Moog Virtual Investor Day 2020 - Presentation - Page 13
Automated Machining Cell
Future opportunities and an on-going focus on operational
excellence require investments in manufacturing technology,
new machines and training. Upgrades to advanced manufacturing
machinery allow machinists to produce the complex geometries
and close tolerances designed into Moog products with better
overall return on capital investment.
Moog’s fully automated machining cell
During the design phase for Embraer’s new E2 jet program, Moog engineers used a designto-manufacturing teaming environment to create a production process for first development
parts. The goal: reduce costs as the program transitioned from development to production.
The team planned and proved-out the design of a small robotic cell for the manufacture of
hydraulic manifolds to improve part flow, labor utilization and machine investment.
The result was a fully automated machining cell with standard off-the-shelf 5-axis equipment. Operated by a robot and using six automated machines for milling, the cell
produces the full product family of complex milled aluminum manifolds for the E2 jet. The quality of the finished product, improvements in capacity along with reduction
in cycle time, tooling costs, floor space and capital investment resulted in the construction of a second similar cell. This new operation is a larger automated manufacturing
cell for manifolds for the Airbus A350 and Boeing 787 aircraft programs.
Industrial Servovalve with Additive Components
Traditional machining turns a block of titanium or aluminum into a part by shaping it with milling and boring machinery during part fabrication, removing portions of the
material. The effects of traditional machining, heat-treat, casting and forging processes on material properties are well known. Additive Manufacturing (AM) describes a wide range
of additive processes and methods. Metal additive at Moog mostly utilizes a Powder Bed Fusion (PBF) process. PBF is a digital automated metal part manufacturing process utilizing
metal powder as raw material. AM allows for new design solutions but requires considerable research and development for use on critical applications and systems.
Commercial and military aviation, manned and unmanned space applications, certain
industrial uses, and medical products require certifications to establish suitability for
service – and often have strict quality and traceability standards. Additive introduces major
process changes, especially for products that require certification because additive
machinery is both the furnace and the mill. Extensive R&D and testing is required and
additive isn’t a complete replacement for traditional, or subtractive machining.
In one application, Moog engineers replaced a conventionally produced servovalve body with
an additively manufactured titanium valve body. Leveraging the advantages of additive
technology, the new body delivers a small internal hydraulic flow improvement and a 50%
weight reduction. Future additive R&D includes identifying
opportunities to consolidate parts into single additive
components, reducing weight and solving thermal
Moog’s powder-to-product Additive Manufacturing Center
Our engineers see additive manufacturing technology as a key enabler for future digital processing and leaner workflows.
Additive offers high-quality rapid prototyping, the option for one-off customized parts and quantity-of-one production runs.
In the field, the day will come when spare part printing is on-demand and completed at the point of use – underwater, in a
factory far away, and even in space.