Farnborough International Airshow 2018 exhibitor preview
22nd Jun 2018 | In News | By Mike Richardson
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The Farnborough International Airshow, held this year from July 16-22, always provides a diverse selection of companies within the global aerospace industry. Aerospace Manufacturing takes a look at what some of the exhibitors will be offering at the event.
In gear for aerospace
Precision gearing specialist Harmonic Drive UK (hall 4, stand 4026) will be at the Farnborough Airshow to advise aerospace manufacturers on the best gearing system for their products.
More than 40 years ago, the first Harmonic Drive gears were sent into space during the Apollo 15 mission. Having been involved in the aerospace industry ever since, Harmonic Drive has developed a range of gears specifically designed for the needs of the industry.
Harmonic Drive’s strain wave gears are favoured by many large aerospace companies due to their excellent positioning accuracy, lightweight design and repeatability. As such, they can be used on a number of aircraft applications such as nose wheel steering, wing flaps and landing gear retractors.
“A particular trend that visitors to the Farnborough Airshow will notice is aircraft manufacturers moving from hydraulic controls for steering, flaps and lifting the wheels, to electromechanical actuation,” explains Graham Mackrell, managing director of Harmonic Drive UK. “To achieve high accuracy, electrical actuators must have high precision gears, as Harmonic offers. The gears must also be lightweight, to avoid adding any additional load to the component and the aircraft.
“Through our years of experience, we have developed gears that are perfectly suited to the needs of the aerospace industry.”
Motoring onto next generation aircraft
Having made a name for itself in motorsport and automotive premium brands with advanced electric motors, Milton Keynes-based Integral Powertrain (hall 1, stand 1330) will show the aerospace sector at Farnborough what is achievable in high performance, high efficiency, and power-dense electric motors.
Integral Powertrain’s key focus is the design, validation and manufacture of motors and control systems suitable for the highest tiers of aerospace and aviation, motorsport and automotive, engineering and defence and marine sectors around the world.
As a technology development partner with major aircraft manufacturers, incorporating bespoke electrical machine and converter design, the company offers innovation to existing and new topologies.
“The motors we have on test today – which will be on our stand at Farnborough – are achieving between 20-30kW/kg with efficiencies approaching 99%. We actually have technology in R&D today that will push this even further,” comments chief engineer Jason King.
The core technology concept of Integral Powertrain’s fundamental designs has been proven at the highest levels in motorsport and is scalable. The bigger, higher speed motors for aerospace could be even more power dense and efficient.
The combination of high power and lightweight logically pushes these motors toward applications in defence and next-generation civil aircraft to be used as generators and propulsors for electric aircraft. Integral Powertrain will be showing on its stand an example of what a 2MW generator could look like for future applications.
Timesaving tool management
Global hand tool manufacturer, Bahco (hall 4, stand C90) has worked with aerospace companies to develop its latest ergonomic tool management system, which helps engineers save valuable time.
Displaying every group of tools in the smoothly sliding drawers of Bahco’s robust, lockable trolleys enables engineers to find whatever tool they need without delay. A ‘push’ device enables easy removal from the stain resisting foam inlays.
Using Bahco’s Configurator software, customers can choose the size and colour of trolley they prefer, as well as the number of drawers and inlay formats. Colour coding in each drawer shows where a tool has been removed, helping to combat the risk of foreign object damage.
For line maintenance engineers on the move Bahco offers a range of heavy-duty portable tool boxes, all with colour coded foam inlay drawers.
Specialised ergonomic tools, intended for working on engines or avionics, are designed to protect even the toughest hands from painful muscular-skeletal disorders.
Precision torque tools in the Bahco range include electronic torque angle wrenches and mechanical torque wrenches with adjustable heads. Also available are electronic torque wrenches with a fixed or reversible ratchet head, torque screwdrivers with pre-set torque values and electronic torque and angle measuring adaptors.
Working the wires
Alloy Wire International (AWI) (hall 1, stand 1330) heads to Farnborough this year with its largest ever range of high temperature nickel alloys, as demand for Nimonic, Inconel, Waspaloy, Rene 41, Phynox (UNS R30003) and titanium reaches new heights.
The company is looking to showcase its products to manufacturers looking for high quality and reliable delivery for use across the aerospace sector where the need for corrosion resistant wire and bar is high.
AWI’s new campaign ‘Certainty in an Uncertain World’ is also being launched, highlighting the firm’s ability to make to order in just three weeks and its huge stock range that now exceeds 200 tonnes of more than 60 different alloys.
“The aerospace sector represents a huge opportunity for us, with spring manufacturers using our wire to produce compression springs, tensions springs, torsion springs and formed parts for use in critically demanding environments like aircraft engines – where other wire just does not perform under such conditions,” explains sales director, Angus Hogarth.
“We also offer shaped wire from square to complicated trapezoidal, precision Inconel flat wire for high temperature sealing, aircraft grade locking wire (DTD 189A) for nuts and bolts and straight bars for CNC turned aerospace parts.
“We can produce any wire size between 21mm to 0.025mm to close tolerances. There has also been a lot of demand for wire that is certified to an increasing number of aerospace specifications or produced to the customer’s own special material properties.”
