Crossen Engineering — the Belfast-based tool maker and sub-contract machinist — has increased its aerospace capability by installing the latest in wire-cut EDM
technology : a Sodick AQ600L from Sodi-Tech EDM Ltd, Coventry
(www.sodi-techedm.co.uk).
Last year, the company formed a new division called Crossen Aerospace to reflect the fact that this sector had become its main area of focus; the latest machine, which replaced two older ones, indicates yet further commitment to the company’s growing portfolio of aerospace customers.
Crossen Engineering serves both civil and military aerospace programmes. Most of its aerospace work is accounted for by maintenance repair overhaul (MRO) and parts manufacturing authority (PMA) activities. The 22-employee company is accredited to the AS9100 quality management approval (Revision C) and produces pressed components, moulded parts, precision machined components and tooling for aerospace customers.
Crossen claims to have installed the very first EDM in Northern Ireland, way back in the late 1970s; and although the company has acquired Sodick machines in the past, the new AQ600L is the first it has bought since 1995. Managing director Paul Crossen says: “Sodick technology has come on in leaps and bounds. The accuracy, surface finish and ease of programming were features that really stood out on the AQ600L. Furthermore, its speed and productivity meant that we could sell our two older EDMs safe in the knowledge that the new machine would cope easily with the workload on its own.”
Installed at Easter 2013, the AQ600L has been set to work manufacturing tool punches and dies used in the manufacture of parts for various legacy, current and future aircraft programmes. Among Crossen’s customers is the nearby facility of Bombardier Aerospace, along with Thales Air Defence, BE Aerospace and LenisAer in the UK. In the USA, air seal manufacturers Chrom-alloy and Seal Dynamics are on-going users of Crossen products.
The company regularly manufactures pressed and formed high-temperature alloy components for aero engines. Hastelloy X, RENE 41 and Inconel 600 are among the sheet and plate materials processed. The high cost of these materials means that scrap is not an option, and the tools produced by the Sodick AQ600L must be of the highest quality. Presswork batch size is normally in the range 100- to 400-off.
“The reliability of features such as the automatic wire feed on the Sodick AQ600L means that we have complete confidence in the work produced, even when running
unmanned,” says Mr Crossen. “We are now likely to buy another Sodick machine — albeit a smaller one — next year.”
The tool-room at Crossen can handle tools weighing up to 2.5 tonnes, and it frequently produces suites of tools. Sometimes, just the tool is supplied to contract shops or customers that want to produce their own components. For example, Bombardier uses press tooling made by Crossen Aerospace; the company also manufactures vacuum form tooling for aircraft-seat manufacturer Kilkeel, a subsidiary of BE Aerospace.
In the three years from 2012 to 2015, Crossen Engineering is aiming to increase its aerospace business by no less than 75%. “We understand the aerospace market and believe that we have the manufacturing and service portfolio to match industry demands,” says Mr Crossen. “While price is obviously important, quality and speed of turn-round are also priorities for our aerospace customers. We have an excellent performance record for projects with short lead times, and installing technology such as the Sodick AQ600L can only help in this regard.”
The acquisition of the Sodick has introduced a new way of working at Crossen. Previously, the company preferred dedicated EDM operators and programmers. Now, it is training all its milling-machine operators to use the Sodick. “The aim is to extend the skill set; we just think that it makes better business sense. EDM ease of use — particularly with Sodick machines — has improved immeasurably in recent years, and we are keen to take advantage of this fact.”