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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
LOCKHEED Fort Worth Company FSCM 81755
METAL REMOVAL PROCEDURES AND LIMITATIONS Contract Number F33657-88-C-O037
Releasability of this material under the Freedom of Information Act is subject to the restrictions on release in DoD Regulation 5400.7-R and DoD Directive 5230.25.
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
LOCKHEED Fort Worth Company FSCM 81755
METAL REMOVAL PROCEDURES AND LIMITATIONS
Prepared and Approved By: .,, . -,, .-
..
/wfk’’tlL/ — .—— S. B. Klehl, Chief Structural and Environment Materials & Processes
FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
LOCKHEED Fort Worth Company FSCM 81755
CHANGE INDEX Revision “E” incorporates the requirements of amendments 1 through 9. The only new requirement is the addition of 3.8.5, which defines allowable anodize clamp marks.
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.,. . . . ,.
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FPS-3017E Date: 17 January 1995 Superseding: FPS-30170
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I AtILt Ul_ GUN 1 ENTS
Para 1
1.1 1.2
Page 1 1 1
SCOPE
REQUIREMENTS LIMITATIONS
2 2.1 2.2
APPLICABLE
3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.2 3.2.1 3.2.2 3.2.3 3:2.4 3.2.5 3.2.6 3,2.7 3.2.8 3.2.9 3.2.10 3.2.11 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.5 3.5.1 3.5.2 3.5.3 3.6 3.6.1 3.6.2 3.6.3 3.7 3.8 3.8.1 3;8.2 3.8.3 3.8.4 3.8.5 3.9 3.9.1 3.10
REQUIREMENTS
DOCUMENTS
1
MILITARY SPECIFICATIONS LFWC SPECIFICATIONS
1 1
RAW STOCK CLEANUP Removal of Mill Decarburization Removal of Mill Skin from Titanium, 10 Nickel, and PH/CRES Alloy Products Removal of Mill Skin from Aluminum Skin Milling Parameters INITIAL CUITING OPERATION Flame Cutting Abrasive Cutting Friction Sawing Circular Sawing Laser Cutting Electrical Discharge Machining (EDM) Plasma Arc Machining (PAM) Abrasive Water Jet Cutting Aluminum Hand Forgings Matte Finishing of Aluminum Parts Machining Of Fully Heat Treated Alloy And Carbon Steel Parts GRINDING Grinding of Steel Parts Grinding of Chromium Plated Low Alloy Steel Parts Grinding of Titanium Parts BENCH WORKING OF METAL PARTS Deburring of Metal Parts Hand and Power Tools HOLE PREPARATION High Strength Steel Chamfering and Spot Facing Close Tolerance Holes HOLE DEBURRING Fastener Holes in Aluminum Fastener Holes in Metals Other Than Aluminum Non-fastener Holes CORNER RADII SURFACE INTEGRITY I Surfac& lntegrityForNon~FatiguwArrd-Nom-Fracture Critical Parts Surface Integrity For Fatigue And Fracture Critical Parts Surface Integrity For Holes MOO1 Anodize Clamp Marks MATERIALS HANDLING Corrosion Protection COOLANTS
ii
2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 6
FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
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TABLE OF CONTENTS Page
Para 4 4.1 4.2 4.3 4.4
QUALITY REQUIREMENTS PARTQUALITYAND lNTEGRllV SURFACEINTEGRITY DIMENSIONALTOLERANCES EXAMINATION
6 6 6 6 6
5
PREPARATION FOR DELlVERY
6
6
ACKNOWLEDGEMENT
6
7
REJECTIONS
6
8 8.1 8.2 8.3 8.4 8.5 8..6
NOTES
6 6 6 6 6 6 6
9
ENVIRONMENTAL HEALTH AND SAFETY
EDGE CORNER EDGE BREAK CLOSE TOLERANCE HOLE FASTENER HOLE CHIPLOADFORMULA
7
LIST OF FIGURES
Page
Figure 1
Polishing Requirements Around the Mold Line of Formed Sheet Metal 7
LIST OF TABLES
Page
Table Removal Amounts
8
1A
Mill Decarburization
IB
Titanium Mill Skin Removal Amounts
8
Ic
10 Nickel and CRES Mill Skin Removal Amounts
9
11A
Minimum Material Removal After .Flame Cutting ,, .
