Production Services

Test Devices by SCHENCK offers various services for our customers to outsource a part of their work for production of rotating parts, including proof/overspeed testing, pre-spinning and machining of jet engine forgings.

In any production operation efficiency and timely delivery is a key agenda. At Test Devices, we offer convenient “one-stop-shop” services to meet your requirements, which includes comprehensive engineering services to design and manufacture the spin toolings, quality controlled processes, performing CMM inspections and preparing necessary quality documentations that integrate seamlessly to support your production flow.

Our facility is compatible with handling and processing thousands of different types of rotating parts, including those with complex geometries. Most importantly, our team with the expertise drawn from over decades of experience in performing high-volume, quality controlled  production operations are well equipped to address and resolve any in-operational issues without causing an interruption to your production flow.

We conduct our operation in compliance with AS9100 aerospace quality standards, which means that you can have full confidence in the integrity and traceability of our work. We have been a trusted partner in serving our customers in aerospace, automotive and broader industry sectors

Learn more about our services and how we can support your testing needs.

Our Services

At Test Devices by SCHENCK, we offer spin testing services and CNC machining services related to the production of high speed rotating parts: Proof / Overspeed spin testing, Pre-spin services, and CNC machining services for jet engine forgings.

Proof / Overspeed Spin Testing Services for Rotor Production

Proof / Overspeed spin testing is a method of verifying the integrity of high-speed rotating components. Typically the test is done to the fully machined parts. Spin testing is an efficient method to subject the components to its validation target (often at the speeds higher than what would be experienced during normal operation), these tests provide objective evidence of a component’s integrity, both at design limits and beyond. It is a critical step for validating the safety and performance of high-speed rotating components, such as turbo-machinery rotors, rocket fuel and oxidizer pump parts.

Forging Pre-Spin Services

Forging pre-spin is a material conditioning process which involves spin testing a purpose designed forging sonic shape to induce a specific amount of plasticity and condition the bulk residual stress state of the forgings before they undergo subsequent machining. 

The benefits of pre-spinning step includes cost savings from a more predictable distortion behavior of the workpiece in subsequent machining process as well as the formation of favorable residual stress conditions for rotor structural performances, to name a few.

CNC Machining Services for Jet Engine Forgings

In addition to our pre-spinning services, we offer CNC machining as part of our comprehensive solutions. Our CNC machining services are specialized in rough and semi-finished machining of jet engine forgings. By combining pre-spinning with CNC machining, we enhance efficiency and cost savings for our customers.

Rough machining is performed prior to the pre-spinning process, shaping the forging into a prescribed sonic shape and preparing it for spin testing. Semi-finished machining, following the pre-spin step, involves removing excess material to bring the parts into the necessary tolerance range for final machining works.

Our facility is equipped with advanced Okuma CNC machines optimized for machining aerospace parts, capable of handling even the most difficult-to-machine aerospace alloys. With a focus on precision and quality, we ensure that the parts we machine meet the exacting standards required for jet engine components.

By offering CNC machining in addition to our pre-spinning services, we provide a comprehensive solution for our customers’ jet engine forging needs, delivering high-quality, precision-engineered parts efficiently and cost-effectively.

Aerospace Forging Pre-Spin and the CNC Machining Process at a Glance

Parts that require pre-spinning, like jet engine disks, start as rough forgings that must be machined to achieve tighter tolerances and prepare the part for subsequent spin testing. Once the pre-spin step is completed, excess material needs to be removed from the forging and bring the parts into the necessary tolerance range for final machining works. 

At Test Devices by SCHENCK, we specialize in pre-spin and machining services to transform rough forgings into components ready for the spin and the final machining. Our CNC machining capabilities are tailored to address the unique requirements related to the processing of aerospace materials. When paired with our spin testing services, we deliver expertly crafted and rigorously tested components that meet the highest standards.

Step 1: Rough Machining

The first stage in preparing a component for spin testing is rough machining. This step is designed to create the required features for attaching spin tooling.

The tolerance for rough machining is typically +/- 0.005 in. (0.127 mm). While this is not as precise as the +/- 0.001 in. (0.025 mm) tolerance required for final machining, it is a significant improvement over the +/-0.020 (0.508 mm) tolerance found in raw forgings. This process leaves approximately 0.050 in. (1.27 mm) of material on all machined surfaces. 

