Shot Peening Systems.  

Wheelabrator Surface Preparation +44 161 928 6388

The Burlington, Ontario (Canada) based shot peening team of Wheelabrator was approached by an aerospace consultant for a unique peening solution for landing gear. The aerospace consultant was acting on behalf of a renowned OEM for landing gear.

In the past, Wheelabrator has successfully manufactured several landing gear peening systems for various manufacturers including Goodrich Landing Gear Systems and Messier Dowty. Such systems involved peening the outside surfaces and bores in separate machines. The current challenge to the shot peening team was to utilize this past knowledge and combine peening of both outside and inside areas in a hybrid system. The approach to a hybrid solution was driven by inherent advantages such as: 

• Common blast cabinet and associated capital costs. 

• Common reclaim system components that assist in process control (such as vibratory classifiers for shot size control and spiralator for shot shape control) 

• Common controls and programming – which accounts for a large percentage of machine cost 

• Reduced part handling time (with common fixtures, the part can stay in the blast cabinet until both wheelblast and airblast operations are accomplished)  

Solution to this challenge resulted in a hybrid system consisting of a rotary table to receive the landing gear mounted on a fixture. The design offered the customer the flexibility to either load the table with a single or multiple fixtures. When loaded with more than one fixture, the table could execute a 360 degree rotation. In the event of a single fixture being peened, the table could be programmed to ‘oscillate’ in a specific quadrant (quantified by degree of oscillation).

This fully utilized the shot flow provided by three strategically located blast wheels without blasting the table. The cabinet was fitted with three (3) EZEFIT blast wheels in three planes in order to optimize the blast pattern on the part outside being peened. When combined with rotation of the part, the multiple angles of attack produced coverage in what are normally considered to be hard to reach areas of the gear. However, to ensure adequate coverage, the landing gear was re-fixtured and peened for a second or sometimes third cycle. In this system, the main and cross bores are peened using a nozzle lance mounted on a 3-axis carriage located outside the blast cabinet.

The lance penetrates the cabinet wall and the penetration area is protected with rubber seals. The z-axis of this carriage accommodates different part diameters. The x-axis stroke is fully programmable for different part lengths. Additionally, the lance spins inside the main and cross bores. Travel and rotation speeds are completely variable using frequency drives. The main table is sized and designed such that it could index the same angle as that between the main and cross bores. This feature reduces set-up time as both the main and cross bores can be peened without the need for refixturing. In addition to the obvious advantages presented by this hybrid solution, the following are longer term: 

1.    Cycle time savings because of reduced part handling when compared to using two independent machines 

2.    Labour savings from having a single operator operating a hybrid machine as opposed to multiple operators for multiple machines.

 

3.    The rigours of certifying a peening machine to a certain specification or audit are extensive. Instead of certifying multiple machines, this hybrid machine needs to be certified only once for multiple operations. 

4.    Blast machines that undergo regular maintenance result in reduced downtime and interruption to production operations. With a hybrid machine, the need to maintain multiple machines is avoided. 

5.    Training requirement for operations personnel is minimized to a single machine as opposed to multiple machines. 

MABS cleans up with Aqueous cleaning

Wheelabrator spray wash machines. 

Aircraft part manufacturer Meggitt Aircraft Braking Systems (MABS) is greasing the wheels of change, by switching from trichloroethylene, to safer, more environmentally responsible cleaning methods with a Wheelabrator spray wash machine. MABS will use the new multi-stage front loading equipment for degreasing complex aircraft parts, used in braking systems, prior to plating and painting.  

Our equipment sales manager said: “We’re delighted to be helping MABS switch to aqueous cleaning methods. Front loading machines are simple to use and ideal for batch processing, making them a perfect fit with Meggitt’s requirements and factory set-up.”  

Prior to investing in the new machine, MABS used trichloroethylene, more commonly known as trike, as a vapour degreaser. With its use being curtailed by the Solvents Emissions Directive which now affects all countries in the EU, the Health and Safety Executive suggests trike, or replacement solvents should no longer be considered in light of aqueous processes – which use the safest solvent of all – water – in degreasing all types of engineered components.  