9
IIB
Recommended Flame Cutting Speeds
9
[11A
Abrasively Cut Surface Layer Removal
IIIB
Recommended Abrasive Blades and Cutting Speeds
Iv
Maximum Feeds for Grinding Titanium Parts
10 10 10
...
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
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METAL REMOVAL PROCEDURES AND LIMITATIONS 1
SCOPE
1. REQUIREMENTS - This specification establishes the requirements for metallurgically damagefree and acceptable surfaces on metallic parts and components from which metal is removed bv. anv. of the common metal removal methods. 1.2 LIMITATIONS - This specification does not cover chemical machining methods. Refer to FPS-
1051 and M039 for chemical milling requirements. 2 APPLICABLE DOCUMENTS - The following publications shall be applicable to the extent specified herein, or as defined in the contract or purchase order. These publications shall be the revision listed in 16PR711, except in cases where a particular revision is specified in this specification. Compliance with any other issues of these publications requires prior written approval from LOCKHEED Fort Worth Company (LFWC) Materials and Processes Technology (M&PT). If any of the publications referred to herein conflict with the requirements of this specification, this specification shall govern. 2.1 MILITARY SPECIFICATIONS - Available from Commanding Officer, Naval Publications and Forms Center, 5801 Tabor Avenue, Philadelphia, PA 19120. MI L-P-3420
Packaging Materials, Volatile Corrosion Inhibitor, Treated, Opaque
MlL-C-l6173
cOrrOSiOt_I PfWE?ntiVe
Compound, Solvent Cutback, Cold
Application 2.2 LFWC SPECIFICATIONS - Available from LFWC Service Library, P. O. Box 748, MZ 1519, Fort Worth, TX 76101. FPS-1051
Chemical Milling of Metals
FPS-1089
Grinding of Steel Parts and Chromium Plated Steel Parts Heat Treated to 180,000 psi and Over
FPS-1 098
Drilling and Reaming of Alloy Steel Parts Heat Treated to 180,000 psi and Above
FPS-3014
Heat Treatment of Steels (Aerospace Practice, Process For)
FPS-3018
Forming of Aluminum Alloys
“FPS=3086
‘“
‘
‘ Composite?vtachining Procedures and” Requirements
FQPL-3017
Fort Worth Division Qualified Material List for FPS-3017
NDTS 9111
Nital Etch Inspection
M039
Dynamic Etch Process, Aluminum Alloy Roughness and Radius Tolerances For
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
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MOOI
Surface Roughness and Tolerances for Machined Surfaces
M333
Installation of Bushings, Interference Fit
16 PR711
F-1 6 Materials Procurement and Processing Specifications Applicable Issues
3
REQUIREMENTS
3.1
RAW STOCK CLEANUP - The surface finish after skin milling shall be 125 RMS maximum.
REMOVAL OF MILL DECARBURIZATION - Carbon and alloy steels shall have all hot worked 3.1.1 surfaces machined to remove mill decarburization, unless otherwise specified on the engineering drawing. Refer to Table 1A for material removal amounts. This requirement is not applicable to 10 Nickel (HY 180) steels. REMOVAL OF MILL SKIN FROM TITANIUM, 10 NICKEL, AND PH/CRES ALLOY PRODUCTS 3.1.2 Material not deskinned at the mill shall be machined to remove oxide, scale, or contaminated skin before the surface is in a satisfactory condition for use as the surface of a finished part. Titanium products maybe chemical milled per FPS-1 051 in lieu of machining. Refer to Table IB for titanium material removal amounts and Table IC for PH/CRES and 10 Nickel removal amounts. A286 and 300 Series stainless steels are excluded from this requirement. REMOVAL OF MILL SKIN FROM ALUMINUM - When skin milling aluminum, proper speeds and 3.1.3 feeds shall be maintained in order to achieve a chip load of .006 -.01 O“, with a preferred chip load of .008 .010”. Refer to paragraph 8.6 for instructions on determining chip load. Cutters used for skin milling must have a positive axial rake angle and a positive radial rake angle for their cutters/inserts. In addition, the skin milling operation must be run with coolant or microlube. 3.1.4 SKIN MILLING PARAMETERS - If only one side of a billet is required to be skin milled, the amount of material removed shall not exceed 0.249. If the amount of material to be removed is 0.250” or greater, equal amounts are to be machined from both sides. When only one side is to be skin milled but the material size has been substituted with a thicker material, equal amounts shall be removed from both sides until the final thickness is achieved. 