Doosan applies cool machine tool tech to build hot jet engines

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2019-07-25 15:19:00

When it comes to aerospace, Doosan has contributed to almost every segment of the market. Parts made on our machine tools can be found in just about anything that flies. The list includes commercial jets, corporate jets, private planes, military aircraft of both fixed-wing and rotating-wing (helicopter) configurations and even crop dusters. We work with a range of customers from the big corporate players down to the tier two operations that supply smaller components from their job shops.

Jeff Sturtevant, Doosan’s Key Account Manager – Aerospace, is a 34-year veteran in the machine tool industry, specializing in aerospace since starting in the business in 1985. His responsibilities at Doosan include taking care of inquiries from aerospace clients, helping find the right engineering solutions by understanding the customer's application and recommending the proper Doosan machine to handle the work.

We asked Jeff to summarize Doosan’s involvement with the aerospace segment and give us some background on the Doosan machines in use today and a quick glimpse into the future.

What is Doosan’s Role in the Aerospace Segment Today?

If there is any area where we have a bit of an edge, it’s on the jet engine side, especially what we call the ‘hot side’ of the engine. We have a complete line of boxway vertical and the horizontal machines like the Mynx and NHM series that are well suited for the high temperature steel alloys used in the industry. The usual parts they machine can include compressor housings, fan disks, diffusers, rings, seals, blisk bodies, covers, cases and many others.

Coming in Hot

The Mynx vertical series offers a variety of spindle speeds (6,000 – 12,000 r/min), spindle tapers (CAT50 and CAT40) and an X-axis table range that starts at 40" and can go all the way up to 98.5". The Mynx series spindles support direct-driven and geared head systems.

The NHM horizontal series has the capability to machine general and hard-to-cut metal. The heavy duty, gear-driven spindle provides power while the M- and W-type ribs in the one-piece bed structure bring stability and stiffness for hard materials like those found in aerospace. 

What Other Doosan Products Are Doing Well?

We are well-established at large OEMs and tier ones with our vertical turning products like the PUMA V400 and V8300. Our PUMA SMX multi-tasking machines are also in demand. One advantage we have is that we have an outstanding technology versus price ratio.

Another product that is selling well is our LPS Pallet Systems (LPS). We can’t build enough of them. Our customers are adapting to the lack of available operators and need to increase spindle utilization with less labor. More and more of our customers in aerospace are heading in this direction.

Turning Their Heads

The PUMA V400 vertical turning center is built with boxways for heavy duty cutting in a compact space (58" x 82"). The 3,000 r/min spindle is powered by a 30-horsepower motor.

The PUMA V8300 series has a wider machining area for larger/more diverse workpieces. It has a maximum turning diameter of 32.7” and accepts a range of chucks from 15" up to 24". The spindle motor provides 60.3 Hp (45 kW) of power, 1912.9 ft lbs (2,592 Nm) of torque and has a maximum rotating speed of 2,000 r/min. Left- or right-hand versions are available, as well as a newly released ATC magazine.

The PUMA SMX is a roller linear guideway multi-function turn-mill machine that sports left and right opposing spindles. The B-axis rotating milling head has access to an 80-tool magazine which can be expanded up to 120 tools. The PUMA SMX ST models incorporate a lower 12 station turret that is capable of milling operations up to 5,000 r/min giving you ample turning capability. 

What’s Available for Customers Who Want the Advantages of 5-Axis?

Our premium 5-axis machines offer state-of-the-art control (Fanuc and Siemens) and machine design in a very competitive product line. Our DHF8000 5-Axis Horizontal heavy duty “A” axis machine and DVF5000, DVF6500 and DFV8000 (turning option available) are trunnion-based 5-axis. All machines have available automation options. Our LPS, RPS (Rotary Pallet System) and AWC (Automatic Work Changer) are popular options on the 5-axis machines because they greatly increase spindle utilization.

What’s the Latest Doosan Technology That’s Making a Difference?

Our customers have found distinct advantages and significant cycle time reductions using cryogenics. Doosan has joined forces with 5ME^® Cryogenics to showcase the benefits. 5ME’s unique, multi-patented cryogenic machining process is a breakthrough technology that enables higher metal removal rates and longer tool life. We have experienced a minimum of four times coolant-based tool life, and 50% reductions in cycle times are typical. Cryogenics works by delivering liquid nitrogen at -321°F through the spindle/turret, cutter body and cutting tool directly to the cutting edge. It’s environmentally friendly and increases throughput, part quality, tool life and profitability, while eliminating cutting fluids and reducing energy consumption.

We have proven interfaces available for both machining and turning centers. Working with 5ME, these cryo machine kits are now commercially viable and easy to justify. 

What Will We See from Doosan in the Future?

We've just released a high-speed horizontal profiler, the HFP 1540. We are also developing a larger version of the PUMA SMX (model 5100) for bigger parts. Another machine we are excited about is the VTR 1012F, a 1-meter fixed rail vertical turning center with tool magazine, quad index tool block and Capto interface.

Beefed Up for the Monster Parts

The HFP 1540 horizontal profiler is made for the high-speed machining of large aluminum workpieces like the structural components on an F-15 or F-35. It’s equipped with a large 157.5" x 59" table with a servo driven pallet changer for added productivity. The 30,000 r/min HSK63A universal spindle gives the machine its A and C axes.

Can You Sum Up the Doosan Aerospace Advantage?

The goal is very simple for all of us in this industry - put more chips in the hopper at the lowest cost possible without sacrificing machined part quality. There are many ways to accomplish this: increase tool life, cubic inch metal removal and spindle utilization; and/or reduce cycle times and down steam processes. Each of these areas must be considered for each unique aerospace application. Sometimes tradeoffs are required.

Our product line is wide enough that we can apply different machine tool platforms and designs that specifically address the challenges of rough, semi and finish machining nickel-based, heat-resistant aerospace alloys. For example, we can offer boxway/geared spindles for heavy roughing and much better tool life, as well as providing linear way machines for high-precision finish machining. This flexibility, along with our experience and service, gives aerospace OEMs the edge they need to deliver superior products at competitive prices. 

Final Thoughts?

Doosan has been involved in aerospace for a long time, and as you can tell by the products we have in the pipeline, we are listening to our customers and moving into new areas. The key Doosan difference is price points and value. If you want to talk specifics, I would suggest that you contact us for a more detailed conversation. 

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