Bowers in Aerospace

our expertise in your industry
SPRING 2009
Bowers Bore Gauges Flying
High With APPH Basingstoke
Welcome to
Bowers in
Aerospace
Long recognised as the world’s leading
bore gauge manufacturer, the Bowers
Metrology Group is a respected global
leader in the field of precision
measurement for the Aerospace
industry.
In this, the latest edition of Bowers in
Aerospace, we bring you up-to-date with
all the latest developments from Bowers for
your industry. Take a look at how just some
of the solutions from Bowers have helped
revolutionise the working practices of these
organisations:
APPH Basingstoke: flying high
with Bowers Bore Gauges
pg 1
Flight Refuelling: improving their
inspection methods using
ultra-accurate Bowers SmartPlug
technology
pg 3
JWST Project: avoid failure in service
of vital components with a
Bowers Portable Hardness Tester
pg 6
FR Hi-Temp: puts Bowers Metrology
Systems to the test
pg 7
In response to customer demand, and as a
result of the company’s continued
investment in cutting-edge technology,
Bowers produces an increasingly
comprehensive range of affordable, quality
bore gauging and material testing solutions.
Products in Focus in this issue include:
Shave Height and Countersink
Gauges
pg 2
SmartPlugs
pg 3
Universal Gauge
pg 4
Electronic Bore Gauge - Ultima
pg 5
Rangemaster Plus Hardness Tester pg 6
Intex Beam Gauge
pg 7
Part of BBA Aviation PLC, APPH
Basingstoke Ltd provides its growing
international customer base with a
highly
skilled
multi-disciplined
engineering
capability
from
its
impressive 70,000 sq/ft facility situated
in Basingstoke, Hampshire. Boasting
a long list of international approvals,
this
well-known
company
undertake
manufacturing, repair and overhaul work
across an impressive spectrum of Aerospace
related areas such as, Cargo Systems, Electrical
Harness, Rotary Wing and Landing Gear.
As one of Europe’s leading landing gear repair
and overhaul engineering organisations, APPH
Basingstoke has a comprehensive in-house
Grinding, Boring, Milling and Turning capability
and is able to accommodate the vast majority
of landing gear currently in service. When
tasked with finding a flexible gauging system
with the ability to accurately measure the bores
in these safety critical parts, Robin White,
company Inspector found that the wide
diversity in the sizes of landing gear work
undertaken by the company raised an awkward
problem. “Because of our broad range of tight
tolerance bores, we needed to find a system
with the potential to gauge sizes of up to
300mm, in both our production and inspection
areas. The nature of our larger components also
dictated that any new company bore gauging
BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY
system should have the ability to take precise
‘blind’ measurements 2 metres down inside our
components without leaving any kind of
blemish on the fine surface finish of our bores.”
Robin found the answer in Bowers Metrology’s
impressive, XT Xtreme Bore Gauging range.
Ideal for use within inspection departments or
in close proximity to Machine Tools, Bowers’
advanced new electronics boast a very
impressive IP65 rating, rendering them
resistant to coolant, water and airborne
particles. Amongst a long list of useful features
incorporated into the tough new instruments
are a clear digital display, metric/inch
conversion, an RS 232 output and hardwearing
extended travel carbide measuring anvils.
Robin continues, “Having been extremely
impressed by the standard XT Xtreme Bore
Gauge range, Bowers was able to grind a
radius on our instrument’s contact anvils
guaranteeing the integrity of our components
surface finish, whilst retaining the gauge’s
micron capability. Modular, long-reach 2 metre
extensions were also supplied ensuring that we
are able to accurately measure even our
deepest bores. We will be adding further
Bowers measuring heads to our range as the
need arises. Our new Bore Gauges have proven
a great success and are now helping us to
maintain APPH’s excellent reputation for the
high-quality of our work.”
Partners in Precision
Bowers is at the forefront of delivering
innovative and cost-effective solutions
The Bowers Metrology Group is continually working to develop products specifically
designed for the Aerospace industry.
As tolerances are constantly being tightened, the industry is demanding increasingly accurate
gauging instruments and systems. Our Shave Height Gauge and Countersink Gauge are just
two examples:
Shave Height Gauge
The Bowers Shave Height Gauge has
been specially designed to measure the
height of rivets used on aircraft outer skin. If
the top of the rivet is too high above or too
low below the level of the rivet-hole, the
streamlining of the aircraft will be affected.
