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Receiving
Inspection (Test Lab)
Capability to test incoming raw material, adhesive and potting.
Tests are divided into two types, mechanical and physical. These
tests comprise of: two identical 100 Newton MTs Test Frames - for
testing raw material compression and tensile strength. Some of the
compression testing need temperature control during testing. One of the
test frames has an environmental control chamber providing this
capability. Tesnilkut - Cutting test coupons Muffle Furnace - Physical
test on resin content Gel Time - Gel time on physical test Hydraulic
Press - Flow Drying Oven - Volatiles
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CATIA V5 Suite Of
Tools
ACM has experienced programmers to support 3 seats of CATIA V5
(Computer Aided Three Dimensional Interactive Application) - Revision
18 (Service Pack 6) and 2 seats of ENOVIA (Enterprise Inovation)
supporting the aerospace industry. Provides an integrated suite of
Computer Aided Design (CAD), Computer Aided Engineering (CAE), and
Computer Aided Manufacturing (CAM) applications for digital product
definition and simulation. Addresses the complete product development
process, from product concept specifications through
product-in-service, in a fully integrated and associative manner.
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Walk-in Freezer
The freezer internal dimensions are 17.2 m (W) x 17.2 m (L) x 5.5
m (H). It can operate as low as -28o C. The freezer operates
with up to 3 sets of 15 Kilowatt R22 condenser/ compressor packages and
6 sets of R22 evaporators. The freezer is designed for a 6 hours
temperature and a defrost cycle.
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Chemical Storage
The chemical Storage area is housed in a separate building on the NW
corner of the site. The building is 18.53 m x 15.5 m. The building has
its own self contained fire system and is built to explosion proof
specifications. It comprises of six rooms made up of different handling
classes of material. Solvent Dispensing room, Flammable Combustible
room, Corrosives room, Waste Disposal room, Waste Bulk Packaging room
and Staging Vestibule area.
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Core Storage
The core storage warehouse measuring 18 m x 18 m is located next
to the receiving dock on the west side of the Factory.
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Core Block Saw
The Ferry horizontal block saw is designed for close tolerance cutting
of structural foams and rigid cellular material. The saw is a Ferry/
Femco model A-14 rated for 9-lb/ ft³ density polyethylene, 10-lb/
ft³ structure balsa woods, 30-lb/ ft³ density rigid urethane
foam and honeycomb material thickness of .3175 cm to 50.8 cm. Honeycomb
may be metallic or non-metallic in density up to 25-lb/ ft³. The
block saw design is capable of handling bulk material up to 127 cm
high, 173 cm wide and 317 cm long. The cut thickness is controlled by a
precise indexing system that controls cuts from .3175 cm minimum
thickness to 51 cm. The system is adjustable in .0025 cm increments and
has a repeat accuracy of +/- .0076 cm.
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Core Chamfer Saw
There are 2 identical ACM right sized moonshine
manufactured and 1 large Core Chamfer saws from EBCO Inc., (of
Washington, US) they are capable of a full range of angles from 0 to
90° for a straight chamfer cut. The core is held in place by a
vacuum table on the large saw.
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Ovens
There are two identical Ovens from Thermoplus Engineering of Singapore.
The ovens are constructed of a modular, rigid, structural steel frame
and pre-engineered insulating panels. The indirect electrical heating
system is designed to produce a maximum temperature of 177oC.
The ovens are programmable using Honeywell temperature controllers
being upgraded to digital data extract. The ovens have 32 channels of J
type thermocouple junctions complete with Honeywell data-logger and
locally mounted paper controller. There are 32 vacuum ports. The
interior working area of each oven is 328 cm (W) x 635 cm (L).
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Prepreg Automatic
Cutting Machine
Two identical Gerber Automatic Cutting tables
(Model DCS 2500) are used to cut prepreg material ply
patterns. The machines are PC driven. The table size is 208 cm
(W) x 1821 cm (L). The prepreg material is held in place via vacuum table. Third
machine is in process of certification.
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Contamination Control
Area
ACM has a 22,803 ft² Lay-up area, 3,444 ft² Kit-Cut area for
a total of 26,247 ft² of Contamination Control Area (CCA), which
is qualified to Boeing BAC5317 specification.
