An aerospace pylon is a true collaborating process
Aeroplane pylons attach aircraft engines to the wings. Developing this critical component involves collaboration with specialists and industry partners, with Seco leading. Joe Gooding and Gary Meyers explain more.
Pylons are not the most noticeable part of an aircraft. Hidden from view by covers, they are critical for structural integrity and, thus, safe and reliable aircraft operation.
“There are one or two engines per wing, with up to four pylons to attach each engine,” explains Joe Gooding, a UK-based Seco Development Engineer, who supports customer projects with tooling and component machining strategy suggestions. “The pylon is made from titanium that’s often forged and then machined to the required dimensions and tolerances.”
“The aircraft manufacturers use titanium for structural components. It is the best material and the safest option for those aircraft parts,” adds Joe’s colleague, Gary Meyers, Global Product Manager for Solid Milling, based in Sweden.
“There are many applications involved in manufacturing a pylon,” he continues. “From face milling to copy milling strategies, indexable tools, solid carbide tools, drilling, reaming, and new barrel type machining developments for component finishing. The parts are challenging to machine and often have forging inconsistencies and deep pockets that are hard to reach. Being safety critical there are also very tight tolerances and finishing requirements.”
The importance of collaboration and innovation
Gooding and Meyers have been working together for many of years. Their shared belief is in the value of a collaborative, cross-industry approach. Particularly with customers who have fewer in-house resources and are looking for complete solutions for tooling development, machining planning, component fixturing, staff training and toolpath programming support.
There are two aspects to this process – Seco, its customers (Tier One suppliers and aircraft OEMs) and other industry partners need to collaborate to develop the correct solutions. The other is the constant need for innovation and partnerships to improve processes, which led Seco to establish its Innovation Hub concept.
“If you look at the machining of the pylon, Seco makes the tools to machine the parts. What makes it different here is the people available at the Innovation Hub. They have knowledge and contacts with the CAM manufacturers, the coolant suppliers, and the companies that make the work-holding devices. We also maintain relationships with universities that study these materials’ machining,” Gary Meyers explains.
“So, it is a great portfolio, and there is nothing on the pylon that we can’t machine. We are competing at a world-class level. It is more than the tool. We have people like Joe and Innovation Hub colleagues who know how to apply the processes and the tools. They know the customers’ issues and needs, and that gives us the advantage for these types of components.”
In turn this drives quality. The company is involved in it at the earliest possible stage rather than coming in at the end of a machining project for an already defined application.
“We look at the titanium structural components to see what customers need, match it to our portfolio, and add what we need to develop longer tool life and boost the customer’s productivity,” says Meyers.
“In product development and R&D we have an effective triangle with the customer and the team at our Innovation Hub with deep relationships. This helps us to get to the core of what it is they want to achieve. That is beneficial for the customer and for us.”
Changes in machining
The civil aerospace industry is slower to embrace changes such as the use of alternative materials including 3D-printed parts. On a pylon development there are many safety tests to satisfy before anything can be introduced. Titanium still reigns supreme. Nevertheless, the industry is gradually changing.
“Robotisation and digital technologies are coming in, and we are developing a digital offer to match this,” says Joe Gooding. “Some companies are looking at minimum quantity lubrication MQL and even oil-free CO2 methods in the cutting process. Wire Arc Additive Manufacturing, where the plate is welded with a titanium wire arc to build the desired template pylon shape, is also starting to develop, and may affect pylon manufacture in the future. It always comes down to consistent part quality – it must be the same every single time.”
And, adds Gary Meyers, “When it comes to being a tooling company, if you have already heard about a new trend in the market, you are already too late because it takes years to catch up. The important thing is to be connected and in touch and understand the customer needs early on, so one is part of the development.”
In essence, Seco has the critical skills, infrastructure, industry connections and solutions to keep making this crucial component for years to come.