Case Study: Oil Reserve Tank: Precision Aerospace Manufacturing

Client Requirements

Project Overview

A leading aviation firm contacted VCSP to request the production of a unique oil reserve tank. The client had given precise technical drawings with accurate dimensions, tolerances, material specifications, and assembly requirements.

Key Specifications

The project required:

• Accurate production of aerospace quality parts.
• Compliance with specifications in technical drawings.
• Quality material that can be used in aerospace.
• Structural capability to sustain the nature of aviation operation.
• Oil containment system surface finish.

Industry Context

These tanks should be of aerospace grade of structural integrity, leak protection and dimensional fidelity. Special machine apparatus, specialised operators and high-quality control are needed to manufacture such components.

VCSP’s Solution

Manufacturing Process

VCSP employed a three-phase production model that incorporated both high-technology CNC production and traditional skills:

Stage 1: Processes Laser Cutting.

Our Amada LCG 3015 laser cutting system was used to cut the metal sheets per the client’s technical drawings. Our laser cutting functionality made possible:

• Multifaceted contour cutting of an unusual precision.
• Clean edges with little post-processing.
• Material nesting so as to reduce wastes efficiently.
• Accurate position of assembly points.
• Marking and identification where necessary.

Key specifications:

• Capacity of sheet sizes: 3000mm x 1500mm.
• Compatibility of material: Mild steel, stainless steel, aluminium, and specialist alloys.
• Cutting precision: -.1mm tolerance capacity.

Stage 2: CNC Brake Pressing

Components were then pressed out with our Amada HFE 100t Press Brake after laser cutting. At this stage, the two-dimensional cut pieces were altered to produce the three-dimensional tank shape:

• Accurate bending to specific angles in drawings.
• Bending sequences controlled by CNC to the extent of uniformity.
• Repeatability in multi bend operations.
• Length of material handling to 3 metres.
• Angle accuracy: +-0.5 degrees

The brake pressing operation was essential to the control of the proper tank geometry and integrity of the material, and elimination of stress concentrations that could undermine structural performance.

Stage 3: Expert Welding and Assembly.

The last production process entailed accurate welding to stiffen the entire parts into the final oil reserve tank:

• TIG/MIG welding methods that are suitable in aerospace.
• Structural-welds that are fully penetrated.
• Seam construction, leak-proof.
• Inspection/Testing after welding.
• Finishing and surface preparation.

All welds were performed by our licensed welders, who have extensive experience welding components for hard-working applications. Quality control was carried out to the extent that all joints met the required strength and impermeability requirements.

Project Execution

Timeline and Milestones

The project was carried out in a distinct sequence:

1. Design Review: Review of customer-provided specifications and technical drawings.
2. Material Procurement: identification and sourcing of suitable aerospace-grade materials from reputable suppliers.
3. CNC: CNC programming of laser cutting and brake presses.
4. Manufacturing: A series of cutting, forming, and welding.
5. Quality Assurance: Detailed checking and specification checking.
6. Delivery: Packing and delivery in Airbus specification.

Quality Control Measures

During the production, VCSP took strict quality control:

• Checking of dimensions at any level of production.
• Testing and tracing of materials.
• Inspection of all welds visually.
• Leak tests to ensure tanks are good.
• Ultimate cheque v/s technical drawings.

Challenges and Solutions

Problem: Control of high accuracies of tolerances in various manufacturing processes.

Solution: CNC control operations guaranteed the repeatability and accuracy of the entire laser cutting and brake pressing operations. The errors that built up in the programming were avoided by careful programming and checking the setup.

Problem: How to have leak-resistant welded joints that can hold oil.

Solution: Seasoned, qualified welders used relevant methods and filler materials. After welding, testing and inspection of the structures confirmed their impermeability and integrity.

Problem: Control of the material properties during the forming and welding processes.

Solution: The distortion was avoided by properly selecting the material, controlling the forming processes, and managing the heat generated during welding (Heat Management).

Results and Benefits

Delivered Outcomes

VCSP has managed to produce an oil reserve tank that has fulfilled the specifications of the clients:

• 100% accuracy to technical drawings.
• Construction leakage tested.
• Finish on high-quality surfaces suitable to aerospace.
• Punctuality delivery of meeting project schedule.

Client Benefits

• Single-source solution that gets rid of coordination among multiple suppliers.
• Shorter lead times with in-house laser cutting, forming and welding.
• Precision engineering with a long-time partner that guarantees quality.
• low cost production without affecting the quality of aerospace.
• Production based in the UK to reinforce the supply chain.

The successful completion of the oil reserve tank demonstrates that VCSP can meet the components for aerospace applications with high precision. We combined high-technology CNC laser cutting, precision braze pressing and skilled welding, resulting in our integrated approach, which facilitated us to produce high-quality finished products to technical drawings and aerospace standards.

The project serves as confirmation that VCSP is a multifunctional precision engineering partner that can cater to the needs of clients across various sectors. Be it aerospace manufacturing of custom aerospace parts, industrial equipment or even specialised conveyor systems, VCSP provides quality solutions supported by state-of-the-art machinery, professional craftsmanship, and a firm dedication to quality.