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Production Machining of a Flash Suppressor for the Defense Industry

Production Machining of a Flash Suppressor for the Defense Industry

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Project Description

From concept through design, component analysis, material selection, and quality control, Thuro Metal Products, Inc. has in-depth experience manufacturing critical parts that meet the stringent requirements of the military. One hundred percent reliability is essential for any component used in a combat situation, and successful completion of this project was prefaced by four months of preparation to develop and validate the tooling, machining strategies, and post-machining processes for this firearm component.

Specifications for this flash suppressor required the use of 4140 alloy steel, which is easily machined with tight tolerances, but requires heat treating to attain the high strength properties for this application. We expended significant resources developing and validating the mass finishing process necessary to produce a clean part, free of burrs, especially in the area of the 5 slots. Extra care was also required to preserve the integrity of the delicate internal threads. Finished with a heavy phosphate manganese coating, the components were packaged according to MIL-STD-2073-1D, and shipped to the customer accompanied by numerous process documentation and quality test reports.

Over the past 40 years, Thuro Metal Products has provided millions of component parts to the U.S. military, ranging from high pressure fittings for use in military aircraft to various types of ordnance. Our longevity is testament to our high quality products and outstanding level of service. More details about this specific project can be found below, and we would welcome an opportunity to discuss your next project. Contact us today.

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Production Machining of a Night Vision Component for the Defense Industry

Production Machining of a Night Vision Component for the Defense Industry

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Project Description

Thuro Metal Products is a long-term supplier of critical parts to the defense industry. We manufactured the aluminum ring shown here for a night vision application, and it presented many unique challenges, especially in post- machine processing.

This finely-threaded aluminum ring is slotted on both faces. Since the part is 3/32” thick, we built special fixturing to create the slots required on the back face, without compromising the integrity of the delicate threads. Our engineers also developed, tested, and implemented a proprietary post-machining cleaning and deburring process that eliminated all traces of residual grit to ensure 100% thread performance, which was critical to part reliability in the field. Finished according to 7.3.1 of MIL-STD-171 for maximum protection against corrosion, we packaged the components to protect them from environmentally- induced corrosion and other forms of degradation during shipping and storage.

Constructed from 1 5/8” aluminum rod stock, this part featured overall dimensions of 1 ½” in diameter and 3/32” in thickness. Through the use of systematically calibrated and certified testing equipment, we verified that we met or exceeded the ±.0035” tolerance requirement. Our highly precise and automated processes gave us the capacity to manufacture 4,000 units on a daily basis.

Those who protect us deserve expertly engineered and precision manufactured components that they can depend on in mission-critical situations. We are proud to be a valued member of the supply chain.

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CNC Machining of a Fitting for the Aerospace Industry

CNC Machining of a Fitting for the Aerospace Industry

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Project Description

Since 1971, Thuro Metal Products, Inc. has earned a reputation for delivering quality, precision-machined metal components using a mix of technology and experience in a variety of industries including aerospace. Companies recognize these capabilities and turn to us for challenging parts like the W1548 fitting for aircraft fuel delivery systems.

Using the experience gained from more than 40 years of work in aerospace, we machined the part pictured above, from a 4″x6″piece of solid T8511 aluminum alloy per SAE-AMS-QQ-225/6 standards. Our skilled technicians used state-of-the-art equipment including a CNC lathe with live tooling, CNC milling machine and horizontal milling machines to achieve a maximum operating pressure of 65 PSIG inner and 30 PSIG outer for the part. Incorporating a secondary deburring operation, we ensured a 32 RMS surface finish for the O-ring grooves, along with a ±.002″ tolerance for the outside diameter per customer and SAE specifications.

Using our extensive Multi-Tasking CNC Turning and CNC Milling capabilities, in combination with lean manufacturing practices, we completed all of the production tool and fixture design, production and validation, and all programming and 1st piece set up validation, within 8 weeks after inception of the project.

To learn more about this project or similar projects, contact us today.

