CUSTOMER: BAE Systems

PROBLEM: The inboard journal of the taileron spigot of the Tornado fighter aircraft was wearing oval in use and needed to be made round again.  The machining operation needed to be carried out on the aircraft in a hangar, anywhere in the world. The alternative had been to remove and replace the taileron spigots; a costly and time-consuming process.

SOLUTION: A bespoke taileron turning machine has been engineered by Furmanite to provide in-situ machining to very tight tolerances, for the taileron spigot, providing substantial cost savings.  The machine had to be relatively lightweight and portable.

Furmanite's solution was an air-powered machine tool which bolts on to the spigot for use, and can be set to the correct diameters for use by BAE SYSTEM's own technicians.  (Training for the technicians is provided by Furmanite as part of the package). Accuracy was the overriding factor in developing the design to meet the very tight tolerances required, and to get it right every time.  The machine shaves off some 0.25mm from the diameter of the journal, and is accurate to within 0.01mm.  A very smooth surface finish was also essential, the machine having to achieve 0.8 micrometers.

OUTCOME: The Furmanite machine met all requirements, and offered substantial savings on the previous estimated costs to repair each spigot.