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Optical Laser
Template (OLT)
Total 9 OLT's: 2 SL-laser projectors and 7 LAP laser projectors, all
are utilized in the contamination control area. SL & LAP Laser
Projection Systems - offer multitooling and a powerful new digitizing
interface while it handles files from CATIA V5. Handling is easy and
time saving. By simply redrawing the ply boundaries with its
pencil-like tip laser data is produced and projected simultaneously. A
powerful yet simple to use toolbox of polygon and spline functions
converts the coordinates to curves in real time. Reference points are
taken in the same way. While the contour grows on the screen and
automatically optimizes for multi head projection. As soon as the last
curve is finished the complete information on all plies and work steps
is saved in a work file and production can start. An optional rail adds
extended range for large tools.
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Autoclaves
There are three identical Autoclaves. The Autoclaves are from Germany
manufactured by Scholz. The Autoclave Control System is ASC (Aerospace
Controls) of CA, USA. The Autoclaves are 3600 mm ID and 9200 mm usable
length. The tube exchanger for cooling uses cooling water supplied via
a chiller system. The hot oil heaters are heated by diesel fuel. The
nitrogen system consists of three storage tanks 100 m³ with a
maximum pressure of 11.5 bar. These tanks are fed by an on-site
membrane nitrogen generation system. Total of 60 ports available for
vacuum intake and output and 60 thermocouple jacks at each Autoclave.
Maximum Temperature: 260o C Maximum
Pressure: 6.9 bar. New Autoclave which is the Fourth Autoclave is now in production and
has been passed the certification process.
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2½-axis
CNC Water Jet Trim
The water jet is a AS 1412 Flow Master Shape Cutter. The system uses an
abrasive medium (granite) and pump system that boosts the water cutting
stream to 3800 Bar concentrated through a 0.033 cm orifice. The cutting
patterns are programmed using a PC windows based system. This machine
travels in the X and Y direction and is manually jogged in the Z
direction to raise and lower the cutting head. The cutting head has a
powered drill head attachment adding hole-drilling capability. The
working area is 335 cm x 427 cm and is a 'dual zone' system.
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5-axis
CNC Router
The router is a
Thermwood Model 67 with a dual head and single bed. The cutting
envelope is 124" X-axis, 106" Y-axis and 36" Z-axis. Other
router is Jo'mach 146 with
vertical
spindle, mobile cross-beam and fixed table architecture. It is a high-speed milling
center with mobile cross-beams that carries out 3 and 5 axis
milling, routing, drilling, boring and profiling functions for
aerospace industry. This 3/5-axes structure positions the spindle
with respect to the piece and ensures the tool is at right angles
with every point of the surface to be machined allowing roughing,
finishing and super-finishing operations to be carried out at a
spindle rotation speed of up to 24,000 rpm. Able to cover a wide
range of machining, ensuring accuracy and fine finish on various
materials both with simple and double curving with large working
envelop powered by Siemens 840D controller.
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Portable Coordinate
Measurement Equipment
ACM is using a FARO Laser Tracker and a FARO Arm both with Spatial
Analyzer for the portable coordinate measurement equipment. Laser
Tracker: Portable contact 3D measurement system for large
volume which uses laser technology to effectively and accurately
measure large parts, tooling and machinery. It has a 70m (230ft)
diameter range and achieves 0.025mm (0.001") accuracy and runs in
two-distance measurement modes: XtremeADM (Absolute Distance
Measurement) and Interferometer; making it the most accurate and
flexible Laser. Portable measuring arms make measuring complex
objects easy. This includes alignment, calibration, inspection, reverse
engineering and as-built documentation with accuracy up to 13 microns.
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Ultrasonic
Nondestructive Testing Capability
Ultrasonic testing is one of several available nondestructive testing
(NDT) methods. A nondestructive test is one that neither damages nor
alters the material being examined. Ultrasonics operates by introducing
high frequency sound waves into a test object to gain information about
the object. At ACM, our NDT facility utilizes many forms of ultrasonic
testing such as Pulse Echo, High and Low frequency Bond Testing, Manual
Thru Transmission and Automated Through Transmission Ultrasonics. Some
of the world's most advanced ultrasonic testing equipment is available
at ACM and is utilized in the nondestructive evaluation of all Advanced
Composite Materials produced at ACM.
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Distribution
Warehouse
The warehouse is located next to the receiving dock on the west
side of the factory between the freezer and material test laboratory.
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