Military

EXECUTIVE SUMMARY

TABLE OF CONTENTS

Page

PART I - TECHNICAL PROGRAM DATA

PREFACE

N88-NTSP-A-50-8602B/A

A. NOMENCLATURE-TITLE-PROGRAM

1. Nomenclature-Title-Acronym. Hydraulic Tube Bending Machines (HTBM)

2. Program Element. PE84743N

B. SECURITY CLASSIFICATION

1. System Characteristics Unclassified

2. Capabilities Unclassified

3. Functions Unclassified

D. SYSTEM DESCRIPTION

1. Operational Uses. The land-based and shipboard HTBMs are dedicated support equipment used for making accurate horizontal rotary draw bends of tight radii in standard and thin wall aircraft quality tubing of both ferrous and non-ferrous materials. The "land-based" HTBMs are positioned only at shore installations. The "shipboard" HTBMs may be positioned aboard ships, ashore, or at mobile maintenance activities.

2. Foreign Military Sales. Foreign Military Sales (FMS) of the shore based HTBMs (A/E 27M-9) have been processed. For additional information concerning FMS contact the Program Manager, Air (PMA)260.

E. DEVELOPMENTAL TEST AND OPERATIONAL TEST. A Technical Evaluation (TECHEVAL) was conducted on the land-based HTBM (A/E 27M-9) from August 1983 to April 1984 at the Aircraft Intermediate Maintenance Department (AIMD), Naval Air Station (NAS) Lemoore, California. A supplemental TECHEVAL to determine the correction of deficiencies identified during the original TECHEVAL was conducted at AIMD NAS Oceana, Virginia, from March to June 1987. The results of the supplemental TECHEVAL were published in SY50-87-043, dated 23 September 1987. A TECHEVAL on the shipboard HTBM was not conducted. An Operational Evaluation was not conducted on either the land-based or shipboard HTBM.

F. AIRCRAFT AND/OR EQUIPMENT/SYSTEM/SUBSYSTEM REPLACED. Not Applicable (NA)

G. DESCRIPTION OF NEW DEVELOPMENT

1. Functional Description. The land-based HTBM (A/E 27M-9) is capable of bending the following materials and tubing sizes:

The A/E 27M-9 is operated from a movable console, and controlled from either a numerically programmable microprocessor or a secondary manual controller operated by switches. The microprocessor is capable of accepting data in absolute or incremental format. The bending machine is designed for installation in land-based facilities. It may be mounted in a mobile facility, and is air transportable. The land-based HTBM (A/E 27M-9) is capable of the following types of bends.

The tabletop shipboard bending machine (CL-215-2/EL-215-2) is a smaller, semi-portable, hydraulically powered bender, capable of bench mounting. This bending machine will bend tubing from 3/8 inch O.D. to 1 inches O.D. with 0.20 inch wall thickness of copper, aluminum alloy, steel, and stainless steel to MIL-T-6845 and MIL-T-8504. Capabilities of these HTBMs are listed below:

Two adapter kits are currently available for use with these tabletop shipboard HTBMs:

• Kit H60, with special Ampco Bronze mandrels and wiper dies and special size bend dies for bending 21-6-9, stainless steel
• Kit F/A-18 and AV-8 (same part number) containing special mandrels and wiper dies for bending titanium

a. Major Components, Land-Based. The land-based HTBMs consists of the following components.

(1) Tooling. Tooling consists of bending dies, clamping dies, pressure dies, follower dies, wiper dies, mandrels, mandrel rods (quick disconnect type), collets, collet pads or inserts, and mounting adapters. All tooling is self-aligning and interlocking.

(2) Nose. The nose assembly is steel casting bored to accommodate precision tapered roller bearings, top and bottom.

(3) Spindle. The spindle is made of precision ground alloy steel sufficient in size and strength to withstand the forces applied when the machine is operated at maximum rated capacity.

(4) Bending Machine. The stationary and swing arms are steel castings sufficient in strength to withstand the forces applied when the machine is operated at maximum rated capacity. The arms are accurately machined and fitted with tool holding slides. The mounting boss of the swing arm is fitted with keys and a locating ring for accurately locating the bending dies.

(5) Pressure Die Assembly. A pressure die assembly is provided to apply pressure during the bending cycle. The pressure die holder is mounted at right angles to the tube to be bent and is operated by means of a direct acting hydraulic cylinder. A gauge for reading the pressure and a control for setting the pressure is provided. A pressure die assist is provided to minimize required clamp lengths.

(6) Clamping Assembly. The clamping die assembly is mounted on the side of the swing arm and operates by means of a direct acting hydraulic cylinder. A gauge for reading the pressure and a control for setting the pressure are provided. The clamping die assembly is designed to provide easy alignment and uniform clamping pressure over the entire area.