This wind-resistance will be magnified many
times depending on the number of rivets
present in the outer hull of the aircraft. The
rivet-height gauge measures the height of
the top of the rivet in relation to the level
of the surrounding aircraft skin, enabling
tolerances to be maintained and providing a
valuable reference measurement to help
determine the streamlining of the aircraft
and the consequent effects on it’s
aerodynamics and fuel efficiency.
Features
• Rivet diameters : 3/16", 1/4", 5/16", 3/8"
available as standard
• Other rivet diameters available on
request
• Digital display with mm / inch conversion
and preset function
• Resolution : 0.0005" / 0.001mm
• Repeatablility +/- 0.003µm
• RS-232 data ouput
• Scalloped base to facilitate visual location
over the rivet
• Very easy to use
• Small portable format
• Robust construction
Digital Countersink Gauge
The Bowers Countersink Gauge
can be used to check the major
diameters of countersinks in the
aircraft outer skin, prior to the
application of rivets. The gauge can
also be used for countersink
measurement in general
applications within the aerospace,
automotive and other related
industries. The unit shown here is
with a digital indicator but can also
be fitted with a digital readout and
probe.
Features
• Standard range diameter 6 - 16mm /
1/4" - 5/8"
• Switchable resolution - inch/metric true
conversion
• Preset facility
• Tolerance mode
• All digital indicator features can be locked for
security
• RS-232 data ouput
• Robust construction, hardened plunger,
induction hardened body
• Standard plungers available to measure 90º,
100º and 110º
• Other angles available on request
• Setting master supplied as standard
Bowers can deliver innovative and cost-effective solutions to the most demanding measurement challenge. If you have a
specific requirement that you would like Bowers to assist with, please contact [email protected].
2
BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY
Partners in Precision
‘Smart’ Thinking from Bowers
Renowned for the quality of their manufactured products,
well-known aerospace company, Flight Refuelling Ltd, took
delivery of a series of Bowers SmartPlug Heads linked to high
accuracy Sylvac transducer probes feeding into a Sylvac D100s
readout unit. The ingenious system now helps measure the
critical concentricity of a series of vital parts within a
complex Airborne Weapons Firing Mechanism.
Company Manufacturing Manager Steve Grindey explained
“The safety critical nature of these tight tolerance,
complex components meant that our previous
inspection methods, involving a Coordinate
Measuring Machine, was exceptionally time
consuming and caused a bottle-neck for other
inspection work at the CMM. Although our
specification for this gauging project was
extremely demanding, Bowers fully understood
the brief and supplied on time, on budget and,
most importantly, our new gauging equipment
actually exceeds our accuracy expectations. Our
Bowers SmartPlug/Sylvac system sends its dimensional
findings to a PC instantly updating our records and as
inspection times have now been slashed the system is well
on its way to paying for itself.”
SmartPlugs & D100
For more information on our range of SmartPlugs
Email: [email protected]
BOWERS SMARTPLUGS
The robust, easy to use SmartPlug range is designed to give the operator greater speed of use, unmatched measuring
accuracy and superb repeatability, especially in harsh shop-floor environments. Advanced hand held ergonomics allied to
an ingenious mechanical / electronic system render SmartPlugs the easiest to operate Bowers bore gauging system to
date. The flexible nature of Bowers SmartPlugs range means that they can be supplied fitted with easy to read electronic
indicators (ideal for automatic data collection), conventional analogue indicators, or transducer probes linked to remote
digital readout units.
Features
• Range 6 - 280mm
• Tough, robust construction
SmartPlug with ceramic contacts
• High accuracy dedicated plug-gauges
• Hand-held measurement
• Protective indicator shroud (with some
indicators)
• Repeatability ≤1 µm
• 2 - point measurement as standard
• Depth-stops available
• Extensions available for deeper bores
• Guide chamfer for easy entry into bore
• Plug body coatings: Hard-chrome
(standard), T.i.N., Plain steel
SmartPlug with
depth stop
SmartPlug with TiN
coated body
SmartPlug with transducer holder
and standalone display
For more information visit www.bowers.co.uk
Partners in Precision
3
Universal Gauging from Bowers
The Bowers Universal Gauge’s
ingenious
modular
format
enables
it
to
be
quickly
configured to suit almost any
measuring challenge. Whether
measuring
internally
or
externally, the Universal’s clever
constant pressure device ensures
accuracy and consistency of
reading. The gauge’s findings are
displayed on its built in clear
digital readout.
