Horizontal 5-axis machining, high spindle power, long-term reliability, small floorspace and the flexibility to efficiently machine all their big structural parts on one machine: these have been the crucial facts which lead to the decision to include a 5-axis horizontal machining centre from the HBZ AeroCell series into the uniquely extensive production chain of Aircraft Industries.

Aircraft Industries unifies all their competences and processes "under one roof" within one compound, a fact on which both owners and employees are proud of. From design, aluminium sheet and roll forming, steel forming, machining, welding, riveting to surface treatment, hardening, painting, measuring, assembly, testing and overhaul and much more: for building their own aircraft. The L 410 twin turboprop commuter aircraft, which is pre-destined for the most severe flight conditions, the company is covering the whole process from raw material to the finished aircraft. The German machine tool manufacturer Handtmann has been selected to be an integral part of this uniquely extensive production chain in the Czech Republic and is playing an important role with their horizontal machining centre HBZ AeroCell for the production of the L 410 and to subcontract other OEMs and international aircraft programs.

Aircraft Industries is not just the only producer of small civil transport aircraft in the Czech Republic, but also a major supplier of structural aircraft components. The professional know-how, large production capacity as well as the quality and level of technology enables Aircraft Industries to supply parts for other important aircraft manufacturers and suppliers, such as GKN Aerospace Transparency Systems (leading edge slots for the wings of Boeing 787 Dreamlinerand engine air intakes for CASACN-235 aircraft) besides machining their own aircraft parts. Due to the latest significant machinery modernization the production capacity for subcontracting has even increased and therefore the aircraft manufacturer can offer their expertise to other valuable partners as well.

With the new generation of L 410, the amount of milled aluminium parts will significantly increase and way larger parts will be included in the wing structure like the approx. 6,300mm x 1,000mm wingpanel. The fact that all milled parts for the L 410 NG are being produced under Aircraft Industries’ roof shows the large machining capabilities of the company. To be prepared for this amount of milled parts, Aircraft Industries was looking for a machine able to manage the large variety of structural parts in a most productive and space-saving way. "We needed one machine for all big structural parts. The machine has to cover 20 parts varying in size and type: from small ribs up to the large wing panel, sized approx. 6,300mm x 1,000mm, milled from one solid aluminium block, and building the wing structure. Flexibility and productivity have been the keywords in the buying process" says Oldrich Zich (NC programmer) who has been involved in the buying process from the very beginning. Also, "the horizontal concept was a prerequisite from the beginning. Aerospace structural parts require maximum material removal when aiming for short cycle times and good surface quality at once. Chip and coolant management as well as tool life are never better than with horizontal machining." The machine’s pallet size of 7,000 mm length and 2,000 mm width and axis travels of 7,800/2,050/700mm in X/Y/Z-axis fits all these parts as well as all other requirements such as high spindle parameters with a maximum power of 156 kW and 30,000rpm spindle speed, perfect for roughing and the integrated pallet changing system. Travel speed of 80 m/min and accelerations up to 7 m/s2 represent the required dynamics.

Early in 2015, Aircraft Industries started to machine all their structural parts on the Handtmann HBZ AeroCell. The machine's utilization will increase with start of serial production of the L 410 NG, but despite of this, enough capacity for subcontracted deliveries will remain. Currently getting prepared for the serial production, Aircraft Industries can already prove some impressive decrease in machining times, compared to various 5-axis vertical machining centres. Machining time of bogie beams (size: approx. 3,300 x 200mm) not only decreased about 50% from 40 hours to 20 hours, but also the number of following operations could be reduced; for the bottom wing panel (size: approx. 6,300 x 1,000mm), Aircraft Industries reached a significant decrease of machining time from 100 hours to 30 hours with the HBZ AeroCell. Machining time of the upper wing panel (size: approx. 3,300 x 1,200 mm) decreased from 80 hours to 25 hours whereas the machining time for the segment fuselage with a length of almost 2,000mm decreased by approx. 45% to 9 hours and reduced following operations as well.

Not only has the significant decrease of machining times due to the high power spindle convinced the customer. Jiri Urminsky, who operated the HBZ AeroCell during the test milling of parts in preparation for serial production, is especially highlights the high speed of the machine, which is much better than others on their shop floor. Even the speed of the chip conveyor is incomparably high, transporting the large amount of chips quickly outside of the work-zone. To handle the huge amount of chips, Aircraft Industries decided to install an extra-large briquetting plant. Despite the complex and advanced technology of the machine it is "easy to operate", says Urminsky. He also highlights the training which "was extensive and profound. If there’s still any problem the remote control and quick support from the Handtmann service makes it easy to get the machine running again quickly."