Doubling Aircraft Part Production

A manufacturer doubled aircraft brake parts production thanks to innovative ARROW® Workholding Fixtures. All World engineers upgraded a previous fixture with a bold new design tailored for higher volume production. By using two new ARROW Workholding Fixtures, Rockford, Illinois-based Modern Advanced Manufacturing reduced reliance on operator skill level and substantially increased productivity.

Transitioning from manual to hydraulic fixtures has reduced load and unload times from 4 to 2 minutes per part, while cycle times have decreased from 11 to 7 minutes, resulting in a productivity increase from 4 to 8.5 parts per hour.

“We didn’t just want to make a hydraulic version of the three-operation manual fixture—which would have been like hitting a single—we wanted to swing for the fences. By adding a fourth operation to remove distortion of the part, which might seem counterintuitive, we were able to vastly improve the quantity and quality of parts coming off of that fixture,” said All World Sales Engineer Steve Hagedorn and Engineering Manager at the time of the project.

Preparing for Takeoff

In 2012, Modern Advanced Manufacturing started using ARROW's manual fixtures to secure a complex part used in commercial aircraft braking systems. The fixture evolved to accommodate similar parts, but the growing part volume annually necessitated increased support for part supply.

Modern Advanced Manufacturing used the original fixture on a Mazak vertical machining center with a rotary indexer to manufacture parts in three operations. It required the operator to manually move the part to each of the three locations and clamp and unclamp it. The first operation involved milling, drilling, and pocketing of the part with a wedge design on the top surface. The second operation involved milling the angled sides, and the third operation entailed milling two areas on the bottom side surface.

“Depending on the operator, parts were either very consistent or inconsistent. It took a highly skilled operator to properly clamp and unclamp the parts into position and to monitor the in-process tolerances required,” Hagedorn said.

A New Concept Takes Flight

By 2022, the volume of parts required began to exceed what could be produced in three shifts on one machine, and Modern Advanced Manufacturing approached All World for a new solution.

Engineers developed a hydraulic fixture to improve part clamping consistency independently of operator skill. Instead of a vertical, they opted for a horizontal machining center to expedite machine operation by enabling loading while parts were being machined on another pallet.

In addition, a fourth operation—a final pass—was added to eliminate distortion in certain components due to excessive stock removal. With the old design, when this step was required, all parts needed to run through the machine a second time because it only had three stations. Now, all parts are completed the first time they go through the machine, eliminating potential errors and confusion.

Engineers also implemented a significant change in the setup of the third operation. Previously, having the part located on only one side posed challenges in maintaining centerline tolerance, leading to the need for strict in-process tolerances. This meant operators had to constantly monitor part width and make frequent adjustments. By introducing a centering mechanism at the third station, operators gained more flexibility within the permitted part tolerance range and eliminated the primary cause of scrap parts.

“That saved a lot of money because many of these parts were made of Inconel, which was much more costly than the original stainless steel,” Hagedorn said.

Pumping Up the Volume

Once the decision was made to switch from manual to hydraulic workholding, ClampMAX® Hydraulic Power Systems was the obvious choice to supply consistent pressure. ClampMAX, the workholding-specific brand of hydraulic pump systems within the All World line of machine accessories, delivers high-flow, low-temperature, energy-efficient hydraulic power capable of supporting up to 12 valves. Thanks to their flexibility, ClampMAX systems can be configured for nearly any machine tool without the need for a custom interface.

“We knew it would provide a robust and cost-effective solution,” Hagedorn said. “As a bonus, ClampMAX systems are extremely energy efficient compared to traditional workholding pumps, and their versatility allows us to retrofit existing machine tools with ease.”

This upgrade not only improved efficiency but also enabled the production of more parts within the same series. Due to budget constraints, the first fixtures were built with single-acting hydraulics with a disconnect-style coupler. The success of the project opened up more opportunities, and similar fixtures were built with the hydraulic pump fully integrated with the machine tool and live hydraulics through rotary unions. By moving to live hydraulics, the solution became faster, safer, and more reliable than a manual connection while taking additional workload off the operator’s hands.

Savings That Add Up

The use of the new fixtures has significantly reduced machining time and operator fatigue while increasing parts repeatability, according to Modern Advanced Manufacturing Technician Stewart Bowman.

Switching to hydraulic fixtures reduces the time it takes to load and unload parts and doubles productivity. Furthermore, the hydraulic fixtures are reliable with minimal downtime due to malfunctions.

Bowman said the largest benefit is the ability to have an inexperienced operator run the parts with minimal training versus a well-trained machinist. Not having to turn clamp handles or clamp screws also alleviated operator stress and fatigue.

Enhanced machining capabilities and superior part quality have not only boosted operator morale but also impressed customers by demonstrating a commitment to leveraging advanced technology.

“It shows we care more about the product,” Bowman said.

A Legacy of Precision

Since the 1960s, ARROW Workholding Fixtures have been evolving to deliver unmatched reliability. Designed to hold parts securely and clamp them consistently in the same location every time, these fixtures are built to last—often 10 to 20 years.

“We do not skimp on quality materials or construction methods and buy the absolute best components. Workpiece contact surfaces are hardened tool steel or carbide, and other steel components are black oxide coated for long life and corrosion resistance,” Hagedorn said.

Each fixture is engineered with purpose: to reduce operations, minimize handling, and cut idle spindle time—driving faster part production. At the same time, maintainability is prioritized through accessible fasteners and the use of standard, off-the-shelf components whenever possible.

“We are proud of designing fixtures that are simple for the operator to use correctly and free of sharp edges and pinch points,” Hagedorn said. “Our customers recognize that their reliability and maintainability make them an excellent investment.”

As part of All World’s Machine Accessories operations, the ARROW Workholding Fixtures team benefits from expanded resources, including a new 30,000-square-foot shop equipped with more space, more machines, and the capacity to handle and inspect larger components than ever before.