3.2 INITIAL CUTTING OPERATION - Initial cutting operations such as flame cutting, abrasive cutting, bandsawing, friction sawing, circular sawing, laser cutting, plasma arc machining (PAM), electrical discharge machining (EDM), and abrasive water jet cutting are permitted provided that either a damage free surface is maintained or the damaged surface layer is subsequently removed, unless otherwise stated on the engineering drawing. 3.2.1 FLAME CUTTING - Steel with carbon content greater than .30% and all low alloy steels maybe preheated at 500 ‘F* 25 ‘F prior to flame cutting to reduce cracking. After flame cutting, these materials shall be stress relieved per FPS-3014 at 1175 ‘F* 25 “F for a minimum of 2 hours. When flame cutting 10 Nickel steel in section thicknesses greater than 2 inches, the material shall be preheated to 250 “F*50“F prior to cutting. Refer to Table IIB for recommended cutting speeds. Do not flame cut aluminum. After flame cutting, the damaged surface layer must be removed per Table II IA. 3.2.2 ABRASIVE -CU?77NG - Materia+-whict?is abrasively-cut must tiavethe damaged surface layer removed per Table II 1A. Alloy steels which are subsequently hardened and tempered may be stress relieved per FPS-3014 at 1175 “F * 25 “F for a minimum of 2 hours after abrasive cutting in lieu of the surface removal requirements. Refer to Table IIIB for recommended blades and cutting speeds. FRICTION SAWING - Friction sawing is not recommended for aluminum due to its high thermal 3.2.3 conductivity. Friction sawing is also not recommended for material greater than 1/2” in thickness due to inadequate softening of the workpiece during the cutting operation.
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
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3.2.4 CIRCULAR SAWING - Circular sawing is not recommended for steel or titanium products due to the slow cutting speeds which are required. 3.2.5 LASER CUTTING - Laser cutting is permitted for all alloys. A minimum of 0.01 O“ shall be removed from all laser cut surfaces to ensure removal of the recast zone, the heat affected zone, and the microcracks caused by the laser cutting. If the laser cut surfaces are to be subsequently welded, metal removal after laser cutting is not required. Company specific deviations to the minimum metal removal after laser cutting may be allowed as follows (a)
Manufacture specimens from (1) 2024-T3, T62, or T81, (2) titanium representative of any titanium cut, (3) carbon steel representative of any carbon steel cut, and (4) stainless steel representative of any stainless steel cut. Two specimens from each material must be used. One specimen must be a cut edge, the other must be a cut hole. After cutting, NO additional work may be preformed, i.e., deburring, polishing, buffing. The specimens can be any convenient size or thickness, as long as they can be sectioned and analyzed.
(b) The specimens must be submitted to an independent laboratory to determine the thickness of the recast zone and the heat affected zone. A report, including original photographs at 100X minimum, must be submitted to LFWC M&PT for analysis. 3.2.6 ELECTRICAL DISCHARGE MACHINING (EDM) - EDM is permitted for all alloys. A minimum of 0.01 0!’ shall be removed from all EDM cut surfaces to ensure removal of the recast zone, the heat affected zone, and the microcracks caused by the EDM. 3.2.7 PLASMA ARC MACHINING (PAM) - PAM is permitted for all alloys. A minimum of 0.010” shall be removed from all PAM cut surfaces to ensure removal of the recast zone, the heat affected zone, and the microcracks caused by PAM. 3.2.8 ABRASIVE WATER JET CUTTING - Abrasive water jet cutting shall not cause any material degradation. 3.2.9 ALUMINUM HAND FORGINGS - When machining fully heat treated/aged aluminum hand forgings, care must be taken to minimize warpage. Parts shall not be finish machined on one side before starting on the other. 3.2.10 MATTE FINISHING OF ALUMINUM PARTS - Machined aluminum parts which are not fracture critical may be matte finished by the wet abrasive blasthlurry method. Wet abrasive blasthlurry systems shall not cause any material degradation. 3.2.11 MACHINING OF FULLY HEAT TREATED ALLOY AND CARBON STEEL PARTS - Alloy and carbon steels heat treated to Ftu = 180 ksi and over which are machined in the fully heat treated condition, shall be nital etch inspected for burns per NDTS 9111 and baked at 50”F below the tempering temperature for a minimum of two hours perFPS-3014. 3.3
GRINDING