Seven in a row
FSL Aerospace (hall 1, stand 1532) has announced it is going for its seventh consecutive SC21 Bronze Award at Farnborough this year, one of the first organisations in the UK to achieve this trade accreditation organised by the UK’s trade body, ADS Group.
The specialist supplier of fasteners and fixings has a 99.3% right-first-time performance and 96.5% on-time and in-full delivery (OTIF) accuracy rate.
Farnborough is the most important event in FSL’s calendar. Over half its staff across the key functions of purchasing, sales and quality will represent the company throughout the show and it has scheduled meetings with 41 suppliers and customers.
Carly Prickett, managing director of FSL Aerospace comments: “We are really looking forward to Farnborough and finding out if we have secured our seventh consecutive SC21 Award. It will be great to share this with some of our most important clients and suppliers, and we’re planning to see them there.”
Italian turnkey machining
Established in 1978, Italian company, MCM (hall 1, stand 1540) specialises in the design and manufacture of high-performance horizontal machining centres and flexible manufacturing systems (FMS).
The core business is focused on machining centres, on systems integration and turnkey solutions. Moreover, for more than 30 years, MCE, the IT division of MCM, has been designing its own supervising software, which supports manufacturing processes, allowing the centralised coordination and management of a whole shopfloor.
MCM machines are designed following the latest Industry 4.0 principles and are largely employed for aerospace parts manufacturing and wherever important machining challenges occur; i.e. hard to cut materials, high precision requirements, high production flexibility, advanced combination of milling and turning operations.
MCM boasts solid know-how gained through its history, thanks to the development of many turnkey solutions and high-efficiency customised machining applications. Its machining centres are said to offer excellence in terms of speed, precision, power and reliability.
Three main product families are available: the Clock family; Tank/Tank G family; and the Jet Five family. Thanks to the complete range of machines and machining-auxiliary technologies, MCM, can cover the machining of a wide range of materials and workpiece sizes.
Metalworking in the additive age
Visitors to the Farnborough Airshow this year will be able to discuss the merits of using quality CNC turning, prismatic metalcutting and grinding equipment from eight different machine tool builders in Germany, as well as additive manufacturing (AM) equipment from France capable of highly consistent production of components in large volumes.
This is because Geo Kingsbury (hall 4, stand 4135) is sole sales and service agent for all of them in the UK, Ireland and the Middle East. The machine tool producers are: Index and its subsidiary, Traub, which offer CNC single- and multi-spindle lathes; Hermle, which builds 3- to 5-axis machining centres; and four large prismatic metal cutting machine manufacturers, Burkhardt + Weber; F Zimmermann; SHW and Waldrich Coburg. The latter machine ranges are handled by Geo Kingsbury’s Large Prismatic Machines (LPM) division in Warwick.
At the beginning of 2017, Geo Kingsbury set up a new Grinding Technology (GT) division in its Warwick office following the company’s appointment as agent for grinding machine manufacturer, Haas Schleifmaschinen. Use of grinders is strong in the aerospace industry, particularly in the competitive field of turbine blade tip and root grinding.
In early 2018, the supplier's product portfolio was extended further by its appointment as exclusive distributor for AddUp, a joint venture owned by Michelin and the Fives industrial engineering group. It takes Geo Kingsbury into a new area, as it is now able to offer production solutions based on powder-bed additive techniques that Michelin has developed over the past 15 years for production of tyre mould inserts.
Richard Kingsbury, managing director of Geo Kingsbury comments: “We are delighted to be able to showcase our full range of top-quality German machine tools at Farnborough and to be able to introduce our additive manufacturing division's capabilities. Right across the range of applications and component sizes, from a few millimetres to tens of metres, we can offer turnkey solutions that are optimised to a user’s requirements, with full support every step of the way.”
Aerospace expertise on-hand
From the largest structural parts to the smallest workpieces, including blades and blisks, and in all materials especially aluminium and titanium, Starrag (hall 4, stand 4163) can provide machining solutions for the global aerospace market.
Underpinned by guaranteed uptimes (up to 96%) and lowest piece part costs, whether the need is for a large-capacity Ecospeed 5-axis machining centre or the smaller capacity 5-axis Heckert 500 X and STC 800 X machining centres – and including the dedicated blade (LX) and blisk (NB) machines – Starrag has unrivalled expertise in meeting all machining demands in the most cost-effective and productive manner.
With a large product range of machines available under the Starrag brand - Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP and Starrag and TTL – and a world lead in Industry 4.0 strategies, the machine tool builder’s stand will be manned by experts promoting Starrag’s maxim ‘Engineering precisely what you value’.
Simulation for metallic and composite manufacturing
CGTech (hall 2, stand 1120, booth 2) will showcase its expanded range of software applications for the aerospace industry in at Farnborough 2018.
CGTech’s VERICUT is widely used in aerospace and defence to improve the efficiency of all types of CNC machine tools. VERICUT is CNC machine simulation, verification and optimisation software that enables users to eliminate the process of manually proving-out NC programs.