The unique modular construction of
the Bowers Universal Gauge allows
the fitting of a large variety of
measuring contacts and adaptors,
enabling countless measuring tasks
to be completed with ease.
Accessories for the measurement of
threads, grooves, splines, gears, hole
centres, and many others are
available as standard, whilst special
adaptations for more unusual
applications can be quoted on
request.
Features
• Range 30 - 250mm internal / 0 - 215mm
external 15mm anvil travel
• Constant measuring pressure
• Digital or mechanical readout
• 150mm and 500mm extensions
available. Can be screwed together
in multiples (up to maximum 3m
recommended)
• Measuring table and supports available
for conversion to bench gauge for the
measurement of small components
TGUDEMO2
• Covers approx 90% of all applications
Keeping You in The Know
Bowers Metrology has been manufacturing high quality bore gauging
systems for over 50 years and the demand for ‘special’ gauging systems
to suit our customers’ specific requirements has never been greater.
To help keep you up-to-date with all our latest Special Applications, a new
brochure has been released. With the use of simple line drawings, the brochure
describes some of the most popular applications based around our standard
range of flexible gauging systems. By changing either the measuring anvils or
the measuring head, our products can be converted economically into
‘special’ gauges to solve our customers’ specific problems.
To request your copy of the brochure, simply email your details to:
[email protected] or why not download it now at
www.bowersmetrology.com.
4
BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY
Speci
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Fabri
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Sond
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Partners in Precision
Bowers Gauges Aerospace
Thanks to its continued investment in cutting edge technology and
drawing from over 50 years of experience, Bowers Metrology is in an
enviable position of being able to deliver innovative and costeffective solutions to the most demanding of measurement
challenges.
Following a detailed discussion of requirements, and with the rigorous
inspection processes associated with the Aerospace industry always at the
forefront of the design considerations, Bowers developed a range of gauges
for a leading name in Aerospace. Presented in a tough, portable case perfect
for the harsh shop-floor, the Bowers gauge kit includes; a Drivematic Slug
Rivet Gauge, two different sized Shave Height Gauges for measuring rivet
height on an aircraft outer skin and a Digital Countersink Gauge for
checking countersink diameters in the outer skin prior to the application of
rivets.
Drivematic
Slug Rivet
Gauge
Shave
Height
Gauge
Shave
Height
Gauge
Digital
Countersink
Gauge
The gauges shown are with a digital indicator but can also be fitted with a
standard probe and readout unit.
For more information on how Bowers can help you find your ideal
measuring solution, email [email protected].
For more information visit www.bowers.co.uk
Product Focus:
The Ultima in
Bore Gauging
Bowers’ Ultima Bore Gauge offers a
choice of resolutions up to 0.0001mm.
Featuring the Bowers ‘FASTFIT’
measuring heads with extended
measuring range (above 14mm), the
Ultima boasts a simple lever operation
and a constant measuring force,
ensuring outstanding ease of use and
repeatability under laboratory or
shop-floor conditions.
The Ultima Features:
• UKAS certificates standard for all
measuring heads and setting rings
• Measuring range 2 - 310mm
(0.080" - 12.000")
• Resolution: 0.0001mm (0.00001")
• Constant spring pressure for improved
repeatability
• Good positive feel as heads self-centre
in the bore
• Bowers Fastfit measuring heads for
rapid changeover
• Ceramic anvils on heads above 12mm
• Blind-bore measurement standard
above 12mm
• Possible to connect several probe
holders to one single readout to
measure different bore sizes at one
measuring station
• The complete range of Bowers special
heads is available for the Ultima
(grooves, threads, splines, deep-bores etc)
• Depth stops available for all heads
• Available without digital readout unit
(if not required)
• Alternative Sylvac digital readouts
available
• Interchangeable probe option, allows
use of other manufacturers probes and
displays
For more information email
[email protected].
Partners in Precision
5
Bowers Material Help For
JWST Science Mission
Product Focus:
extremely weak signals, microshutters
that enable programmable object
selection for the spectrograph, and a
cryocooler for cooling the mid-IR
detectors to 7K.
