SACMA Group Revolutionizes Aerospace Fastener Production with New ‘Smart’ Manufacturing Solutions
A new generation of machines from SACMA Group promises to significantly optimize the production of aerospace fasteners, addressing the industry’s demand for high-precision components and increased efficiency. The company is expanding its capabilities with a range of equipment designed for both high-volume and small-batch production runs, utilizing advanced technologies like the Internet of Things (IoT) and warm forming techniques.
Meeting the Demands of Aerospace Manufacturing
The aerospace industry requires fasteners manufactured to exacting standards, often using specialized materials. SACMA Group’s new machines are engineered to meet these stringent requirements, handling wire diameters from 3mm to 25mm and operating at temperatures between 300°C (572°F) and 900°C (1,652°F). This versatility allows for the processing of a wide array of materials commonly used in aircraft construction.
According to a company release, the machines are designed to support “Smart” manufacturing practices, leveraging real-time monitoring and data collection to boost productivity and efficiency. This integration of IoT technology allows for proactive maintenance and optimized performance.
Versatile Warm Forming Technology
At the heart of the new range are SACMA’s warm forming headers, equipped with a universal heating unit. These presses offer exceptional versatility, capable of producing fasteners, nuts, brackets, and customized solutions all on a single machine. The quick changeover capabilities and motorized adjustments minimize downtime and maximize flexibility.
The multi-stage warm forming machines employ a precise tool design to create near-net-shape blanks, potentially eliminating the need for costly grinding operations. This is achieved through a fully integrated heating unit featuring two induction coils – one positioned behind the wire feeder and another within the frame near the shear bush. This unique configuration ensures uniform heating of the wire, guaranteeing consistent material properties for optimal forming. Furthermore, continuous thermoregulation of the frame and coolant system optimizes tolerance management.
Key Models for Aerospace Applications
The SP270WF900 and SP370WF900 models are particularly well-suited for the aerospace industry, capable of producing 80% of commonly used screws and nuts. These machines feature an intuitive Human-Machine Interface (HMI) program and store partial recipes without restriction, facilitating rapid changeovers for low-quantity production batches. The KSP12 model combines hot forming and threading into a single process, streamlining the production of simple fasteners.
Ingramatic Thread Rolling: Enhancing Quality and Speed
Complementing the header range, Ingramatic’s warm forming thread rolling machines can thread both cold and hot blanks, adapting to varying material requirements and production speeds. These machines utilize the innovative I-Thread concept, delivering significant improvements in thread quality, productivity, and efficiency. A maximum production speed of 300 parts per minute (ppm) allows for the efficient production of titanium components in warm forming mode, reducing cycle times and improving material flow.
The WF thread rollers can process a diverse range of bolt, screw, and stud shapes, even those made from materials traditionally difficult to roll. Popular models include the RP220WF (12kW heating unit) and RP420(L)WF (24kW heating unit), both featuring quick, fully motorized setup systems. A one-piece cast iron frame and reaction block minimize bending during the threading of specialized materials. The machines also provide real-time temperature and kilowatt usage data via the HMI.
Secondary Operations Streamlined with HS ASPE
For secondary operations, HS ASPE offers the HDT12 and HDT20 models, combined machines capable of drilling, boring, facing, chamfering, broaching, and tapping. These operations can be performed sequentially or simultaneously, utilizing up to four spindles. This functionality increases product consistency, output rates, and overall productivity while reducing the need for multiple machines.
SACMA Group’s comprehensive approach to aerospace fastener production, combining advanced technology, versatile machinery, and a commitment to efficiency, positions the company as a key partner for manufacturers seeking to optimize their operations and meet the evolving demands of the industry.