3.3.1 GRINDING OF STEEL PARTS - Alloy or carbon steels heat treated to Ftu = 180 ksi and over shall be ground per the procedures of FPS-1 089. If the material is in the fully heat treated condition, Ftu = 180 ksi and above, it shall be nital etch inspected for~rinder burns per NDTS 9111. 10 Nickel, PH Steels, maraging steels, and alloy or carbon steel heat treated to less than 180 ksi are excluded from this requirement. 3.3.2 GRINDING OF CHROMIUM PLATED LOW ALLOY STEEL PARTS - Grinding of chrome plated low alloy steel parts heat treated to 180 ksi and above shall be performed per FPS-1 089. 3.3.3 GRINDING OF TITANIUM PARTS - Low stress grinding shall be performed on the last 0.010” of material on exterior surfaces and the last 0.005” of material on internal cylindrical surfaces (0.01 O“ on the internal diameter). Maximum feeds shall be per Table IV. All parts shall be visually checked for overheating
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FPS-3017E Date: 17 Januaty 1995 Superseding: FPS-3017D
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after grinding. Parts which are bright silver, gold, or light blue are acceptable. All other colors shall be cause for rejection. 3.4 BENCH WORKING OF METAL PARTS DEBURRING OF METAL PARTS - Parts shall be deburred to eliminate sharp edges and 3.4.1 projections. It is unnecessary to deburr for cosmetic purposes only. Surface integrity shall be per paragraph 3.8. Parts which utilize an automatic sheet deburrer do not require the edges broken if they will be 3.4.1.1 broken in subsequent operations. However, if the sheet deburrer is used as the final operation, the edges must meet the requirements of paragraph 3.4.1. When planning specifies the use of vibratory deburr, hand deburring may be substituted. If 3.4.1.2 the planning specifies hand deburring, vibratory deburring may be substituted provided that the part meets engineering drawing requirements. Special care must be exercised when vibratoty deburring parts under .050” thick, parts in the annealed condition, or long, thin parts without stiffeners due to the risk of deformation. It is recommended that parts not be run in the vibratoty deburring/finishing media longer than 45 minutes due to work hardening effects. After removal, the parts shall be thoroughly rinsed and
dryed. Sheet metal which is punched, blanked, or pierced shall be polished to remove smeared 3.4.1.3 metal where the mold line intersects a net edge of the part, see Figure 1. The polished area shall extend to approximately 1/2” of either side of the mold line. HAND AND POWER TOOLS - Hand and power tools may be used in the removal of minor flaws, 3.4.2 over tolerance areas, and surface marks which have been machined, ground, or them milled to drawing dimensions. Scraping, filing, or grinding should be accomplished using gentle passes all in the same direction, preferably the direction of grain flow. It is not necessary to blend two intersecting surfaces unless the intersecting radius is less than 0.060”. Do not use scrapers on high strength steel parts. Do not hand grind using stone grinding wheels or arbor mounted stones. Planned excess metal removal during installation shall be accomplished by course grinding or sanding, tool routing, sawing, or using a hand held shear. A 120 or coarser grit shall be used to avoid overheating. The part must remain within blueprint tolerances after metal removal. 3.5 HOLE PREPARATION - Holes may be prepared by using methods such as reaming, boring, honing, burnishing, and grinding. If drawing requirements can be met, the drilling of holes maybe used as a finish machining operation. Regardless of tool type, the tool shall be kept rotating during withdrawal. A withdrawal rate of less than one inch/second is preferred. When machining through both metal and composites, refer to FPS-3086 for composites machining procedures and requirements. HIGH STRENGTH STEEL - Preparation of fastener holes in steel heat treated to 180 ksi and 3.5.1 above shall be per FPS-1 098. Precipitation hardening steel and 10 Nickel are excluded from this requirement. 3.5.2 CHAMFERING AND SPOT FACING - Oversize drills shall not be used for chamfering with hand power tools. Adequate tooling shall be used for chamfering and spot facing. 3.5.3 CLOSE TOLERANCE HOLES - Metal removal for close tolerance holes used for bearing and bushing applications shall. follow of this specification and M333. , .the provisions ,, 3.6 HOLE DEBURRING - When deburring non-bonded stacks of metal, the stacks shall be disassembled for hole deburring unless otherwise specified on the engineering drawing. Peel shim shall not be deburred prior to assembly. FASTENER HOLES IN ALUMINUM - Fastener holes in aluminum do not require deburring 3.6.1 unless specified on the engineering drawing, when required for fit or function, or if sharp burrs or protrusions exist.