The JWST project represents an
international
collaboration
among
NASA, the European Space Agency and
the Canadian Space Agency. With
Northrop Grumman Space Technologies
as prime contractor and Goddard Flight
Centre
managing
the
huge
development effort, on completion
JWST will be operated by the Space
Telescope Science Institute.
The prevention of failure in service
of vital components, is often the
principal motivation for stringent
quality control regimes, this was
never truer than in the case of the
James
Webb
Space
Telescope
project. Scheduled to be launched in
2013, the JWST will be a giant step
forward in the human quest to
understand our place in the universe.
With its infrared-optimised telescope
cooled to tens of degrees above
absolute zero, hanging in the darkness
of space far from earth, JWST will
examine every phase of our history, from
the first luminous glows following the
big bang, to the formation of solar
systems capable of supporting life on
planets such as Earth. Following its
launch, JWST will be the premier space
observatory for astronomers world wide,
extending the tantalising discoveries of
the Hubble Space Telescope, the Spitzer
Space Telescope, and the giant
ground-based telescopes.
Maximising the mission’s potential to
make new scientific discoveries, JWST
will have a large 6.5-meter primary
mirror, passively cooled to approximately
45K by a sunshield. It will be sensitive to
light from 0.6 to 27 micrometers. JWST
will contain four advanced scientific
instruments on its Integrated Science
Instrument Module (ISIM), the Near
Infrared/Visible Camera (NIRCAM), Near
Infrared Spectrograph (NIRSPEC), Mid
Infrared Instrument (MIRI) and Fine
Guidance
Sensor
(FGS).
Mission
innovations include a folding segmented
primary mirror, adjusted to shape after
launch,
ultra-lightweight
beryllium
optics, detectors that are able to record
6
Enjoying an excellent international
reputation in its field, the University of
Leicester
Space
Research
Centre
provides the project mechanical
engineering lead for the Mid
Infrared Instrument (MIRI) and is
responsible for the design and
provision of the MIRI Primary
Structure in collaboration with
the Danish National Space
Centre, whilst also providing
support for MIRI test and
calibration activities.
As failure in service of any of the
MIRI components could prove
disastrous to the JWST mission, the
University of Leicester Space
Research Centre applies stringent
quality control regimes at every
stage
of
the
MIRI
manufacturing process. When
faced with the need for a
high
quality,
portable
hardness tester that would
be able to give accurate
results over a wide cross
section of components, Jon
Sykes (MIRI European Consortium
Mechanical
Engineering
Lead)
purchased a CV Rangemaster from
Bowers Metrology. John enthused, “The
Rangemaster allows us to make an
assessment of material yield strength at
various stages of the Primary Structure
manufacturing process. This information
is critical, as it provides confirmation that
the structural performance will be
within our predicted limits, and
therefore that structural failure will not
occur during test or in flight. The
portability, range, ease of calibration
and measurement repeatability of the
Bowers device renders it entirely suitable
for this application.”
BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY
Portable
Hardness
Testing for
Aerospace
The Bowers CV Rangemaster Plus
Hardness Tester represents an ideal
solution to the problems associated
with portable hardness testing in
aerospace. Its clear digital display,
ease of use and ability to operate in
all major international scales make it
the most comprehensive unit of its
type currently available. The optional
sturdy bench stand adds further to the
flexible nature of this
ergonomic gauge.
Rangemaster Features:
• Dynamic test indicator
• Large digital
readout
• Hardness values
in all major
international
scales with simple
conversion facilities from
one to the other
• RS232 output for
connection to PC or
serial printer
• Memory storage
capacity for in excess
of 400 readings
• Statistical summary
• Integral icon facility provides
operator with easy visual
identification of mode in which unit is
operating
• Operates in temperatures from -5ºC to
+35ºC
• Upper and lower control limits
• Last reading recall
• Supplied with two UKAS certified test
blocks, adjuster key and carrying case
For more information contact
[email protected].
