Yorkshire-based MetLase is an engineering specialist that has worked with the Advanced Manufacturing Research Centre (AMRC) to revolutionise the making of crucial aerospace parts by cutting down the weight of the components by 12 per cent. The creation of these components would require 7000-grade aluminium, which has extreme internal residual stress and warps while machining.
MetLase has 30 employees present at its high-end facility in Rotherham and has worked immensely hard with AMRC to run trails for the research suggesting the application of smart positioning to ‘lightweight’ structural airframe components.
The company will use its expertise along with its MetElements hardware and software protocol. A row of distance sensors has been installed within the existing fixturing of a machining tool.
These sensors are not better than the quality we receive in smartphones, yet they are designed in a way so that they cannot block the cutter path.
The Business Development Manager at MetLase, Richard Gould, thoroughly illustrated: “The 7000-grade aluminium used in these types of airframe components is renowned for its internal residual stresses and its habit of warping during machining; especially if the component is thin-walled, as this lowers the geometric stiffness of the final component.”
“We have a strong relationship with the AMRC, so used this collaborative partnership to work with its engineers to explore how sensors could be used in adjusting the machining process in real-time, compensating for any warping as the part is being cut, and delivering better geometric accuracy in the final component,” Gould added.
Richard Gould continued: “Leveraging the power of MetElements, we were able to give live feedback about the component’s geometric condition during the milling process, with a 3D display created that showed how the component was distorting in near real-time (60Hz). The results of the trials delivered a 12% reduction in the final part weight due to the reduction in wall thickness.”
The Technical Fellow in the Aerostructure and Landing Gear Team at the AMRC, Daniel Smith, picked up where Gould left and said: “The project successfully demonstrated the power of adding sensing equipment to existing industrial processes, and the positive impact harvesting live in-process data can have when validating model data and ultimately improving the quality of the output component geometry.”
“MetLase has been instrumental in the implementation of sensor technology throughout this project, working with us from the start and then supporting us with its own design, engineering, and digital manufacturing expertise. It has delivered several tangible results, but importantly has given us a solid use case on how industry could retrofit low-cost smart i4.0 sensing to existing off-the-shelf-machining equipment,” Smith painted the whole picture.
The Product Development and Innovation Manager at MetLase, Stewart Lowth, in conclusion, said: “MetElements gives us an adaptable platform for any connected technologies to communicate with each other, whether they are traditional industrial automation sensors or modern small-factor smartphone style sensors.”
“Just like on the AMRC project, this digital flexibility allows the right sensing solution to be used for the right job, saving money for SMEs and large organisations alike,” Lowth seemed very positive.
MetLase was founded in 2015, beginning a journey to supply precision-engineered components to the automotive, aerospace, maritime, power and Formula One industries. Now it has a tier 1 clientele base from the Original Equipment Manufacturers (OEM) department worldwide.
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