The software simulates all types of CNC machining, including multi-axis milling, drilling and trimming of composite parts, waterjet cutting, robotic machining and mill/turn, additive and hybrid machining processes. VERICUT runs standalone but can also be integrated with all leading CAM systems used in aerospace.
Throughout the show, CGTech will demonstrate VERICUT’s optimisation capabilities, which have recently been enhanced with the introduction of the new Force module.
Force is a physics-based optimisation method that determines the maximum reliable feed rate for a given cutting condition based on four key factors: force on the cutter, spindle power, maximum chip thickness, and maximum allowable feed rate. It calculates ideal feed rates by analysing tool geometry and parameters, material properties of the stock and cutting tool, detailed cutting tool geometry, and VERICUT cut-by-cut contact conditions.
Force interpolates cutting conditions using a proprietary set of materials coefficients to account for the strength of material and the effects of friction and temperature. The materials data is generated by actual machining tests and does not rely on extrapolating from finite element analysis results. The bespoke cutting coefficients used by Force result in the most accurate cutting force calculations available today.
CGTech will also demonstrate Composites 8.1, the latest versions of VERICUT Composite Programming (VCP) and VERICUT Composite Simulation (VCS). CGTech’s Composites 8.1 release of VCP and VCS features a completely redefined Graphical User Interface (GUI), enhanced suite of programming and analysis tools, and redefined methodology through the use of the powerful new Laminate Manager.
Into the blue
Aerospace engineering firm JJ Churchill, on the Midlands Aerospace Alliance stand (hall 1, stand 1330) will be showcasing its new Blue Photon technology, which has reduced by half the number of machining operations per part number at Farnborough.
The technology has already been successfully applied to a titanium aluminide blade component, which is an extremely difficult material to fixture and machine. Each machining operation can need its own fixturing, so any reduction in the number of operations will have a huge impact on the efficiency of the process. JJ Churchill will also be presenting its EDM capabilities, an area where it has recently invested heavily.
The company is focused on what it describes as ‘sticky niches’ i.e. engineering projects which require a high degree of technical and organisational skill. It works in areas which require highly skilled engineering in difficult geometries, difficult dimensions and challenging materials – the type of project where the first reaction is, “that can’t be done”.
Multi-tasking solutions for aerospace
At this year’s Farnborough Airshow Okuma (hall 3, stand 3710), represented in the UK by NCMT, will feature some of its very latest machining technology, including its latest multi-tasking machines for both additive and subtractive manufacturing, large-part machining and smart factory solutions.
On the additive front, Okuma’s Laser EX series of super multi-tasking machines, equipped with a powerful Trumpf TruDisk laser, enables high-quality laser metal deposition (LMD) to create complex parts like Inconel turbine blades with integrated cooling channels.
To maximise efficiency, the Laser EX series is able to automatically switch between up to four powders mid-operation without changing the nozzle. To eliminate the need to completely replace worn or damaged parts, the Laser EX series enables easy spot repairs via LMD. Laser hardening reduces thermal deformation to a minimum, resulting in unparalleled workpiece accuracy.
The Laser EX machines’ capabilities include conventional turning, cutting, milling and grinding even of materials like titanium and Inconel. This is especially useful for finishing aerospace components to achieve excellent surface quality.
When it comes to large part machining, with a 1m square pallet, its sheer dimensions make the MU-10000H 5-axis machining centre an impressive sight. Given its high-torque, high-speed machining capabilities and chip removal rates up to 1,000cm³, it also delivers the performance to back up its size, as it can handle even large titanium components like 200kg engine cases with ease.
Additionally, Okuma has partnered with renowned experts to offer the best solutions for the demanding aerospace industry. In order to make full use of the abilities of modern 5-axis machining centres, the manufacturer cooperated with CAM developer Open Mind on their performance package hyperMILL MAXX Machining. With its innovative CAM strategy 5-axis tangent plane machining time savings of up to 90% can be achieved. In addition, the package includes modules for efficient roughing, finishing and drilling, which allow for significant time-savings and increased surface quality.
Okuma’s comprehensive smart factory application Connect Plan enables advanced factory visualisation, data processing and analysis as well as predictive maintenance.
Comprehensive casting options
UK aerospace and defence foundry, Maycast-Nokes, has completed a major expansion of its gravity die service making it the most versatile aerospace foundry in the UK, according to the company.
The Essex based engineering firm which will be exhibiting at the Midlands Aerospace Alliance stand (hall 1, stand 1330) at this year’s Farnborough Airshow has invested significantly to create a dedicated gravity die foundry alongside its sand and investment production lines at its base in Halstead, North Essex.
Dave Blower, sales director at Maycast-Nokes explains the reasoning behind the investment: “Expansion of our gravity die service gives our customers more choice when choosing the right casting method for projects. Increasingly our customers are looking for a one-stop-shop offering multiple casting options. The enhancement of our gravity die production facility complements our precision sand and investment casting services by offering a process more suited to high volumes of components.”
The new foundry is supported by an in-house tool room which allows Maycast to make alternations to tools at short notice, providing customers with as much design freedom as technically possible. Maycast will be offering gravity die castings in their full range of aerospace-grade aluminium alloys including higher operating temperature alloys such as RR350. In 2018 the company was a finalist at the UK’s National Apprenticeship Awards, becoming the first foundry ever to reach the finals.