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
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3.6.2 FASTENER HOLES IN METALS OTHER THAN ALUMINUM - Holes shall bedeburredto0.015“ chamfer maximum, unless otherwise specified on the engineering drawing. A radiusing tool may be used when entrance and exit surfaces are normal within 2° to the hole. Otherwise, deburring shall be accomplished by hand. NON-FASTENER HOLES - All hole edges shall be chamfered or radius deburred, unless 3.6.3 otherwise specified on the engineering drawing.
I
3.7 CORNER RADII - Undimensioned corners, both internal and external, on air surface skins shall be square. On internal skins, the radii for undimensioned external corners for both hand routed and machine routed aluminum sheet metal parts shall be .25” maximum. For parts produced on blanking dies, permissible radii on external corners is 0.12“ maximum and on internal corners is 0.15“ maximum. A dimensioned corner is a corner having a specified radius. 3.8 S U R F A C E I N T E G R I T Y SURFACE lNTEGRllY FOR NON-FATIGUE AND NON-FRACTURE CRITICAL PARTS- Surface marks do not need to be removed unless they are greater in depth than 10% of the material thickness, .004” maximum.
3.8.1
3.8.2 SURFACE INTEGRITY FOR FATIGUE AND FRACTURE CRITICAL PARTS- Surface marks which are discernible by touch shall be rejected. A fingernail or a plastic indicator shall be used to determine the presence of a rejectable surface mark. A surface mark which is visible but cannot be physically felt is acceptable. 3.8.3 SURFACE INTEGRITY FOR HOLES - Unless otherwise specified on the drawing, hole integrity in parts and assemblies shall be verified as follows: (1) Visually examine for processing flaws such as axial and spiral tool marks. (2) Any visible flaw which cannot be physically felt is acceptable. (3) Axial flaws which can be felt shall be rejected. Spiral or circumferential flaws which can be felt shall be compared to a surface roughness comparator. Spiral or circumferential flaws which compare to a surface finish of 125 RMS or smoother are acceptable.
I
3.8.4 MOOI - MOOI defines the limits to which machined sutface roughness and mismatches may be permitted in order to minimize hand finishing on machined parts, and is applicable when specifically called out on engineering drawings. 3.8.5 ANODIZE CLAMP MARKS - Anodize clamp marks are excluded from the requirements of Paragraph 3.8. For machined parts, anodize clamp marks shall meet the requirements of MOOI, with a maximum depth per side of .004”. For formed parts, anodize clamp marks shall meet the thinning requirements of FPS-3018. 3.9 MATERIALS HANDLING - Care shall be taken to avoid damage to materials and parts during storage, work, and transportation. Parts shall not be left on machines covered with residual coolant when not running for longer than 2.days without being removed-and cleaned. In addition, all parts shall be cleaned after machining. Cleaning shall be accomplished by a parts washer, alkaline cleaning, or caustic etch. 3.9.1 CORROSION PROTECTION - After machining, and during transportation and storage, parts shall be protected from atmospheric corrosion. Paper or plastic may be used to cover the parts. In addition, MIL-P-3420 vapor phase inhibiting (VPI) paper maybe used on aluminum and either MIL-P-3420 VPI paper or Ml L-C-l 6173, Grades 2 or 3 Oil may be used on non-corrosion resistant steel. Do not use MIL-P-3420 to protect cadmium plated surfaces.
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
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3.10 COOLANTS - Coolants shall be used during all machining operations on steel and titanium products and when necessary to prevent overheating when machining aluminum. Coolant is recommended for machining aluminum. Coolants shall not cause pitting, corrosion, or staining of machined parts. Coolants shall be cleaned from parts per 3.9. Water soluble cutting fluids shall be maintained at a ratio of 1 part concentrate to 30 parts or less water. Deionized water or distilled water may be used. Clean tap water is permissible when machining steel or aluminum.
