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• Getting Started
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Testimonials

Bell Helicopter

Bell Helicopter’s transmission plant in Grand Prairie, Texas, was pushed to the limit.  Orders for new military and commercial helicopters were flowing in, in increasing numbers year after year.  The problem was machining capacity had run out.  With literally no space left on the shop floor for new machining centers and the existing machines already over-utilized, Manufacturing Engineers needed something new.  Somehow, cycle times had to be reduced.

Enter Third Wave Systems’ process-modeling and optimization software and services.  By placing a Third Wave Systems engineer on-sight for a technical and applications training period, Bell Helicopter quickly became experts on applying AdvantEdge™ FEM and Production Module™ machining solutions.  Within one month, machining cycle times for critical part families were reduced by 30-40 percent.

 

Kennametal

At the Kennametal World Headquarters in Latrobe, Pennsylvania, cutting tools are designed and manufactured from the ground up.  The process starts with tools and inserts being designed and modeled in CAD software.  From there, prototype tools are manufactured and tested in a variety of environments.  The test results are then analyzed and used to make any necessary modifications to the original design.  This cycle of design, test, and redesign is repeated until the final product is up to Kennametal world-class standards.

Working closely with Third Wave engineers to use AdvantEdge™ FEM, Kennametal was able to streamline this design process.  The software provides valuable test data to analyze without having to go through the long, costly process of manufacturing prototypes every time.   This allows the engineers to efficiently design a better tool that is more suited to its specific purpose.

 

Cessna Aircraft

Cessna was looking to improve the machining processes for several titanium parts from its aircrafts.   As is common when machining titanium, there was room for improvement in tool life and cycle time.  Using AdvantEdge™ FEM and Production Module™, Cessna improved tool life and increased material removal rates to produce a 50 percent reduction in cycle time.

Cessna first analyzed a door hinge machined from Ti-6Al-4V.  Using AdvantEdge™ FEM to simulate the heat distribution through the tool, workpiece, and chip, the engineers improved their tool design and created more aggressive cutting conditions such that they could machine faster without sacrificing tool life.  Cessna reduced the cycle times for this part by more than 58%.
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Cessna also analyzed its titanium flap tracks.  Once again, the engineers analyzed their tooling and cutting conditions to increase material removal rates.  They also analyzed and improved the toolpaths to reduce non-cut time.  Overall, improvements resulted in an improved machining time for analyzed tools that was half as long as the original.
(View Presentation)