50 years of cultured engineering
Tridan Engineering (hall 1, stand 1556) is celebrating 50 years of engineering excellence this year. Established in Clacton on Sea in 1968 to provide machining services - manufacturing from all materials to customer drawings and specifications.
The company has grown to become one of the largest employers in the local area, with a current headcount of 77, and it is now a globally-recognised provider of high precision components.
Tridan has invested over £2 million over the last two years in its team and in the latest technology. The company has a range of CNC machine tools, from sliding head, horizontals, 5-axis – and with its most recent purchase a Mazak 5 Axis i500 Smooth X with a six pallet Palletech system – it is taking its ‘lights-out’ machining to new levels.
With the latest level of capital expenditure, plus a recently added new weekend shift system, Tridan has increased its capacity by 500 hours per week. Crucial to the success has been introducing a coaching culture from the top down and operating on a management belief that individuals can find the answer. Thirteen of the 77-strong team have completed their apprenticeship, and a further six are currently enrolled on a similar scheme.
Tridan believes its apprentice programme has been a significant success: it has contributed to its growth and will continue to do so. In fact, the first apprentice has received a promotion to a managerial position and Tridan will be looking to recruit a further 3-4 apprentices by summer 2018.
Seeking seals appeal
Technetics Group (hall 4, stand 4420) designer and manufacturer of engineered components for demanding applications, will showcase its aerospace product lines during the Farnborough Airshow.
Technetics designs and manufactures custom-engineered aerospace components, specialising in innovative sealing, fluid conveyance, pressure regulation, and noise control solutions.
Offerings include a wide variety of rotating shaft sealing solutions, such as hydrodynamic face seals, circumferential seals, abradable seals, and brush seals. Additional sealing solutions include elastomer seals and static metal seals for airframe and engine applications.
Technetics also designs acoustic media for noise control, burst discs for pressure regulation and metal bellows for fluid conveyance. These innovative sealing and component technologies ensure that aircraft operate safely and efficiently while meeting increasingly stringent industry requirements.
Turning up the heat
In (hall 2, stand 2427), the Wallwork Group will showcase its aerospace heat treatment, vacuum brazing and hard coatings capabilities. In the two years since the last show, the company has added new prime approvals, made a company acquisition and invested heavily in new vacuum brazing and plasma nitriding processes and equipment.
“Providing a high quality and quick service to aerospace component manufacturers is key to our success and continuing growth. Acquiring the business of Metaltech in Newcastle, last October, not only added extra production capacity, but with part of the transport fleet now based there it also allows even faster access to our services for customers in the North East and Scotland,” explains CEO, Peter Carpenter.
Two new vacuum brazing units have been established, one at the company’s Manchester site the other at Cambridge. Further to their commissioning, both units have achieved Rolls-Royce approvals. In addition to these, the company also carries approvals from BAE Systems, Airbus, Safran, Bombardier, Moog and many others, for specific heat treatment and plasma nitriding processes.
Wallwork Cambridge was one the first companies to achieve AS9100 Rev D. With its expanding order book there is major investment at the site in a further vacuum brazing furnace and two additional plasma nitriders.
The company has also developed Nitron CA coatings that provide an environmentally safe alternative to hard chromium plating. Applied by physical vapour deposition, under vacuum conditions at low process temperature, Nitron CA coatings will help manufactures comply with REACH regulations in the EU and OSHA legislation in the USA.
As well as a full range of heat treatment services, the company also provides Nadcap approved processing of complex aluminium and magnesium components.
Keeping it clean
A specialist provider of washing solutions, fluorescent penetrant inspection (FPI) lines and surface treatment equipment to the aerospace sector since 1981, Turbex (hall 4, stand 4042) will focus on cleaning machines and lines for manufacturers and MRO organisations in the aerospace supply chain. Emphasis is placed on problem-solving, especially for processing parts of complex geometry to a superior standard.
The Turbex product portfolio includes the Galvatek range of surface treatment lines, notably for chemical cleaning and anodising. More than 600 turnkey installations in over 35 countries have been designed, delivered and installed. The equipment is typically automated and is renowned for technological developments that ensure efficiency, reliability and low emissions.
Galvatek is especially renown in the aerospace industry as its multi-stage lines for chemical cleaning, anodising and etching are widely used.
Chemical surface treatment plants are built either for one specific purpose or as part of a larger package for preparing parts for other surface treatment phases. Turnkey solutions are regularly supplied, complete with waste water purification and recycling systems.
Non-destructive testing (NDT) and component cleaning are closely related. Through Turbex's experience of cleaning, it has developed an extensive knowledge of the FPI process and the systems required. Its FPI systems utilise expertise in automation and process control to provide consistency and traceability.
Precision cleaning machines with basket rotation and flood wash options, will also be promoted. These machines use a world-patented system whereby rotation of the holding basket and spray jets is individually adjustable, allowing them to rotate in the same or opposite directions. Programs can be tailored, together with other movement options such as rocking of the basket, to clean even the most complex parts efficiently. Integral condensing eliminates the need for extraction.
