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Archive: Oct 2021

Defense Turnkey Program Manufacturing Services

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Primus Aerospace    

Capability: Turnkey Program Manufacturing Services

 

Description:

With our vertically integrated manufacturing capabilities, Primus Aerospace offers turnkey program manufacturing of high-precision, high-complexity machined products for the aerospace, defense, and deep space industries. We manage the entire manufacturing program, from engineering and design to tooling, multi-axis precision machining, assembly, and specialty processes. Our services incorporate robust, end-to-end quality assurance and we administer program-specific inventory systems that align with custom workflows and stock control policies.

As a technology-oriented company, we engineer solutions that integrate intelligent product design with sophisticated manufacturing processes. We operate a state-of-the-art production facility housing high-value machining centers capable of reliable and repeatable production of critical parts. With equipment assets that include 7-axis mills and 9-axis turning centers, our capabilities include complex milling and turning as well as thin-walled machining down to .010” wall thickness. Along with microtube machining and microtube bending, we also perform hard turning and milling up to 70 Rockwell C. We work with all primary aerospace alloys, such as aluminum, titanium, Hastelloy®, and Inconel®, and we also machine parts from advanced engineering composites. We uphold dimensional tolerances and repeatability up to ±0.0001” with measurement accuracy to .00001” on parts as large as 20.0” in diameter and 84.0” in length.

Our services platform incorporates all aspects of mechanical and electrical assembly as well as value-added processes such as EDM, lapping, grinding, welding, and heat treating. We handle any surface finish and deburring requirements. Inside our climate-controlled Quality Assurance Laboratory, trained quality inspectors leverage a full array of test and measurement equipment to verify products comply with specifications. Accredited to both ISO 9001:2008 and AS 9100 Rev C, our quality management program supports FEMA, PPAP, and customer-specific risk analysis, and we maintain robust traceability documentation for raw materials, machining processes, outside processes, assembly, and all other critical services.

With our program management expertise, value engineering, and robust manufacturing systems, we help companies reduce lead-time and improve product quality while reducing costs and simplifying supply chain management.  Contact us directly for a consultation.

 

General Capabilities Engineering and Design:

·         Support

·         Mechanical

·         Electrical

Multi-Axis Machining

Assembly And Specialty Processes:

·         Electrical

·         Mechanical

·         Soldering

·         Grinding

·         Lapping

·         Gear Cutting

Inventory Stocking Arrangements:

·         Consignment

·         Vendor Managed Inventory

·         Kanban

·         Safety Stock

Exotic Materials

·         Titanium

·         Composites

·         Hastelloy

·         Inconel

Dimensional Tolerances and Repeatability To 0.0001”. Measurement Of Tolerances Up to 10 Millionths.

Milling Size Capability Up to 84” Lg.

Turning Size Capability Up to 20” Dia.

Finishing

Contract Manufacturing

Manufacturing Process 5-Axis Aerospace Machining

Complex Milling

Complex Turning

Thin-Walled Machining

Casting & Forging Machining

Exotic Material Machining

Hard Turning and Milling

Complex Machining

Assembly Services

Engineering Services

CNC Machining

Additive manufacturing (3D printing)

Machining Processes Milling

Drilling

Boring

Turning:

·         Contour Turning

·         Form Turning

·         Taper Turning

·         Straight Turning

Threading

·         External

·         Internal

Tapping

Countersinking

Pocketing

Profiling

Reaming

Spline

Parting/Cutting

Facing

5-Axis Machining

 

.060” to 23” in Rotation
Complex Milling

 

.060” to 84.0” in Length
Complex Turning

 

.060” to 22.0” in Diameter
Thin-Walled Machining .010” Wall Thickness Achieved on Cylindrical Housings, Deep Pocket Milling and Micro-Tubing
Hard Turning and Milling

 

Up To 70 Rockwell C
Milling Axis 3 axis

4 axis

5 axis

6 axis

7 axis

Turning Axis 2 axis

3 axis

5 axis

9 axis

Dimensional Tolerances and Repeatability

 

± 0.0001”
Measurement Of Tolerances

 

Up to 10 Millionths
Mechanical Assembly Capabilities Staking

Swaging

Broaching

Crimping

Potting

Adhesive Bonding

Wet Primer

Welding

Plug Installation

Bearing Installation

Valve Installation

Helicoils

Rosan Fittings

NAS / MS Hardware

Clickbonding

Nut plates

Riveting

Kiting

Electrical Assembly Capabilities Soldering

PCB Installation

Cables / Harnesses

Conductivity / Continuity Testing

Examples Of Manufactured Products Castings & Forgings – Machining of Aluminum, Steel And Titanium