4
QUALITY
REQUIREMENTS
4.1 PART QUALITY AND INTEGRITY- Machining practices shall not induce metallurgical degradation to the metal surface. Surfaces shall not exhibit visual evidence of overheating, shall not be smeared or galled, and shall be visually free from contamination and defects. 4.2 SURFACE INTEGRITY - Surface roughness shall be in accordance with the drawing callout. When surface roughness is not specified on the drawing, machined parts roughness shall be 250 AA maximum. The length of the surface roughness measurement taken shall be 0.03 minimum, unless otherwise specified on the face of the drawing. Surface marks and edges shall meet the requirements of paragraph 3.8. 4.3 D I M E N S I O N A L engineering drawing.
T O L E R A N C E S - Parts shall meet the dimensional tolerances of the
4.4 EXAMINATION - One of the first five parts produced when establishing a new, fixed set of machining parameters shall be checked and meet the requirements of paragraphs 4.1, 4.2, and 4.3. This examination shall be repeated after significant changes in machining parameters.
5
PREPARATION FOR DELlVERY - This section is not applicable to this specification.
6
ACKNOWLEDGEMENT - A vendor shall mention this specification number and its revision letter in all quotations and when acknowledging purchase orders.
7
REJECTIONS - Product not conforming to this specification, or to modifications authorized by the purchaser, will be subject to rejection. 8
I
NOTES
8.1 EDGE - The edge is the intersection of two surfaces.
8.2 CORNER - The corner is the intersection of three or more surfaces. 8.3 EDGE BREAK - An edge break is the amount of material removed from the theoretical intersection of two surfaces. This may be chamfered or radiused. The chamfer shall be burr free. 8.4 CLOSE TOLERANCE HOLE - A close tolerance hole is one with tolerances equal to or less . ..:.> than A .002”. 8.5 FASTENER HOLE - A fastener hole is a hole which any type of fastener goes in including, but not limited to, bolts, screws, rivets, and blind rivets. 8.6 CHIPLOAD FORMULA - The formula for computing the chipload is as follows:
(1)
Chipload = Inch Per Inserl
(2)
Number Of Inserts= Number Of Inserts In Face Mill Or Number Of Flutes Per Endmill
6
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LOCKHEED Fort Worth Company FSCM 81755
FPS-3017E Date: 17 January 1995
Superseding: FPS-3017D
(3)
Table Feed Rate = Inches Per Minute
(4)
Inch Per Insert X Number Of Inserts X RPM= Table Feed Rate
(5)
RPM = Spindle Speed
9
ENVIRONMENTAL HEALTH AND SAFETY - Appropriate persona] protective equipment is required when melting, forging, machining, forming, or otherwise processing metals. The nature of the processing activity will determine what equipment is necessary, i.e., glasses, respirator, protective clothing, and/or ear protection. Contact an occupational health professional to make the appropriate determination.
Deburred Area
I 1/2” I 1/2” I FIGURE 1: Polishing Requirements Around the Mold Line of Formed Sheet Metal
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,.
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
LOCKHEED Fort Worth Company FSCM 81755
TABLE 1A: Mill Decarburization Removal Amounts
I
NOMINAL DIAMETER OR MAXIMUM DISTANCE BETWEEN OPPOSITE FACES
MINIMUM AMOUNT OF STOCK REMOVAL FROM EACH SURFACE
t c .188”
None
.188” 5 t c .250”
.010”
.250” s t < .375”
.015”
.375” s t < .500”
,020”
.500” < t c .625”
.025”
.625” < t < 1,00”
.030”
1.00” < t c 2.00”
.055”
2.00” s t < 3.00”
.070”
3.00” s t c 4.00”
I
I
.085”
4.00” s t < 5.00”
.115”
t > 5.()()”
.150”
TABLE IB: Titanium Mill Skin Removal Amounts PRODUCT
MINIMUM AMOUNT OF STOCK REMOVAL FROM SURFACE
Forged Bar and Billet
.040”
Hot Rolled Bar Condition “A” Piate
.030”
I
.020”
I
Condition “RA” Plate
.025”
Condition “Beta Annealed” Plate
.025”
Extrusions
.015”
Die and Hand Forgings
.040”
No. 2D Surface Finish Sheet &-Plate
Not Required
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
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TABLE IC: 10 Nickel and CRES Mill Skin Removal Amounts MINIMUM AMOUNT OF STOCK
I
I
PRODUCT
REMOVAL FROM SURFACE
Forged Bar, Billet, and Hand Forgings
.040”
Hot Rolled Bar and Plate
I
.030”
Extrusions Die Forgings
Per Engineering Drawing
No. 2D Surface Finish Sheet & Plate I
No Removal Required
Per Engineering Drawing
TABLE 11A: Minimum Material Removal After Flame Cutting MINIMUM CLEANUP A~ER FLAME CUTTING
MATERIAL THICKNESS
10 NICKEL
STEEL
TITANIUM
t c 1.00”
.15”
.15”
.15”
1.00” < t < 2.00”
.20”
.20”
.20”
2.00”
.40”
.25”
.30”
TABLE IIB: Recommended Flame Cutting Speeds MATERIAL
Titanium
MATERIAL THICKNESS
CUITING SPEED (lN./MlN.)
