We were recently contracted by a defense industry customer who required the machining of high precision stator pins for use in one of their products. As a full service provider, at Andrew Tool & Machining, we were able to deliver the extensive assistance required to develop the specifications for the product. This was a critical aspect because the potential for error in the final application was high, without a detailed evaluation of the desired application and creation of applicable standards. The parts were machined from Inconel nickel-chrome superalloy, and required precise machining and a detailed quality control process to ensure that the finished components met or exceeded the project specifications.
The pins were built to dimensions of 0.30″ diameter and 1.928″ in length, with the diameters maintaining a tolerance of ±0.001″ from the specified value. Fabrication was accomplished using a computer numerical control (CNC) lathe, a four-axis vertical machining center (VCM), jig grinders, a wire electrical discharge machine (EDM), and a sink EDM. The pieces were inspected following turning operations on the lathe, as well as before each of the steps of grinding, milling and sink EDM application. They were also subjected to a multi-layer final inspection before approval.
The orders were completed in lots of 32 to 144 pieces, which were turned around in a time period of eight weeks after receipt of order. A primary reason for the success in creating high-quality pieces from Inconel lies in the detailed approach to the machining process and the insistence on thorough quality control. These factors played an integral part in the completion of this project, to the satisfaction of the customer.
Specifications
Capabilities Applied/Processes
- Primary: Lathe
- Secondary: Vertical Machining Center
Equipment Used to Manufacture Part
- 4 Axis VMC
- CNC Lathe
- Jig Grinders
- Sink EDM
- Wire EDM
Overall Part Diameter
Overall Part Thickness
Tightest Tolerances
Material Used
Material Finish
In Process Testing/Inspection Performed
- Inspect after grinding and before milling
- Inspect before sink EDM
- Inspection after turning and before grinding
- Multilayer inspection for final Inspection
Volume
Delivery/Turnaround Time
Delivery Location
Additional Facts
- We helped this customer develop requirements
Why Did You Choose This Project to Showcase?
Part has a lot of opportunities for error. Worked closely with the customer to ensure the proper requirements were laid out.
