual data, exposing opportunity for improvement and optimal machining decisions.
5) How does Force impact the aerospace industry?
The aerospace industry encompasses some of the most complex machined parts made from the most challenging materials in the manufacturing market, and it involves hundreds of suppliers. Every one of these suppliers has the challenge of making its products better, cheaper, and faster. Suppliers must also compete for work, win with competitive bids, and perform while making a profit.
What if VERICUT Force could help a machine shop make its products 30% faster than the competition? This advantage could turn into reducing price and delivery time (which every aerospace company is pressing for), increasing shop capacity, increasing profit margins, or possibly all three.
For more info: www.cgtech.com/force
The future of the aerospace fasteners market looks lighter and stronger, thanks to engineering innovation by Sky Climber Fasteners, with designs that are quickly outmoding many commonly used aerospace fasteners.
1) Design engineers continue to seek lightweight fastener options, using materials such as aluminum, aluminum alloys, plastics such as PEI and PEEK, titanium, carbon fiber, stainless and carbon steel, nickel, and nickel-chromium. While aluminum and plastics weigh less, they typically lack the strength of steel versions. Most lightweight fasteners have considerable flaws that limit their safe use.
2) The key to circumventing these weaknesses is using engineering innovations to develop new designs without the weight of steel, the expense of titanium, or limits of adhesives or lock wire. Sky Climber Fasteners is at the forefront of fastener engineering innovation, with products that are outperforming these fastener types and establishing a new generation in aerospace hardware.
3) The Rhino Hybrid Nut™ from Sky Climber Fasteners shatters aerospace fastener standards by combining lightweight materials with patent-pending locking or non-locking inserts. Combining these elements has yielded incredibly high strength-to-weight ratios and a slew of other benefits:
- 50-cycle lock-torque performance in all materials with no crimping, adhesives mean fastener is reusable without significant change in lock torque performance
- Some designs permit torqueing to specific values, locking in place every time
- Eliminates FOD
- Less expensive than titanium
- 30,000-cycle vibration test certified
- Can eliminate expensive, dangerous coatings such as silver plate, cadmium
- Requires no special installation tools
4) More impressive, though, are the tensile and torque results demonstrated during quality testing. The Rhino Aluminum Nut™ has exhibited significant advantages of strength, torque, and torque consistency when supplied as locknuts with the locking inserts. Aluminum nuts have not historically been available with locking torques certified to 15-cycles, proving that the Rhino Aluminum Lock Nut™ represents a significant advancement in fastener design.
- Tensile strength 23% greater than steel based on NASM25027 requirements
- Nearly double the wrench torque required by NASM25027 standards for steel
- Less than half the weight of steel alternatives
5) Rhino Lock Nuts™ with patented locking inserts deliver unprecedented strength in Hybrid and Aluminum versions and are available now from Sky Climber Fasteners. With this fastener and its family of designs, Sky Climber Fasteners is establishing a new generation in high-performance aerospace hardware.
Sky Climber Fasteners LLC
- First flight: Planned for 2020
- Role: Develop electric aircraft certification standards
- Developed from Tecnam P2006T
- Primary user: NASA
- Wingspan (Mod. IV): 32.8ft (10.0m)
- Length: 28.5ft (8.7m)
- Height: 9.3ft (2.8m)
- Cruise speed: 172mph (at 8,000ft)
- Motors: 12 high-lift x 19.3hp (14.4kW); 2 cruise x 64.5hp (48.1kW)
October 2019 answer: de Havilland Canada DHC-2 Beaver
OCTOBER 2019 Winner
Staff Mechanical Engineer,
Leonardo DRS/Electro Optical Infrared Systems,
How long have you been in the aerospace business? 35 years
How did you become interested in aircraft? In my childhood, I closely followed the Apollo program, which led me into mechanical engineering for my college degree. My first employer after college (Texas Instruments) had a flying club. They taught me how to fly, and I obtained my private pilot’s license.
What is your favorite aircraft and why? For its simplicity and economy of operation, the Cessna 152.
Wayne Corrigan, Director of Maintenance Training, FlightSafety Int'l, Downsview, Ontario, Canada
Scott Homerding, Manufacturing Engineer Paradigm Precision - Machining N. America Tempe, Arizona
To enter the contest, visit https://www.AerospaceManufacturingAndDesign.com/form/namethatplane/ and fill out the provided entry form. Only completed forms will qualify. A full set of rules is provided.
The entry deadline for this issue’s contest is Feb.28, 2020.Winners will be announced in the April 2020 issue.
Have fun, and good luck!
Look what Brian won!
Enter today to win your own high-quality desktop aircraft replica!
No one predicted the grounding of Boeing’s 737 MAX fleet a year ago. Or that Boeing’s best-selling narrow-body airliner would not return to service for at least a year, maybe more. However, there is certainty that a lot of effort is going toward putting the 737 MAX back in the air – from the manufacturer, regulators, and airlines. Only the exact timetable is unclear. This uncertainty makes a forecast for 2020 problematic, but I am optimistic the plane will be recertified this year and the U.S. commercial aerospace sector will endure this temporary upheaval.
Reasons include new management at Boeing (see page 10). New President & CEO David Calhoun’s first email to employees stressed “taking steps to maintain our supply chain and workforce expertise so we’re ready to restart production.”
Boeing is reassigning 3,000 workers to other jobs as it halts production of the 737 MAX jet. Meanwhile, Spirit AeroSystems – which supplies about 70% of the 737’s structure – is furloughing 2,800 employees with two months’ pay. Since Boeing has already compensated five major airlines hundreds of millions of dollars in total for financial losses incurred by the 737 MAX grounding, it makes sense that Boeing management should consider sharing the burden with a principal supplier to help maintain its workforce beyond that period. Just days before Calhoun took over, Spirit AeroSystems President and CEO Tom Gentile stated in a press release, “We continue to work with Boeing to develop a new production schedule for 2020 with an eye toward minimizing disruption, maintaining the stability of our production capabilities.”
Minimizing disruption and maintaining supply chain stability is a stated Boeing goal, so maybe Calhoun’s promise that “Boeing must keep innovating to succeed” includes supporting a supplier for which the 737 MAX represents more than 50% of its annual revenue? Boeing’s position as the world’s largest aerospace company, a top U.S. exporter, and anchor in the Dow Jones Industrial Average calls for innovative thinking. And consider the 737 MAX backlog, valued at $500 billion.
While Boeing’s woes dominate the headlines, the company retains a six-year backlog on its 777 widebodies. There is other good news, noted on Aerospace Manufacturing and Design’s news pages in January.
Airbus is increasing the production rate of A320 family aircraft at its U.S. manufacturing facility in Mobile, Alabama, by the beginning of 2021. The company also will add 275 jobs for the A220 assembly line opening this year and construct an additional support hangar on the site.
The U.S. government ordered 50 more Lockheed Martin C-130J transports, worth $3.4 billion. And Lockheed Martin continues to ramp up production of the F-35 fighter – with its 1,500+ global suppliers and more than $44.2 billion total economic impact – increasing 2019 output by 50 units from the year before. The defense giant plans to deliver at least the same number of F-35s this year (141 jets) and increase production to reach a peak in 2023.
So, despite one platform’s challenges, aerospace manufacturing’s broader outlook remains promising. – Eric