Manufacturing the Future: Special Edition | Page 16

Build it Stronger , Lighter , Cheaper : The Challenges of Aircraft Lightweighting
Leading Propeller Manufacturer Relies on a Beckwood Press for Compression Molding of Composites
A leading manufacturer of propellers needed a compression molding solution to form composite aerospace components . They partnered with Beckwood Press Company to develop a custom 100-ton heated platen press that could maximize productivity and offer precise temperature , pressure , speed , and positional control .
Capable of temperatures up to 350 o F , the press features two 20 ” x 75 ” electricallyheated platens . Multi-zone heaters divide each platen into five sections which can be independently controlled for ultimate temperature uniformity . A hydraulically powered bed shuttle reduces cycle times and increases manufacturing efficiency while a push-button-activated booking ram with 90-degree booking capability facilitates easy die cleaning and maintenance .
To reduce energy consumption Pneumatic Dwell System , a pressure lock valve holds the desired pressure in the cylinders for the pre-determined dwell time , turning the primary motor off during inactivity . If a drop in pressure occurs , the pneumatic pump adds additional pressure back into the cylinder to reach the desired force .
Feedback for position and speed is controlled through independent zones with linear and pressure transducers that work with an Allen Bradley control system for critical precision . The speed is variable throughout the stroke , and the press is equipped for a variable dwell under pressure .
With their new Beckwood press , the aerospace manufacturer is able to fulfill orders faster , reduce operating costs , extend the life of their expensive mated dies .
Boeing Chooses a Beckwood Press to Form Laminate Components
Boeing needed a state-of-the-art press to manufacture reinforced thermoplastic laminate ( RTL ) components for their 737 and 777 slat track flex tabs . They also wanted a partner who understood the intricacies of automation and integration in their production process .
They approached Beckwood Press Company because of the firm ’ s proven track record engineering hydraulic presses and ancillary equipment for production line assembly . Additionally , the level of collaboration , creativity , and responsiveness Beckwood offers throughout the design process made Boeing ’ s decision an easy one .
“ We found a press company who understood our application and was able to work with us to develop the project ,” said Mark Shead , Boeing Engineering Specialist . “ The flexibility of design was extremely important as we had to integrate a specialized pre-heat oven with the press , and we needed a company willing to work with us on a tight timeline .”
Beckwood partnered with Boeing to develop a compression molding solution that worked seamlessly with their existing pre-heat oven and shuttle system . The custom 230-ton heated platen press features multi-zone electric heaters capable of temperatures up to 450 o F and a 1 ” -thick insulation board to isolate the heat from the structure . This unique heating system gives Boeing the precise temperature control and process repeatability required to form their laminate parts .
“ Beckwood was chosen because they offered the best value and could meet our tight timelines . The most impressive · aspect of the press is its reliability ,” Shead concluded .
“ Flexibility of design , integration with our existing equipment , and fast turn around were integral in our decision to choose Beckwood .”
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