This equipment is aimed primarily at high-precision cleaning applications in the aerospace sector with the possibility of simulated clean room conditions.
Growing sales for gear specialist
Business continues to grow for Mini Gears (hall 1, stand 1522) manufacturing machined parts and geared components into the aircraft interiors market, supplying parts for first class, business class and pilot seating.
The AS9100-registered, the company has saved its customers over £4.5 million over the last four years through innovation and continual investment in new machine tools as it believes in offering a fair price for aerospace components.
Mini Gears will be showcasing the seating mechanisms manufactured at its 35,000ft² UK factory, together with the range of precision machined parts including aluminium profiles for privacy screens, table plate support hinges, brackets, seat supports, handles and door release mechanisms. The team looks forward to welcoming visitors onto the stand.
The cream of the cluster
The West of England Aerospace Forum (WEAF) (hall 1, stand 1340) is hosting the cream of the UK’s aerospace industry at the Farnborough Airshow.
The following companies will be exhibiting on the WEAF stand: Walker AEC; Impcross; Groveley Engineering; AVPE; South West Metal Finishing; Tewkesbury (Diamond Chrome) Plating Co; Rotamic; Ontic; Opex Logistics; YTL Developments; Hempel Special Metals; ESI UK; National Composites Centre; VHR; Derichebourg; Beagle; South West Aerospace; and NATEP.
The South West has one of the largest concentrations of aerospace and defence capabilities in Europe and is the biggest aerospace cluster in the UK worth more than £7 billion worth of related orders in the region.
AM strategies for aircraft construction
CAD/CAM developer Open Mind (hall 4, stand 41660) will be exhibiting its latest software developments for companies in aerospace industry in the show halls.
The latest hyperMill software for 5-axis machining pushes the limits of machining centres to meet the special industry requirements for complex parts and sophisticated materials. Open Mind will provide information about milling, turning, and HSC, HPC, 2.5D, 3D, and 5-axis machining, as well as process chains involving PLM and simulations.
Open Mind’s proven solutions for the aviation industry has modules for easy, secure programming of impeller, blisk, and blade machining. HyperMILL also includes many interesting features for the challenges posed by other complex parts. These include a range of innovative 5-axis simultaneous strategies that enable efficient machining of challenging geometries such as free-form surfaces or deep cavities.
For example, 5-axis helical drilling, a helical tilt milling method in which the milling tool is tilted in cutting mode, allows holes to be formed easily and efficiently. A second tilt prevents collision with the hole wall. This is advantageous because only one tool is needed for different drill diameters, or open pockets of varying sizes. Pre-drilling is not necessary, and the strategy is ideal for materials that are hard to cut.
The hyperMILL MAXX machining performance package is comprised of a set of machining strategies that are very popular in the aerospace industry. Machining strategies in this package include the extremely efficient finishing of difficult-to-access surfaces for which Open Mind has developed 5-axis tangent plane machining with conical barrel cutters. This offers enormous potential for optimisation as it takes 90% less time than conventional methods.
Prototypes in a virtual world
An innovator in virtual prototyping, ESI (WEAF zone, hall 1, stand 1340) will present its solutions to support aerospace manufacturers in the fast and cost-efficient delivery of quality products and disruptive innovations.
Attendees can discuss with ESI’s engineering team and learn how its software solutions can help with virtual manufacturing of metal or composite parts and components – from mastering casting to sheetmetal forming, joining and welding.
ESI’s virtual engineering solutions can also support manufacturers in predicting and improving the performance of existing and future products, not only as manufactured, but also as used in service.
From electromagnetics to vibro-acoustics, CFD and systems engineering, all aspects of product performance can be covered long before any prototype is created. Additionally, engineers can experience future products collaboratively and immersivity using virtual reality.
Thanks to its Hybrid Twin approach, ESI enables the coupling of advanced simulation with theoretical and real data harvested by Industry 4.0.
www.esi-group.com/industries/aerospace-defense
Reliable waste management
BKP Waste & Recycling (hall 2, stand 2011) has an extensive portfolio of services to suit virtually every application for every market sector. Being involved in the waste industry for more than 50 years, the company has built a reputation with its clients for being not only reliable and efficient, but customer friendly as well.
Its services range from bulk tankering for hazardous and non-hazardous waste-streams, industrial cleaning services - including confined space entry and full BA, drainage maintenance and repairs, hazardous waste collection and safe disposal, servicing and maintenance of pump stations and sewage treatment plants, as well as a fast emergency response service.
By having its, drivers and operatives trained to the highest standards, BKP has the flexibility to manoeuvre manpower where it is needed most; essential when it comes to an emergency requiring immediate response. The company owns and operates its own licensed treatment facility with a unique site permit, so we can provide a cradle to grave service for each of our customers.
BKP has built a wealth of experience working with clients from the aviation industry, advanced manufacturing and engineering industry as well as logistics and cosmetic production companies.
A new way to innovation
Dassault Systèmes (Chalet B9) is committed to breaking down barriers in innovation. Aerospace and defence are an essential part of this philosophy because the mass application of digital technologies is prominent in the industry.
For more than three decades manufacturing, software specialist Dassault Systèmes has been at the cutting edge of innovation in the sector, working with companies to revolutionise ways of working.