Partners in Precision
Bowers Go To Product Focus:
Great Lengths Intex: A Closer Look
In an effort to further improve
their already stringent inspection
routines, one of the country’s
leading
suppliers
to
the
aerospace industry, FR Hi-Temp
has taken delivery of two
innovative
3
meter
length
measuring machines, designed
and manufactured by Bowers
Metrology Systems. Unable to
find an ’off the shelf’ solution
capable of accommodating parts of
such great lengths and able to match
the
company’s
demanding
specification, FR Hi-Temp, mindful of
the Bowers reputation within the
challenging
Aerospace
industry,
approached
Bowers
Metrology
Systems.
Following
a
short
consultation period, an innovative
machine design evolved, giving the
user
the
high
accuracy
and
repeatability (0.001 inch over 10 feet)
and the many useful facilities
required when in use.
Developed to measure both internal and external diameters and
lengths, the Bowers Intex Beam Gauge’s aluminium extrusion
beam gives it a rigid, yet lightweight quality – making it ideal for
shop-floor environments. The simple release of a locking thumb screw
enables the gauge’s measuring direction to be changed easily and quickly.
The four gauges in the Intex range have been designed to measure
components from 200mm up to 1m long – extended lengths are available
on request.
Features of the Intex Beam Gauge:
• Lightweight and rigid - typically weighing less than 2kg
• Internal and external measurement
• 2mm travel on moving contacts
• Adjustable fixed contacts with a range of adjustment up to 250mm
• Digital or mechanical readout display
• Hardened steel wear pads locate gauge on to the
component aiding accuracy, repeatability
and prolonging the life of the instrument
For more information email
[email protected].
Plant Manufacturing Engineer Mark
Sheath enthuses, “FR Hi-Temp enjoys
a reputation second to none within
the Aerospace industry for the
quality of our output. Our new large
capacity acquisitions are already
proving a great success, allowing us
to measure, amongst many other
large parts, our entire range of flap
operating shafts and fuselage
strengthening struts. The new
Bowers machines now enable us to
match and exceed the dimensional
tolerances
demanded
by
our
customers and have significantly
speeded up previously long and
laborious measuring routines”.
For more information visit www.bowers.co.uk
THE NEW BOWERS
INTEX BEAM GAUGE
Partners in Precision
7
Bowers
Launches
UniCal: Flexibility at Your Fingertips
New Website!
Designed to accurately perform a staggering variety of measuring tasks,
Product Focus:
Bowers Metrology has launched its long awaited UniCal multi-purpose digital
caliper range.
Available in standard 300mm, 600mm and 1000mm capacities, with larger versions
available upon request, Bowers’ revolutionary new technology boasts tough, lightweight
reinforced beams, giving them incredible strength and an amazing weightlessness.
Bowers Metrology has launched
its new, all-inclusive, user-friendly
website; www.bowers.co.uk.
Bowers’ flexible UniCal’s advanced features include a large, easy to read digital display, a
preset facility, a constant measuring force, a metric inch conversion and a RS232 data output
port.
Although a wide range of standard UniCal accessories enable a multitude of measuring
tasks to be performed, for more unusual applications Bowers will manufacture ‘one-off’
adaptations allowing the most difficult of gauging routines to be undertaken.
For more information about the UniCal email [email protected]
Claimed by Bowers to feature the
largest selection of measuring and
material testing instruments, the
comprehensive new website is
designed specifically with ease of
navigation in mind, enabling all
visitors to access information quickly
and easily.
Users of the new site now enjoy
improved access to a full range of
company technical support and are
able to instantly download product
data sheets, installation manuals,
free software, dimensional drawings
etc.
Measuring contacts for face-groove and V-groove
ø measurement
Shoulder anvils Code: TGUA 011
Disc anvils Code: TGUA 013
Cylindrical measuring pins
A TOTALLY NEW
SOLUTION FROM BOWERS
Semi-cylindrical anvils Code: TGUA 012
8 BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY
Company Managing Director Steve
White explained, “The phenomenal
rise in visitor numbers to the old
website, together with the large
increase in the range of products and
services
offered
by
Bowers,
prompted us to totally re-design our
website. The improved architecture
enables visitors to find exactly the
information they are looking for –
quickly. We are hoping that the
comprehensive nature of our new,
user-friendly site will give an
enhanced experience to visitors,
further increase company web-traffic
and help give an improved service to
all of our many valued customers.”
Keep up-to-date with news and
developments from Bowers by
registering your details online at
www.bowers.co.uk/register
Partners in Precision