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COST BENEFIT SUMMARY | TAPPING A286 + INCONEL AIRCRAFT PARTS

July 9, 2020 5:52 pm Published by

PROBLEM STATEMENT: HIGH COST OF TAPPING AEROSPACE ALLOYS

CUSTOMER’S PROBLEM:  THE CUT TAPS USED TO PROCESS AIRCRAFT PARTS  MADE OF A286 AND INCONEL IN MEDIUM LATHE LAST APPROXIMATELY 40 – 60 PIECES IF EVERYTHING GOES WELL. WE PROCESSES OTHER ALLOYS WITH THE SAME CHALLENGES. 

Material: A286 is an iron-base superalloy which is a heat/corrosion resistant austenitic iron-base material age hardened to increase strength. A286 is often used for applications requiring tough strength and corrosion resistance up to 1300F (704C) as well as some lower stress applications running at higher temperatures. Other suitable A286 uses include low temperature applications requiring a ductile, non-magnetic high strength material at temperatures down to -320F (- 196C). It may also be used for moderate corrosion applications in aqueous solutions. Industry Applications Include * Jet Engine Components *  Fasteners   *  Springs *  After Burner Parts * Industrial Gas Turbines * Non-Magnetic Cryogenic Equipment

Material: Inconel® is a chromium-nickel-iron base, age hardenable superalloy designed for high strength and corrosion resistance at elevated temperatures. It is hardened by precipitation of nickel, titanium and aluminum compounds. It is non-magnetic with high strength up to 1400F and oxidation resistance up to 1600F. Industry Application Include * Gas Turbine Engines  *  High Temperature Bolting

Goal: Implement process changes that yields increased efficiency, increased part uniformity and reduced tooling cost (faster, better and cheaper). Usually only two of the three are achievable, simultaneously. Our goal is to achieve all three in this CI and provide maximum benefit to our customer.

What We Did: Designed special taps for the customer’s applications 1/4-28, 5/16-24 , 3/8-24 Jarflo Ultras | SEE: INDIE JARFLOS

Results:jarflo ultra roll form indie tap

  • Faster: Improved Speed: Aircraft parts tested could be processed quicker because the roll tap processing speed is higher; speed went from 15 S.F.M to over 35 S.F.M
  • Faster: Productivity Gains: Reduced downtime; with increased tool life less time was spent changing tools; tool life went from 40-60 to 500
  • Better: Improved Quality: Tap wear that caused part defects was all but eliminated; part uniformity was enhanced
  • Cheaper: Current Cut Tap: Using round numbers the cost per part using cut taps was ±$1.00 Fiddling with gauges to determine whether a part is still good though produced with a cut tap that is well into its service life added another ±.25 cents per part; +.05 cents for lower tapping speed; + another .05 cents for frequent tap changes = $1.35
    • Jarvis Roll Tap: Jarvis taps produced an order of magnitude greater parts (500 or more). Special Jarflos (24 pcs qty) at 1/4 $77.91, 5/16 $86.16, 3/8 $93.91. The math becomes, a roll tap part costs approximately $0.15 per part to tap. The savings is approximately $1.20 per part.
    • Currently there are open orders for at least 3400 pieces X $1.20 = which is approximately $4100 in tool cost savings off open orders alone. Through repetitive production and long-term use there is significant savings.
    • And . . . we’re just getting started. There are numerous other P/Ns. The total CI is probably an order of magnitude greater than this one example, tens of thousands of dollars in Medium Lathe, alone. These same tools can be used in other departments too.

Customer QuoteJarvis cutting tools has offered our company a tremendous savings and we will use Jarvis across the entire thread size ranges on both right and left hand threads.”

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