Dassault Systèmes maintains companies need to make progress in cooperation, product development and production in order to develop in a future-proof manner. Pioneering companies that push the limits of what is feasible when it comes to their vision, their ways of working and their services and products will the ones that succeed. Some of these ‘New Ways of Working’ will be presented at Dassault Systèmes at its chalet.
Visitors can take the opportunity to experience various customer presentations of Dassault Systèmes’ 3DEXPERIENCE software platform live, learn exclusively about their experiences, business drivers and advantages of the business platform.
Dassault Systèmes experts from industry and technology will show visitors all that they need to know about these ‘New Ways of Working’ and how barriers to innovation can be removed.
Finishing touches for additive
Additive Manufacturing (AM) has taken many industries by storm and the aerospace industry is certainly no exception. The industry has leveraged 3D printing technologies to produce a wide range of components including fuel nozzles, bearing housings, guide vanes and airframe components.
The complex geometries and relatively rough surfaces generated by AM technologies, and the fact that many aerospace applications have stringent surface finishing requirements, mean that finishing is a huge challenge.
As an expert at the leading-edge of finishing technologies for over 50 years, Extrude Hone (hall 4, stand 1656) has been approached by companies facing challenges in internal and external surface finishing. Abrasive Flow machining (AFM), which uses a non-Newtonian fluid loaded with abrasive, is the perfect solution for internal finishing as the medium takes the form of internal passages and abrades as it flows.
Spotting an unmet need for effective and reliable external surface finishing, Extrude Hone developed COOLPULSE technology, which is capable of internal and external finishing and, unlike electro-polish, uses an eco-friendly electrolyte and works on a wider variety of materials whilst yielding comparable or better results.
These processes are suitable for aluminium, stainless steel, Inconel and titanium and for a broad range of geometries meaning that most components can be finished by an Extrude Hone technology or combination of technologies.
Extrude Hone has recently set up a new business unit called Extrude Hone Additive and has struck a partnership with MMP Technology to introduce an exclusive new product called FINISH3D which is capable of surface roughness lower than 1µin Ra, regardless of incoming surface condition.
40 years of flying controls
Barnbrook Systems (hall 1, stand 1320) is taking its strongest delegation so far and latest product ranges to showcase at the 2018 Farnborough Airshow.
The Fareham-based family run company – a leading member of the Farnborough Aerospace Consortium (FAC) – is attending the Airshow in its 40th anniversary year, to display and demonstrate such products as its aerospace contactors, engine controls and innovative inflight refuelling technology.
Managing director Tony Barnett says: “The Airshow is an opportunity for us to demonstrate our capabilities and showcase our successful product ranges. It is particularly significant as it is falls in our 40th anniversary year. We look forward to welcoming existing clients and business associates to our stand.”
Barnbrook Systems also designs, manufactures and supports such products as electromechanical and solid-state relays, circuit breakers, actuators, test sets, pressure transducers and interconnect systems.
It also carries out new build, repair and overhaul of contactors and engine control units. It has extensive test facilities, including vibration and environmental to test and qualify its products to the respective standards.
Value-added metals
Established two years ago, Böhler Aerospace UK (hall 4, stand 41145) is now established as a leading distributor of aerospace materials.
Based at Oldbury, West Midlands and part of Voestalpine High Performance Metals UK, the accelerated growth of the division can be seen in both the financial performance and customer numbers. This is a result of significant stock investment in aerospace materials in both British Standard and AMS grades.
Böhler is aware that just stockholding material is insufficient to meet evolving customer demands. Success comes from working in partnership with customers to provide fast and efficient solutions.
Paul Chruscinski, UK divisional manager of aerospace and power generation, explains: “The strength of the Voestalpine Group and expertise of its production companies means the UK business will continue to benefit from a strong supply chain, extensive product portfolio and financial backing. This has allowed for extensive investment in our award winning, purpose-built distribution and value-added service facilities at Oldbury, ensuring we are better placed to meet our customers’ existing and future needs.
“Value Added Services give our customers access to cutting, machining, bevelling, testing and other services providing turnkey customer solutions. This includes an onsite testing service, used when customers require additional certification to that supplied by the mill.”
Additionally, as the world’s largest special steel producer, Böhler Edelstahl leverages metallurgical knowledge and manufacturing options. A specialist team in the UK can support specific customer requirement, from supply of our Additive Manufacturing branded powders to finished parts.
Precision casting close-up
For the first time ever, GF Machining Solutions and GF Casting Solutions, through its new entity GF Precicast (hall 4, stand 4164) will take the world stage together at the Farnborough.
GF’s aerospace manufacturing solutions, range from manufacturing equipment and additive manufacturing (AM) technology to precision casting, also known as investment casting. Guests at the stand will get a close-up look at a titanium aluminide turbine blade representing a wide range of manufacturing processes and technologies. Focusing on four complete manufacturing studies, the eye-catching turbine blade will highlight the value each step adds to the process chain: machining from bar stock, close-shape forging, precision casting, AM and post processes such as Milling, grinding, and wire electrical discharge machining (WEDM).
