The -102T part is a T- cross section extrusion requiring stretch forming to a variable contour, milling to profile and chem milling to thickness per the standard process specifications. The complexity of this part required the use of XF, XM, and XJ. We demonstrated the full suite of XTRU™ machines to produce the -102T directly in final 7075-T temper.

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The cross section and overall contour of the part fell well within the capabilities of our XF machine, but had one localized region with a very tight angle or “kink” that was tighter than the achievable range for XF. We were able to use our XJ machine to perform a series of joggles in that region of the part to bring the tight angle into spec.  

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Watch XF-3 in action!

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We then used our XM milling machine to profile the part and demonstrated mechanical thinning in place of chemical milling. Thinning was required on the back flange of the part, as well as on one side of the web. The capability to mechanically thin parts has significant potential in reducing extrusion inventories that are required to be kept on hand if parts can be mechanically milled down to the required profile and thickness, while avoiding toxic chemical baths.

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Watch XM-3 in action! 

 

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​​The final result:  

XTRU's capabilities produced -102T part without building part specific tooling!

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Final part showing all forming and machining (profiling and thinning)

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