Global industrial group Leonardo has achieved a dramatic manufacturing breakthrough in its complex carbon-fibre tiltrotor blade by shifting from traditional prototyping to a CAD-driven metrology approach.

To align and validate parts, engineers now probe and measure components relative to the CAD model, but because each composite blade inherently deviates from nominal geometry, conventional alignment fails. Leveraging MSP s advanced metrology tools, Leonardo can accommodate these variances and reliably produce complex composite blades in just 3 days, down from a 20-week production cycle, an increase in productivity of over 4500%. 

As part of this, Leonardo has also seen their part alignment process reduced from days to 5 minutes, their estimated scrap rate reduced from 95% to 0% and their reliance on using fixtures for part alignment processes eliminated. 

Faced with the challenge of producing large, twisted composite blades that were deemed impossible to manufacture by simulation software due to varying levels of distortion and a thin tip making them hard to fixture, Leonardo turned to Metrology Software Products Lmt. - MSP's PerfectPart suite of metrology products. 

David Madigan, Tooling Design Engineer at Leonardo, explained: To align our parts, we would normally probe and measure parts using the CAD, but as the composite blades are often all different and never conform to this data, we had to find another way . 

Originally, Leonardo considered tackling the problem themselves using traditional manufacturing methods, but this was predicted to create a 18-20 week lead time and, was therefore, deemed an unsuitable option.

The only feasible solution was metrology package MSP PerfectPart. It's NC-Checker and NC-PartLocator product modules give manufacturers error-free and right-first-time part production. 

NC-Checker was introduced as a standard operating procedure at Leonardo for its ability to assess the geometric performance of a CNC machine tool to check it is capable of machining parts to tolerance.

David stated: The tiltrotor blades are low-volume and high-value, so you don t want to risk scrapping any. NC-Checker allows us to monitor the machine tool in a simple way and gives us the confidence that no error on the machine will negatively impact the parts. Before we machine a blade, it is a stipulation that the software is run. Then, if something does go wrong, the first question is Well, did you run NC-Checker? . 

NC-PartLocator was introduced to solve Leonardo s main challenge of accurately aligning the blades despite the unknown amounts of distortion. NC-PartLocator is different to traditional part alignment methods. The software uses 5-axis probing to measure a part on the machine and generate an accurate best fit alignment in 6-degrees of freedom.
Most importantly in Leonardo s case, the software compensates for any discrepancy between the physical part location and the nominal machining program to show where the part really is on the machine. The updated alignment is automatically uploaded to the controller and any misalignment errors are automatically removed.

David admitted the product shocked him: NC-PartLocator s alignment results can be quite surprising. The software often shows that the blade should be somewhere else entirely, even when it doesn t look any different on the surface . 

It s also aided David s fixturing routine: I designed the fixtures based on the fact that you move the machine to the part instead of moving the part. All I needed to do was hold the part in position so it could be probed. It didn t matter that the blades were all variable and the position wasn t correct as I knew NC-PartLocator would compensate for that. 

Source - mspltd.com