Inca-Geometric wins aerospace parts production on back of efficient machining

The batches of control housing components involves machining every facet from a solid aluminium tooling plate. Inca's initial prototype method overcame previous problems when the customer produced the parts from castings. Among the problems experienced from use of cast material was a particular difficulty in maintaining a constant depth and form on special sealing grooves in the joint face. Managing director of Inca Mike Cain explains: "We were approached to quote for machining the castings, but the Mazak VTC gave us the opportunity to put forward a very competitive alternative process for complete machining from solid. This also gave us the ideal opening to break into a new sector from which we can expect further contracts." The Mazak set up involved A and B fixturing to create a pendulum-based process. Says Mr Cain: "This meant we were loading during machining and were able to complete the process in a relatively quick cycle time." Each control housing requires face and profile milling, slotting, drilling and engraving of legends that were previously cast onto the control panel face. On the reverse side, extensive pocketing and profiling of the seal groove was carried out.