Fuzing Systems

Missile Systems

Safing & Arming Systems

Landing Gear

Passenger / Crew Seating

Fairing Assemblies

Cargo Handling

Space Vehicles

Actuation Systems

Hydraulic Systems

Turbine Components

Ground Support

Frames

Switches

Housings

Shells

Panels

Reservoirs

Pivot Assemblies

Supports

Struts

Spindles

Materials Aluminum

Ceramics

Steel

Stainless Steel

Composite

Fiberglass

Titanium

Inconel

Hastelloy

Brass

Long Glass Fiber Reinforced (LGFR) Plastic

Rubber

Lead Times Quoted On Job-by-Job Basis

Emergency Services Available

Rush Services Available

Efficiency Six Sigma Certification

Lean Manufacturing

Kaizen/5S

Certifications AS 9100 D

ISO 9001:2008

Machined defense parts

 

Additional Information

Industry Focus

 

Defense

Commercial Aerospace

General Aviation

Military Aviation

Space

Industry Standards AS

Aerospace Industry Standard

ISO 9100

International Organization For Standardization

Mil-Spec

Military Specifications

NADCAP

National Aerospace And Defense Contractors Accreditation Program

File Formats Mastercam

CATIA

Pro-E

PartMaker

SolidWorks

 

 

Aerospace honing now offered by Primus Aerospace

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What is honing?

Honing is mechanical finishing process used by aerospace machine shops and outside processors to achieve a precision surface on a metal part.  Hones use superabrasives, also known as a honing stone, to a specific finish over the entirety of a metal surface.  These abrasive stones are configured on a tool assembly to provide consistent abrasion to the work piece..  Honing is also called bore finishing, as it’s most commonly conducted on cylindrical surfaces as a finishing technique.

Honing is conducted with honing stones or with wire brushes that provide a very specific level of abrasion to the metal work piece.  Honing stones are generally an aluminum oxide or silicon carbide abrasive material, which is bonded with resin.

Aerospace honing tool application

 

Where did honing originate?

Modern honing techniques date back to the 1940’s with the foundation of Superior Hone in Elkhart, IN.  The original intend of mechanical honing equipment was to deglaze automotive cylinder bores, but as the technique was perfected, additional applications presented themselves.

 

What are common types of mechanical honing equipment?

  • Vertical hone – Vertical honing machines use a drive shaft that is oriented vertically and moves along the work piece in an up and down motion. An example of a vertical hone would be the Ohio Tool Works PowerHone.  Primus Aerospace utilizes an onsite Barnes 3010 honer to provide in-house honing as part of a turn-key manufacturing solution.
  • Horizontal hone – Horizontal honing machines are laid out across a floor footprint where the drive shaft moves forward and backward through a work piece. An example of a horizontal hone would be the Ohio Tool Works VersaHoneSunnen is another manufacturer that specializes in honing equipment for vehicle engine applications.

Honing machines also differ in their capability to handle various bore diameters and part lengths / heights.  Primus’s honing capability specialize in parts that are ideally used for aerospace hydraulic reservoirs and cylinders.

 

What is single pass vs multi pass honing?

Most honing applications take multiple passes (known as stroke honing) to achieve the desired surface finish and depth.  Specific applications, such as engine crank arms or cam bores, require single pass honing to ideal performance.

Barnes Drill Company Vertical Hone

Why is honing performed in aerospace and defense applications?

Honing allows a manufacturer to achieve a precision surface finish that is critical for some aerospace applications, such as hydraulic systems.  Aircraft manufacturers and tier one suppliers design hydraulic systems as part of the control system.  In addition to aerospace control systems, honed aerospace parts are found in pumps, valve sleeves, accumulators, fuse pins, and landing gear components.  Parts are honed to reduce friction, remove burrs, and increase equipment dependability over it’s service life.  In specific aerospace applications, the inner bores of gears or weapon barrels are honed.

 

What is the advantage of a machine shop that has integrated honing?

While many aerospace and defense machine shops offer honing as part of their production sequence, very few have the honing capability inside their company.  When aerospace machine shops produce a part, the production sequence may require additional capabilities (such as honing, painting, precision grinding) to meet the customer’s build-to-print requirements.  When those capabilities are not organic to the part manufacturer, they will utilize outside processors (also known as OP Houses) to perform the specialized work.  More sophisticated machine shops have additional value added services inside the company, which allows them to expedite priority parts and ensures adherence to a single quality management system (QMS), generally at the AS9100 level.  Primus Aerospace is constantly adding additional capabilities, such as wire EDM, honing, and grinding, to it’s ability to provide turn-key manufacturing solutions for aerospace and defense parts.

 

Does Primus offer honing to aerospace & defense customers?

Yes! Primus Aerospace offers honing as a valued added service to it’s build-to-print aerospace part production service.  Primus does not offer today, stand alone honing as a separate service to other local machine shops, but could in the future.