Our Wheelabrator Group expert said: “Aqueous cleaning methods are not only better for the environment, but also safer for staff involved in the degreasing stage of Meggitt’s manufacturing operation. “During the selection process we invited MABS to run a number of trials at our Surface Technology Centre in Birmingham. This enabled us to refine and agree the exact specification of the machine required and demonstrate the high quality finish aqueous cleaning provides.” 

Coventry-based MABS is a leading provider of high technology solutions to the aerospace industry, serving a range of customers from aircraft manufacturers to airlines and operators. The braking systems department designs, develops and manufactures carbon composite brakes, braking systems and lightweight alloy wheels. 

Wheelabrator Group launches a compact machine for the

shot-peening of blades. 

Wheelabrator Group has recently launched a new shot peening machine for reactor blades and root blades in answer to increasing demand from engine component manufacturers in the aerospace industry. The machine features an indexing table, enabling work pieces to be loaded in a safe area outside the cabinet, whilst other work pieces are being peened within the cabinet. A sliding door system opens and closes the cabinet at each process stage. This guarantees that the peening process is completely enclosed and the cabinet is soundproofed. The illuminated barriers allow the operator to work in safety. A work piece masking system effectively masks the component so that only the exposed areas are peened, and the work piece holders are flexible enough to hold a wide variety of different work piece heights. The airblast cabinet can be used with steel shot in accordance with aerospace shot peening requirements, these include:

 

- A cyclone for the dust removal from the shot 

- A vibrating sifter to calibrate the steel shot 

- A storage shaft to recycle the cleaned and calibrated shot 

The shot projection, a multi-nozzle suction-fed type, can achieve the specified Almen measurements and work piece coverage. Each nozzle flow is regulated and controlled by magna valves to comply with the control requirements in the blasting process of aerospace parts.  

An efficient dust collector with cartridges and with an automatic anti-warping filter system is fully integrated to ensure good ventilation, effective dust removal and the pneumatic transport of the abrasive. Its excellent rejection rate allows the machine to be set inside the workshop. This airblast cabinet from Wheelabrator Group has passed the tests and the approvals of several Aerospace OEMs. 

Clean green approach as aircraft manufacturer lands one of the

Wheelabrator surface treatment washing sytems. 

A new washing system from Wheelabrator Group is helping one of the UK’s leading aircraft manufacturers remove contamination and increase the life of its innovative 

reusable packaging system. The Wheelabrator wash, rinse and dry machine is being used by the customer to achieve its zero-tolerance standard that drives the application of its reusable packaging system. In this process, parts are placed in plastic containers with high-density foam liners to prevent metal-to-metal contact, as they are moved through a variety of manufacturing stages. Its impressive performance has resulted in the machine being awarded one of the customer’s coveted awards for excellence. 

Our general manager of the Wheelabrator product range, said: “As the 10,000 containers travel around the site they pick up a variety of contaminants such as cutting and lubricating oils, metallic swarf and paint particles, from the different processes. Oil and fine particle contaminants in particular, can build up on liners and transfer to parts causing rejection and rework where surface condition is an important feature. Prior to installing the new machine, our customer discarded a high percentage of their liners due to oil contamination. In many 

cases, the new washing capability has extended their life from one to three 

years and they are, understandably, pleased with the result.”  

Before implementation of the reusable packaging system, parts protection was based on the application of consumable packaging, such as bubble wrap, which required operators to wrap and unwrap parts at every stage. As a consequence, labour cost was high for a non-value adding operation and the volume of waste disposal impacted greatly on the local environment. The gradual change to reusable packaging has accelerated workflow through better presentation of parts and reduced handling, and given a significant year on year reduction in waste disposal. 

Our expert said: “Our engineers worked with the customer to modify a standard conveyor machine to include two one metre buffer zones, fitted with powerful air knives, to ensure minimal fluid carryover and contamination between the process stages. Other refinements include steam extraction and condensing, fine particle filtration, energy metering, softened water and oil water separation. Washing and rinsing the contours of the boxes and foam would inevitably result in a degree of splash back, but the integral buffer zones mean this is now nullified. The liners also presented a challenge, due to the need for a quick dry capability, so extra attention was given to a sophisticated drying section, which incorporates double fan driers. “At Wheelabrator we’re seeing increasing numbers of companies buying equipment to clean components at different stages of manufacture and prior to delivery to customers. Many, though, forget their products also get dirty whilst moving around their facilities in dirty containers or boxes. In fact, we believe a staggering 40 per cent are experiencing contamination problems as a result of dirty component packaging. This could be easily avoided without the need for considerable capital investment.”