3“
33 - 36
4“
30 - 33
5“ 6“ - 7“
27 - 30
3“
6 - 6.5
20 - 27
10 Nickel ~ , ,,
Steel
2“
14 - 20 10 - 14
4“ 6,, - 7,,
7-12 5 - 8
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FPS-3017E Date: 17 January 1995 Superseding: FPS-3017D
LOCKHEED Fort Worth Company FSCM 81755
TABLE IIIA: Abrasively Cut Surface Layer Removal
I
MINIMUM CLEANUP AHER MAXIMUM MATERIAL THICKNESS
l%??=
t < 1.00”
.15”
.10” .15”
1.00” s t c 2.00”
.20”
I
2.00” s t < 3.00”
I
.20”
I
.30”
I
3.00” < t s 7.00”
I
.25”
I
.30”
I I
TABLE IIIB: Recommended Abrasive Blades and Cutting Speeds MATERIAL
BIADE TYPE
WHEEL SPEED (RPM)
Steel Titanium
Aluminum Oxide Silicon Carbide
5500 - 6500 3000 - 6000
TABLE IV: Maximum Feeds for Grinding Titanium Parts
I
.0005” per Pass to Within .002” of Finish Surface
Initial Low I .001” per Pass to Within .002” of Finish Surface Stress Passes Finishing Low Stress Passes
I
INTERIOR CYLINDRICAL SURFACES
EXTERIOR SURFACES
PASS
I
3 Passes @! .0004” 4 Passes @ .0002” Final Pass with No Feed
I
I
10 Passes @ .0002” Final Pass with No Feed I
10
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LOCKHEED MARTIN Tactical Aircraft Systems FSCM 81755
Amendment 1 to FPS-3017E Date: 9 September 1999
AMENDMENT 1 TO FPS 3017E METAL REMOVAL PROCEDURES AND LIMITATIONS
Releasability of this material under the Freedom of Information Act is subject to the restrictions on release in DoD Regulation 5400.7R and DoD Directive 5230.25.
LOCKHEED MARTIN Tactical Aircraft Systems FSCM 81755
Amendment 1 to FPS-3017E Date: 9 September 1999
This amendment incorporates and supersedes all previous amendments. This amendment forms a part of and shall be attached to Lockheed Martin Tactical Aircraft Systems Specification FPS-3017, Metal Removal Procedures and Limitations, dated 17 January, 1995. This amendment is effective immediately upon issuance. Paragraph 1.3
Change:
Add the following new paragraph 1.3: 1.3 ALUMINUM-LITHIUM ALLOYS Aluminum-Lithium (Al-Li) alloys are aluminum-based alloys such as FMS-4097 which contain intentional additions of lithium above 0.15% by weight. Requirements for metal removal of Al-Li alloys are identical to those for conventional aluminum alloys, EXCEPT WHERE OTHERWISE NOTED HEREIN.
3.1.3
Reason:
To define Al-Li alloys as used in this document.
Change:
Add the following new sentence to the end of paragraph 3.1.3: Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9, Materials Handling.
3.2
Reason:
To highlight the requirements for scrap segregation of Al-Li alloys.
