Schaeffler Aerospace Germany GmbH & Co. KG, based in Schweinfurt, is a
Subsidiary of Schaeffler Technologies AG & Co. KG. With around 600 employees, the company is a leader in development and manufacturing.
high-precision rolling bearing systems for aerospace. The core competencies
include not only manufacturing but also development, design, and
Test bench testing of complex bearing systems specifically designed for the application case.
to be designed. In addition to new manufacturing, Schaeffler Aerospace also offers a
comprehensive MRO program to sustainably refurbish bearings and a
to ensure long-term supply security. To perfectly meet all these requirements
and to implement precisely, a total of six WFLs have been introduced in recent years.
MILLTURNs have been acquired. The latest addition is an M50 MILLTURN with
Automation cell.
Rolling bearings for aerospace must withstand extreme temperatures, demanding conditions
Withstand profile tolerances and high rotational speeds. Additionally, the industry requires over 70 years of traceability and documentation obligations with the highest standards for component quality and reliability. Furthermore, the production of the bearings must be ensured over the complete usage cycle of several decades.
The bearing components manufactured by Schaeffler Aerospace are used 75% in engines of passenger and military aircraft and 25% in helicopters as well as in aerospace applications. The materials processed, such as Inconel 718, case-hardened steel M50Nil, or Cronidur 30, are considered extremely tough and difficult to machine. At the same time, the machining must adhere to the tightest tolerances and realize thin-walled geometries without causing microstructural damage.
Efficiency through complete machining
To meet these requirements, Schaeffler Aerospace has been successfully using WFL MILLTURNs since 2006. Before their acquisition, many machining steps were carried out separately on traditional 2-axis lathes and 5-axis milling machines. With the MILLTURN, a process-integrated complete machining could be realized for the first time. Machining steps such as turning, milling, drilling, or measuring now take place on a single machine, which reduces setup times, avoids repositioning errors, and improves machining quality.
With average batch sizes between 15 and 50 pieces, the number of setup processes plays a crucial role. "A particular advantage of the MILLTURN machines is the integrated B-axis. By using swiveling tool positions, complex component geometries can be realized in just one clamping with a small number of tools," explains Thomas Memmel, who is responsible for technology development at Schaeffler Aerospace.
Despite occasionally longer overall cycle times, the consolidation of the
Processing operations provide an economic advantage, especially with regard to autonomous layers or multi-machine operation.
The MILLTURN machines also offer comfortable CNC programming and are excellently integrated into CAM environments, allowing for efficient implementation of machining strategies. This integration enables quick adjustments and optimal planning of the machining steps. At Schaeffler Aerospace, this reduces programming times and maximizes process stability even with small batch sizes and variable geometries.
The decision to collaborate with WFL was primarily based on the characteristic machine features: maximum rigidity thanks to the slant bed design and the doubly supported B-axis. Due to the long-standing positive experience with this machine concept, as well as the consistently competent service team, Schaeffler Aerospace has relied on WFL for nearly two decades.
An additional essential point is the provision of complete solutions. "Having the machine and automation supplied from a single source is a great advantage for us," says Thomas Memmel.
Application Areas
In this specific case, the manufactured bearings are used, among other things, in modern
Aircraft engines from Rolls-Royce, such as the Trent 1000, Trent XWB, or Pearl 10X models. These engines are used in the 787 Dreamliner, A350, or business jets. Components from Schaeffler Aerospace are also installed in engines for the new short- and medium-haul aircraft A320neo and 737MAX. These engine programs are of central importance to aviation.
In addition, bearing solutions from Schaeffler are also trusted in the helicopter sector.
Aerospace. Here, the bearings in gears, transmission shafts, and the
Gyroscopic disc highest running smoothness and reliability – even under varying loads and
difficult climatic conditions.
Another outstanding application field is aerospace. Schaeffler bearings, for example, are used in the turbopumps of the RS-25 engine – the high-performance engine used in the first stage of NASA's SLS (Space Launch System). These bearings must not only withstand enormous rotational speeds, but the environmental conditions are also unique. The lubrication of the bearings is done with liquid water and oxygen at operating temperatures below -200°C. Requirements that can only be met by absolutely reliable and precisely manufactured components.
Process reliability is ensured by state-of-the-art measurement technology within the M50 MILLTURN.
supports, for example, through integrated scanning measuring probes that provide an exact
Enable process control during machining.
Required tolerances range from 20 µm for turning and up to 10 µm for milling – values that can only be achieved through consistent process control.
Digitalization, Automation, and Sustainability
Schaeffler Aerospace has committed to digitalization early on to make processes more efficient and ensure the essential traceability for aviation. "To this end, we are developing our own software applications to gradually make manufacturing paperless and to streamline the process chain. This proactive approach shows that the company does not react to trends but anticipates and activates them," explains Thomas Memmel.
In the field of machining, Schaeffler Aerospace relies on connectivity to utilize data.
To drive process optimizations or extend tool life. Particularly noteworthy is the focus on the quality of high-performance components, which is always the top priority. These measures demonstrate a deep understanding of the industry and a clear orientation towards future-proof, high-quality, and production-related processes.
The company is also making consistent progress in the field of automation. Through
Robot-assisted loading and a largely unmanned third shift – even on weekends – can compensate for the shortage of skilled workers and reduce costs. The challenge lies in the sensitivity and high value of the components; loading errors must be reliably detected and prevented. This requires intelligent process monitoring through well-thought-out sensor technology, which is developed by WFL itself.
The rapid pace of technological developments requires Schaeffler Aerospace to make a smart selection and integration of megatrends. In the field of automation, it becomes clear that there are challenges with small batch sizes and changing geometries. Nevertheless, the company places great importance on making systems quickly programmable and minimizing setup times during type changes. Michael Both, Head of Industrial Engineering Aerospace, emphasizes the crucial role of automated and complex solutions in securing competitiveness in a high-wage country like Germany. In the aerospace industry, efficiency and precision are indispensable, which is why advanced technologies reduce errors and enhance production quality.
As a leading motion technology company, Schaeffler understands sustainability as a holistic and overarching theme and takes ecological and social responsibility throughout the entire value chain. To implement the company's ambitious sustainability strategy, collaboration is key – with customers and suppliers, executives and employees, as well as other stakeholders.
Technology, innovation, and the pioneering spirit that has characterized the Schaeffler Group for decades play an important role here. "With WFL MILLTURN machines, we have been continuously improving our processes for over 15 years."
"improve and meet the increased customer requirements," emphasizes Thomas.
Memmel.
The use of MILLTURN technology is a strategic key for Schaeffler Aerospace to meet the highest quality standards – today and in the future. In combination with digitalization, automation, and sustainability, the company consistently pursues its role as a reliable and innovative partner in the global aerospace industry.
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