Moreover, visitors to the stand will experience how the two GF Divisions add value to a variety of high-value aerospace components, including helicopter diffusers and structural parts, impellers, aerofoils, turbine disks, outlet guide vanes, bearing supports, and hubs, as well as structural parts.
GF Machining Solutions offers a vast range of aerospace component manufacturing solutions, with machining technologies, software and services to match customers’ needs. GF Casting Solutions realises high-quality and complex integrated casting solutions; close cooperation with customers guarantees that its solutions exactly match the market’s requirements.
A celebration of success
Following the acquisition of AeroCision, Bromford Industries (hall 2, stand 2537) will be celebrating success at Farnborough this year. The show gives Bromford the opportunity to promote its global presence, investment in machinery and flagship aircraft engine programmes.
The acquisition strengthens Bromford’s international reach and provides further capability and competitive edge through AeroCision’s two facilities; one in the US and a joint-venture in India.
As a leading critical component manufacturer, significant investment has been made into Bromford in the last two years by Liberty Hall Capital Partners. Bromford has embraced the concept of the Fourth Industrial Revolution, and drive to automation and the Internet of Things and as such, the skills now held by Bromford’s staff are wider ranging, industry leading and driving the company to continued success in the aerospace manufacturing sector.
The company’s focus on innovation and cutting-edge technology is being displayed on its stand at the show. With high-quality visuals, Bromford has worked hard to showcase machining capabilities in a contemporary, experience-enhancing way.
Targeted technology
For BAE Systems (outside exhibit 11) the Airshow is one of the key events in the aerospace and defence industry calendar and provides a fantastic opportunity to demonstrate the breadth of its highly sophisticated products, services and people to the many international military and commercial delegations who attend the show.
The UK defence group will showcase a range of exciting and innovative technologies, including survivability and targeting systems, artificial intelligence operational capabilities, intelligence focused communications as well as the advanced technologies that it is bringing to wider aircraft solutions.
Examples of the Eurofighter Typhoon’s technology evolution will also be on show, demonstrating how the platform is being integrated with the latest technology to meet changing operational requirements, alongside examples of the support and training BAE Systems can offer customers. The exhibit will showcase the group’s central role in the air sector and how it is contributing to the future of Britain’s world-leading combat air capability.
BAE Systems will also be highlighting how its continued investment in skills development and its work to develop the STEM curriculum with local partners contributes to wider economic development through the transfer of skills and technology. This investment into a highly talented workforce and other partners enables customers around the world to realise their visions for the security and prosperity of their nations.
New concepts for turbines
With its headquarters in Remscheid, Germany Leistritz Turbine Technology (hall 4, stand 41370) is one of the leading partners to the OEM in the fields of developing manufacturing solutions for engine components.
It is known as a full-service provider due to working with various forging, machining and inspection processes. Leistritz covers the whole supply chain – starting from the raw parts to ready-to-install components.
In the company’s portfolio you can find ground-breaking technologies such as ElectroChemical Machining (ECM) and in order to constantly be a part of the most recent developments, Leistritz has actively been involved in basic research and testing of new production concepts.
This includes four different production processes for customised lightweight titanium aluminide aerofoils that were developed in close co-operation with strategic partners.
Leistritz has proven experience in the production of the most critical aerofoil design and materials, enabling blisks to perform at their best. Looking into the fan section the team will show an original and patented forming process that facilitates the scalability of the metal leading edge in size, flexibility in material choice and cost competitiveness through its lean approach.
Dimensional accuracy and perfect surface finish are some of the characteristics of the products manufactured on Pulsed ElectroChemical Machining (PECM) equipment, designed and built by Leistritz.
In terms of additive manufacturing, Leistritz will be envisioning future designs for aerospace parts that combine weight reduction, performance and cost improvement.
https://turbines.leistritz.com
The pioneering spirit of Kansas
In 1925, Walter Beech, Clyde Cessna, and Lloyd Stearman formed their own company to build airplanes in Wichita, Kansas (hall 2, stand 2456). These are some of the original aviation pioneers and are great examples of the risk-taking, entrepreneurship, partnership, collaboration, competition, and innovation which is the story of Wichita described as ‘The Air Capital of the World’ and the entire Kansas aviation industry.
These early pioneers went on to chart their own paths and pursue their dreams, leading to the world-class companies of today that are a significant part of the Kansas aerospace cluster.
Clyde Cessna formed Cessna Aircraft Company in 1927, Lloyd Stearman formed Stearman Aircraft Company in 1927, and Walter and Olive Ann Beech formed the Beech Aircraft company in 1932. Beechcraft and Cessna are now part of Textron Aviation and Stearman became Boeing Wichita which is now Spirit AeroSystems.
Kansas continues to foster an environment that leads to this type of innovation and risk taking and forms the next great ventures and success stories in our state.
Recent highlights for the Kansas aerospace sector include: Spirit AeroSystems, the largest aerospace manufacturer in the state, delivering its 10,000th 737 fuselage to Boeing in February; Spirit announcing it will be adding 1,000 new jobs over the next two years and Airbus opening its new Engineering Centre on the Wichita State University Innovation Campus.
https://www.kansascommerce.gov/
Competitive advantages for aerospace
Washington State (hall 1, stand 1385) is the best, most competitive, location in the USA for aerospace manufacturing, according to a comprehensive, independent report.