Step 2: Pre-Spin Testing 

After rough machining, the component undergoes pre-spin testing. During this phase, the part is spun at controlled speeds to yield the material, relieve residual stresses from the forging process, and homogenize the overall forging stress state. This step is essential in enhancing production efficiency, reducing production costs, and improving final component performance. 

Step 3: Semi-Finish CNC Machining

Once pre-spin testing is complete, the next stage is semi-finish CNC machining. This crucial stage removes excess material identified during pre-spin testing, refining the component to tighter tolerances. 

The tolerance of semi-finish machining is +/- 0.005 in. (0.127 mm) and leaves about 0.050 in. (1.27 mm) of material on all final dimensions. This process is critical in the overall manufacturing process and is the final task our team completes before sending components back to the customer for final machining. 

Our Capabilities

Test Devices by SCHENCK is outfitted with state-of-the-art equipment to perform spin testing, CNC machining and dimensional inspection:

• Spin Testing & Forging Pre-spinning
  • 7x state-of-the-art spin pits, each housed in a safety test cell, capable of spinning rotors up to 52in in diameter, and safely containing unexpected rotor bursts.
  • Our facility is equipped for processing batches or a large volume (thousands per year) of parts to specified operation and inspection steps. A quality-controlled manufacturing operation is streamlined to produce consistent, quality products. 
• CNC Machining: 
  • 2x Horizontal Lathes – Maximum turning diameter of 25.96 in. and a maximum turning length of 39.33 in.
  • 2x Vertical Lathes – Maximum turning diameter of 29.92 in. and a maximum turning height of 30.31 in.
• Quality Assurance & Dimensional Inspection
  • 2x CMM machines – Maximum envelope – W=40″ x L=60″ x H=24″. In a climate-controlled inspection room.
  • Our Quality Assurance program is supported by a highly trained inspection team to manage the production flow, and ensure the quality compliance.
• Quality Control & Process Management
  • AS9100-certified. We are committed to full adherence to the aerospace standard and continuous efforts in improving the quality of our services and products.
  • Our DQR (Designated Quality Representative) team is another manifestation of our commitment to our customers to ensure each part meets the customers’ exact specifications.
  • Test Devices by SCHENCK is committed to safety and environmental sustainability, as illustrated by our ISO 14001:2015 and ISO 45001:2018 certifications.
  • Innovations towards industry 4.0 and digitally connected operations – Our recent investments in digital process management technology, like the TULIP software, is an example of our commitment to provide the industry-leading quality management solutions & efficiency. Learn more in our eBook on Quality Control & Management of Aerospace Rotating Components.
• Our Team & the Expertise 
  • While having the appropriate equipment is essential, to deliver the result it will take a team of industry leading experts.
  • At Test Devices by Schenck, our Production Services are supported by a team of committed experts in spin testing, CNC machining, inspections, process engineering and quality management.

Our Commitment to the Safety

Even in carefully planned environments, accidents can still occur during spin testing. Rotors spinning at high speeds store a large amount of rotational kinetic energy that can lead to catastrophic damage if released due to a part failure. Operators conducting forging pre-spin work should be particularly cautious, as heavy and high-speed spun forgings have the potential to cause significant destruction in the event of a burst.

At Test Devices by Schenck, ensuring safety is our top priority. The containment in the spin pit alone is not enough; We take thoughtful measures to protect operators and surrounding equipment from unexpected containment failures. For this reason all our spin pits are housed  in purpose-designed test bunkers with a separate operator room to minimize worker risk.

As a part of preparation against a potential for an accident, we have established a practical contingency plan to respond to and recover from accidents quickly, as downtime in manufacturing processes can lead to client dissatisfaction and increased costs.

In our operation, we invest in various preventative measures, including through training of our operators and regular maintenance and inspection of spin pits and test equipment is an essential part of identifying and addressing the potential issues before they lead to catastrophic failures. 

In the event of a disk burst or other accident, we are committed to conducting a thorough investigation to understand the root cause and implementing corrective actions to prevent future occurrences.

By taking proactive measures to manage the risk of disk bursts during spin testing, we strive to minimize the potential for accidents and ensure the safety of their workers and disruption to our customers production goals.

Applications

Your “One-Stop-Shop” for Outsourcing the Production Work for Rotating Parts

Test Devices by SCHENCK is a global leader in aerospace rotating parts production, spin testing and CNC machining services. With an unparalleled reputation for precision and safety, we create solutions for even the most rigorous projects. We have been AS9100 and ISO9001 certified since 2006, ensuring our customers receive only the best quality services. To learn more about our outsourced production services, contact our team or request a quote today.