Aero-engine shafts are now machined with 45% faster cycle times and 80% fewer manual interventions, thanks to new cutting strategies and flow forming technology developed in this project. The problem was that Rolls-Royce needed to dramatically increase production of shafts for the Trent XWB engine to meet global demand, but traditional machining from forgings wasted material and took too long. The project combined novel cutting tools, computer modelling, in-cycle inspection, and flow forming to produce near-net-shape shafts that require far less machining. The technology has already been implemented at Rolls-Royce’s Derby facility for production of mainline shafts and stubshafts. This has increased UK manufacturing capacity for these critical aerospace components and generated extra work for UK suppliers of tooling, fixtures, and consumables. The improvements in cycle time, manual intervention reduction, and right-first-time rate have been incorporated into a new standard method of manufacture. For passengers, this means more reliable engines and shorter waits for new aircraft deliveries.
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The aim of this project was to develop methods and technologies to deliver step-change improvements in the manufacture of aero-engine shaft components, to achieve reduced cycle times and manual intervention, and improved Right First Time. Such improvements are necessary to enable Rolls-Royce to deliver the volume of shafts required to meet the growing global demand for the Trent XWB. The collaboration with the Advanced Manufacturing Research Centre (AMRC) generated novel cutting strategies, advanced fixturisation, optimised cutting tool configurations, in-cycle inspection, complex computer modelling and dynamic frequency monitoring to machine full-scale shaft components. Traditionally, critical shafts are machined from forgings with low material utilisation rates of typically below 10%. This results in high material input weights and excessive manufacturing time to machine the forgings to final geometry. Working in collaboration with the Advanced Forming Research Centre (AFRC), the project also developed flow forming technology to produce near nett shape shafts. The project significantly exceeded expectations with the Manufacturing Capability Readiness Level (MCRL) raised from 2 to 6 with significant business benefits so far such as: reducing cycle times for shaft machining by 45% against an original target of 30%, reducing manual interventions were reduced by 80% against a target of 50% and raising the feature right first time rate to 99.6%. The High Performance Shaft Machining technology has been successfully implemented into the Rolls-Royce D-site facility in Derby for the manufacture of production mainline shafts and stubshafts. This has led to an increase in productivity enabling the facility to increase UK manufacturing of these critical aerospace components. In addition, this has provided extra workload for the UK SMEs and businesses supplying the tooling, fixtures, services and consumables. The cycle time improvement, the reduction in manual interventions and increase in RFT have been incorporated into a new method of manufacture. “As UK agents for WF we have been very pleased to continue the good relationship with the AFRC. We have supplied new tooling for AFRC. Rolls-Royce projects have extended the knowledge base of AFRC and developed UK knowledge of the possibilities of spinning and flow forming technology. Pearson Panke have had the opportunity of introducing the AFRC to other potential UK users of these technologies.” Pearson Panke Ltd, London (UK rep for WF flow forming machines)
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