The Teal Group and Olympic Analytics conducted the Aerospace Competitive Economics Study (Teal Report), an analysis of the competitive advantages and disadvantages for aerospace manufacturing in all 51 states of America.
The report employs a rankings system to grade states across 41 metrics, grouped in eight categories measuring factors relevant to aerospace production like cost structure, skilled labour availability, global trade connectivity and tax policy.
The Teal Report is the most comprehensive, data-driven state-by-state aerospace competitiveness research ever done in the US. Washington has an aerospace supercluster that produces more revenue, more exports, and more profits than any other state and the Teal Report points to numerous strengths for Washington State, including the highest number of aerospace workers and fourth lowest unit labour costs.
The Teal Report looks not just at the basic cost of the labour, but also productivity. It found machinists and engineers in Washington produce more product for every dollar cost of labour.
Richard Aboulafia, who oversaw the report comments: “The assembly business is hypercompetitive and involves tremendous risk. Manufacturers want to make decisions, especially the critical decision about where to assemble where there is lowest possible risk and the highest potential for success.”
Cecence unveils seat-back composite innovation
Cecence (hall 4, stand 4950) will be exhibiting what is understood to be the first all-composite Airbus line-fit approved 16g seat-back on its stand. The component will form part of a lightweight aerospace seat for long-haul flights by a major flag-carrier.
Investment in R&D, material engineering, innovative process development, training, and the nurturing and management of a robust supply chain, has enabled Cecence to position itself at the forefront of FST-compliant, rapid process composite components for aerospace, rail and other mass transportation sectors.
The company expanded earlier this year and were awarded a large production contract by an innovative aerospace seat supplier, who recognised Cecence’s ability to both develop FST-compliant composite materials and apply processes that would achieve both manufacturing efficiencies and significant weight savings. Ambitious growth plans and its new larger facility mean the company will be able to expand its current output to produce in excess of 12,000 units a year in 2019.
Cecence has utilised its Right Fibre Right Application (RFRA) philosophy, by pioneering the use of hot compression moulding using snap cure materials and establishing the art of making fireproof composite components ‘Cecence’ style,
Adding value with software
Valuechain (hall 1, stand 1120) provides innovative technology to connect smart factories and smart supply chains to build a stronger Industry 4.0. Its DNA4.0 platform provides productivity solutions that streamline operations and convert data captured dynamically from people, plant and processes, into business intelligence. Meanwhile, its iQluster supply chain collaboration and intelligence platform simplifies intercompany communication and securely captures multitier supply chain intelligence.
G&P to make Airshow debut bow
Quality management experts, G&P (hall 1, stand 1330) is exhibiting at the Airshow for the first time with the support of the Midlands Aerospace Alliance.
G&P will use the event to promote how its automotive-derived approach to supply chain management is helping a growing number of aerospace companies meet the increasing demands for aircraft deliveries.
David Whiffin, director of Aerospace at G&P, says: “This is the first time that G&P has exhibited at the Farnborough International Airshow. It will provide an excellent opportunity for G&P to showcase how it is bringing proven automotive quality practices to the aerospace industry. It further demonstrates G&P’s growing intent and commitment to the aerospace industry, which faces many complex challenges, especially due to the multi-national and multi-stage distribution structure within the sector.”
Whiffin, along with G&P’s director of engineering, Stephen Molloy will be in attendance on the trade days on Pod 19, as part of the Midlands Aerospace Alliance stand.
Keep your eyes on the prize
Merit Holdings (hall 4, stand 4956), says it is gearing up to exhibit at Farnborough for the first time. The company has a background working in the aerospace sector – most recently with Rolls-Royce on a pioneering project in Bristol.
As part of its show offering and in keeping with the speed and excitement of the Airshow, Merit will be running an on-stand Batak competition to test people’s speed and reaction times. The fastest competitor from the show will win European Le Mans Series VIP hospitality package for two at Silverstone in August.
Tony Wells, Merit’s managing director, comments: “We are excited to be exhibiting at Farnborough this summer. This premier event is a highlight in many companies’ calendars and we look forward to showcasing our business to a range of companies and seeing the fantastic flying display whilst we’re there too!”
Air in the air
Hybrid Air Vehicles (hall 1, stand 1520) is the developer of Airlander, a low-carbon multi-mission aircraft, providing its users with new choices and connecting them in ways that were not possible before.
Said to be the world’s largest aircraft, the Airlander combines the best characteristics of fixed wing aircraft and helicopters with lighter-than-air technology to create a new breed of hyper-efficient aircraft. It can stay airborne for up to five days at a time and will be able to fulfil a wide range of communication, cargo carrying and survey roles in both the military and commercial sectors, all with a significantly lower carbon footprint than other forms of air transport.
Able to take off and land on unprepared surfaces in previously unreachable places, the airship can provide persistent multi-sensor surveillance for days at a time and take passengers in near-silent luxury to extraordinary destinations, Hybrid Air vehicles say the Airlander challenges the perceptions of what an aircraft can do.
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