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Multi-Spindle Automatic Turning of an Open Sleeve for the Aviation/Aerospace Industry

Multi-Spindle Automatic Turning of an Open Sleeve for the Aviation/Aerospace Industry

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Project Description

Thuro Metal Products has a history of innovation in the manufacture of precision machined metal components. Our initial roots date back to the 1960’s, with Single Spindle Automatic Screw Machines. In the early 1970’s, the incorporation of Multiple Spindle Automatic Screw Machines gave Thuro high production capabilities. In 1978, with the incorporation of CNC machining into its manufacturing capabilities, Thuro gained the capability to effectively produce lower volume, higher complexity component parts. To this day, Thuro maintains and continues to develop it’s abilities to produce high volume parts on Automatic Screw Machines as well as lower volume, complex parts on Multi-Tasking CNC equipment. When selecting the right process to produce your part, we first consider your part specifications. Secondarily, we consider annual quantities, consistency and longevity of demand to determine the best approach. Due to the volume and longevity of demand for this Sleeve used in aircraft engine ignition systems, our engineers designed, developed, tested and refined the processes required to complete all operations required, except for the plating, on a Multiple Spindle Automatic Screw Machine. In order to do so, our engineers needed to incorporate innovative tool design and machining techniques to achieve the 32 RMS in the area of the logo/trademark. Our ability to innovate is made possible by our in- house tooling design and production capability.

The part features overall dimensions of 1.989” to 2.175” in length, an O.D. of 0.0780” (+0.003/-0.002”), which was machined from 12L14 steel with an O.D. of 08125”. This process was completed in a dedicated cell capable of machining 2,500 pieces daily. In the primary process we incorporated deburring and roll stamping operations to achieve a smoothness rating of 32 RMS in the area of the logo/trademark along with a ±.0018” total tolerance required for the pre-plate pitch diameter, followed by careful inspection for dimensional integrity. Each part receives a nickel- plated finish per ASTM B733-97 standards for metallic parts operating at elevated temperatures.

We maintain the capability to supply our client with 6 different versions of this Open Sleeve, as well as 5 versions of a sister part called the Closed Sleeve, with combined volume of 625,000 piece annually. To learn more about this project, or if you have a similar project you would like to discuss, contact us today.

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Screw Machining of a Spanner Nut for the Defense Industry

Screw Machining of a Spanner Nut for the Defense Industry

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Project Description

Thuro Metal Products is a leader in the manufacture of Precision Machined Metal Component Parts for many industries including the military. Our experience in manufacturing products for military operations dates back to the founding of our company in 1971.

The Spanner Nut pictured is a Connector Component used in military communications. We manufacture the nut which measures 1.364” – 1.369” O.D. x 1.155” I.D. by 0.178” – 0.182” height from 360 half hard brass per the ASTM B16 standard using Automatic Screw Machines. Our in-house expertise and capability in tooling layout, design and production ensures burr-free parts without the need for secondary deburring. Each nut receives olive drab cadmium plating which provides a dull finish per military specs. We continually conduct dimensional and final inspection to ensure that our process remains capable of achieving the ±0.0015” tolerances called for in customer specifications. Because of the skill displayed by our employees in machining high volume parts (we maintain the capability to machine 1 million of these Spanner Nuts per year), as demand dictates, we continue to deliver error-free parts with no rejects, to our customer locations in Southwestern and Northeastern United States.

For more information about this project, or if you have a similar project and would like to discuss the details, refer to the table below or contact us today.

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CNC Milling and Turning of a Flange for the Aerospace Industry

CNC Milling and Turning of a Flange for the Aerospace Industry

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Project Description

As a leader in the precision machining of metal components, Thuro Metal Products has gained a reputation for the manufacturing of high quality Component Parts and Assemblies for Aerospace applications. Using our broad range of CNC Milling and Turning capabilities, combined with the help of our local manufacturing extension, we developed a business system based upon lean principles we call the Thuro Rapid Response Capability, which reduced lead times by 80%.

We manufactured the flange pictured above for aircraft cabin lighting and air systems in accordance with a long-term supply contract that included 80 other products. This particular flange measures 11/16” long with a 2-5/8” diameter. A multi-tasking, CNC mill/turn center with live tooling was used to machine this 6061-T6 Aluminum Flange in one operation. Special care and gaging was necessary to attain the required tolerances of ±.0005” for the fit of a mating part along with a 32 micro inch finish. Because of stringent cosmetic requirements for this flange, it was necessary to deburr and apply a special material finish that we polished and then sealed with nickel acetate.

Our Thuro Rapid Response Capability reduced the time it took us to begin machining an order from an average of 18 days to 3 days. The result was that on-time deliveries improved from 76% to 99%. The delivery improvement was achieved by the elimination of queue and wait times from the point of order to the time of shipment. This has helped our customer significantly grow their share of the market. For more information about this product or any of our fabrication services, please contact us.