Change:
Add the following new sentence to the end of paragraph 3.2: Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9, Materials Handling.
3.2.1
Reason:
To highlight the requirements for scrap segregation of Al-Li alloys.
Change:
Add the word “alloys” to the next-to-the-last sentence of paragraph 3.2.1, so that the sentence reads: Do not flame cut aluminum alloys.
3.2.3
Reason:
To affirm that no aluminum alloys shall be flame cut.
Change:
Add the following new sentence immediately after the first sentence of paragraph 3.2.1: Friction sawing shall not be performed on Al-Li alloys.
3.2.5
Reason:
To disallow friction sawing of Al-Li alloys.
Change:
Add the words “except Al-Li alloys” to the first sentence of paragraph 3.2.5, so that the sentence reads: Laser cutting is permitted for all alloys except Al-Li alloys.
3.2.7
Reason:
To disallow laser cutting of Al-Li alloys.
Change:
Add the words “except Al-Li alloys” to the first sentence of paragraph 3.2.7, so that the sentence reads: PAM is permitted for all alloys except Al-Li alloys.
Reason:
To disallow plasma arc machining of Al-Li alloys.
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LOCKHEED MARTIN Tactical Aircraft Systems FSCM 81755
Amendment 1 to FPS-3017E Date: 9 September 1999
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LOCKHEED MARTIN Tactical Aircraft Systems FSCM 81755 3.4.1
Change:
Amendment 1 to FPS-3017E Date: 9 September 1999
Add the highlighted clause to the end of the first sentence of paragraph 3.4.1: Parts shall be deburred to eliminate sharp edges and projections so that injury to personnel and damage to equipment are prevented.
3.4.1
Reason:
To clarify the intent of sharp edge/projection elimination.
Change:
Add the following new sentence to the end of paragraph 3.4.1: Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9, Materials Handling.
3.5
Reason:
To highlight the requirements for scrap segregation of Al-Li alloys.
Change:
Add the following new sentence to the end of paragraph 3.5: Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9, Materials Handling.
3.6.1
Reason:
To highlight the requirements for scrap segregation of Al-Li alloys.
Change:
Add the word “alloys” after “aluminum” in the first sentence of paragraph 3.6.1, so that the sentence reads: Fastener holes in aluminum alloys do not require deburring unless specified on the engineering drawing, when required for fit or function, or if sharp burrs or protrusions exist.
3.8.2
Reason:
To clarify deburring requirements.
Change:
Add the clause “typically greater than 0.001” deep on the bare metal” after “touch” and add 3.8.2.1 so that the paragraph(s) read: 3.8.2 SURFACE INTEGRITY FOR FATIGUE AND FRACTURE CRITICAL PARTS Surface marks which are discernible by touch (typically greater than 0.001” deep) on the bare metal shall be rejected. A fingernail or a plastic indicator shall be used to determine the presence of a rejectable surface mark. A surface mark which is visible but cannot be physically felt is acceptable. 3.8.2.1 Surface Integrity for Painted Fatigue and Fracture Critical Parts When it is questionable on a painted surface whether a surface mark extends into the metal, the paint and prime shall be removed from the area with fine abrasive (e.g., "scotch-brite") by hand. A rejectable condition exists, if the surface mark is discernible by touch on the bare metal. If the surface mark extends only into the paint, a non-conformance does not exist. Touch-up and reapply prime and paint per the appropriate finish code elements.
3.9.2
Reason:
To clarify how “surface marks” should be handled.
Change:
Add the following new paragraph 3.9.2: 3.9.2 SCRAP SEGREGATION OF AL-LI ALLOYS Scrap classified as solids, turnings, and borings where large amounts of scrap material are generated shall be segregated from conventional aluminum alloy scrap. Scrap classified as floor sweepings from bench working, drilling, or assembly where scrap contamination typically occurs, does not require segregation from conventional aluminum alloys.
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LOCKHEED MARTIN Tactical Aircraft Systems FSCM 81755 Reason:
Amendment 1 to FPS-3017E Date: 9 September 1999
To highlight the requirements for scrap segregation of Al-Li alloys.
PREPARED BY:
APPROVED BY:
_M. L. Polley____________ M. L. Polley F-16 Systems Engineering Materials and Processes
L. K. Austin________________ L. K. Austin F-16 Systems Engineering Materials and Processes
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