 

Composite Technology enjoys room for improvement with one of Wheelabrator’s 

bespoke blastrooms. 

Helicopter rotor blade repairer Composite Technology has seen productivity levels lift off after purchasing a bespoke blastroom from Wheelabrator Group. The 10m x 2.4m x 2.4m blastroom, which Composite Technology started using just two months ago, is being employed to remove paint and other coatings from rotor blades during the reconditioning process. Chris Satchwell, production manager at Composite Technology, said: “The new blastroom speeds up the process of stripping paints from aluminium as well as composite substrates, giving us better quality, and a more consistent finish “We previously performed this function with orbital sanding machines, but these were quite slow and laborious so absorbed a lot of man-hours. Where it could take up to a whole day to strip one blade, the blastroom finishes the job in a little over two hours. We’re extremely pleased with our purchase and after specialist training have already seen our production efficiency increase.” At up to 10 metres in length, rotor blades are made of lightweight materials, making them too long and fragile for traditional blast machines.  

Our UK field sales manager at Wheelabrator Group, said: “We’re delighted to have been able to help Composite Technology improve the efficiency of its operation with a new blastroom. As well as increasing efficiency by providing faster and better results, Composite Technology can now allocate the man-hours previously consumed by this arduous task to more value added activities. Blastrooms are becoming increasingly popular in the UK as they are bespoke to each customers individual needs so offer greater flexibility and versatility.”  

The externally sited blastroom, which uses plastic abrasive, is a fully mobile system, including equipment housing and compressor in one unit without foundation work. The customer’s anticipated growth required a solution that could be easily transferred with the site. A silenced dust extractor fan set allows the room to be placed within three metres of the outside wall of the premises.  

Andover-based Composite Technology was established in 1991 and now serves customers in many countries around the world, reaching from Greenland to Africa, the Far East and former Soviet block. It holds approvals as an OEM repair station for Sikorsky, Bell Helicopter Trextron, Agusta, Schweizer and MD Helicopters. It is also approved by Airbus and Boeing to repair composite panels and fairings.  

Blast Cleaning Machines for aircraft rims  –  

Increases efficiency, productivity and environmental responsibility

Wheelabrator Group has recently delivered another airblast machine to a well-known aerospace company to provide an automatic paint striping process for aircraft rims. The machine will prepare the aircraft rims for crack detection, a crucial part of the compliance process within the aerospace industry – with safety being at the forefront of their 

manufacturing process. 

Automatic replaces manual for increase efficiency 

Paint stripping of the aircraft rims was previously done manually and due to the enormous workloads of aerospace maintenance companies the process was proving to be very costly and timely – not forgetting an exhausting job as the rims are relatively heavy! The Wheelabrator airblast machine has now replaced manual labour which has in turn has increased efficiency, productivity and allowed labour to be allocated to more effective tasks. 

In most cases, the rims consist of two halves which are blasted singularly. The operator lays the work piece on a special rotating device which Wheelabrator Group has developed specifically for this application. The rotating device is very flexible and suitable for the blasting of all common rim types for medium to large sized aircraft. 

Easy to use, automated process 

The rotating device is installed on a rail-bound car which can be easily moved by the operator. After placing the rim into the blast position, the operator sets the corresponding blast programme in the machine control panel and starts the treatment process. All other 

functions are fully automatic. A nozzle manipulator with 3 movement axis guides one blast nozzle over the inside and outside contour of the rotating work piece. The movement 

pattern is part of the blasting programme and is unique for each work piece type. 

As usual in the aerospace industry, all further blast parameters like air pressure and abrasive flow are under control. 

The Dry Stripping Process has flexibility and multi-use 

This process is not only used for stripping paint from aircraft rims it can also be used for other applications. In the aerospace industry it is also used for stripping paint from landing gear parts and the military aerospace industry uses this process to strip paint from outboard assemblies. The process is mainly used to prepare components for crack detection or to check for visual changes as for example for military operations for UNO or NATO. 

The process can also be used in the automotive or electronic industry, especially for components that require a gentle of method of cleaning. Dry stripping replaces the 

use of chemicals and thus, contributes to the protection of the environment.