(7) Mandrel Extractor. A hydraulically operated mandrel extractor assembly is furnished. The assembly is sufficient in stroke to extract the entire ball assembly of a three-ball mandrel from the bent section of the tube. The extractor provides the lateral adjustment to allow alignment of the mandrel with the centerline of the bend radii. Longitudinal adjustment is provided for mandrel tangent positioning. Quick-disconnect type mandrel rods are supplied.

(8) Wiper Die Holder. A wiper die holder is provided to use wiper dies to produce wrinkle-free bends with minimum distortion. It provides for horizontal, longitudinal, and vertical adjustment.

(9) Tube Positioning Device. A tube-positioning device is provided. It consists of a data input keyboard, automatic collet equipped carriage, and all necessary electrical controls. Distance between bends, degree of bend, and planes of bend are input through the keyboard along with springback factors. The control includes a display feature and full editing capabilities. The system is capable of displaying operating and programming instructions in an easily understandable form.

(10) Base. The base structure has adequate strength and rigidity to support the components mounted thereon and has the stability required to maintain tool alignment when used at full capacity. The base and oil reservoirs are integral.

(11) Electrical System. The HTBM requires a three phase, 220-Volt Alternating Current (VAC), 60-hertz electrical power source and draws no more than 33 amperes of current. The unit is designed to withstand voltage fluctuations of +10 percent and frequency fluctuations of +5 percent without damage.

(12) Hydraulic System. The hydraulic system is a manifold type to minimize maintenance and facilities repair. An electric motor driven pump provides hydraulic pressure. All lines, fittings, valves, and other parts of the hydraulic system, including the manifold, are designed to withstand all pressures, surges, and stresses imposed by 200 percent of the rated pressure of the system. A filtration system is provided to prevent particles larger than 25 microns from entering the valves. Gages are installed to show hydraulic fluid level and hydraulic pressures.

(13) Numerical Control System. The numerical control system includes memory storage, program data edit, and display capability. The control directs the machine functions from stored part number program data entered by using the Manual Data Input Keyboard.

(14) Operating Controls. The operating control provides the ability to store bend programs for future use. When the angle of bend, plane of bend, and distance between bends data is input into the machine and a good part is made, the control has the capability to store that data, plus the springback factors, under an assigned numerical part number. When that part number is encountered again by the operator, it can be recalled. This data is retained in the programmable electronic control. The solid state, non-volatile storage module can store up to 50 different part programs. The control is on a movable stand to optimize operator efficiency and provide the greatest mobility for safe positioning of the control. The control includes diagnostics to verify proper operation of the electronic controller and the output and input functions of the machine. It also has the ability for solid state, non-volatile storage of up to 50 part programs.

(15) Manual Controls. In the event that the programmable electronic control or any of the electronic components are malfunctioning, the machine is capable of making parts in the manual mode. Dials and scales are provided to accurately position each axis. These are entirely separate from the programmable electronic control to provide totally independent operating capability from the electronic control.

b. Major Components, Shipboard. The shipboard bending machine consists of a base and cover subassembly, angle indicator assembly, hydraulic cylinder subassembly, adjusting screw and handle subassembly, and the clamp arm subassembly. The shipboard bending machine consists of the following components.

(1) Powered drive. A chain and sprocket are powered by a separate hydraulic unit.

(2) Hydraulic Unit. A separate stand-alone pump provides 10,000 pounds per square inch of adjustable hydraulic pressure. The Hydraulic Unit is driven by a 1-1/2 horsepower electric motor (120 VAC, 60 hertz, single phase) and provides 45 cubic inches of hydraulic pressure per minute delivery maximum.

(3) Maximum Bend Angle. The maximum bend angle is 180 degrees with standard dies. (The bend arm will actually bend to 195 degrees to provide springback compensation.)

(4) Degree of Bend Control. The degree of bend control is adjustable in one-degree increments from 0 to 195 degrees.

(5) Bend Arm Return. The bend arm return will position the bending machine spring return to zero after the completion of a bend.

(6) Clamping. The clamp die and pressure die use speed screws to adjust the clamping pressure.

a. Land-Based Hydraulic Tube Bending Machine. This HTBM is 10 feet 3 inches long with arms folded and 11 feet 10 inches long with arms open. The width, including sweep of arms, does not exceed 48 inches. The working height of the machine is 37 inches and overall height does not exceed 45 inches. The shipping weight is 3700 pounds plus tooling.

b. Table-Mounted Shipboard Hydraulic Tube Bending Machine. The HTBM model CL-215-2 unit is 42 inches long, 9-1/2 inches wide, and 15-3/4 inches high. The shipping weight is 164 pounds without accessories.

c. Hydraulic Tube Bending Machine with Stand. This unit has the same capability as the Table-Mounted Shipboard Hydraulic Tube Bending Machine. The assembly is mounted on an integrated 10 foot long stand with hydraulic mandrel extractor for tube bending. This unit is 12 feet long with the mandrel arms extended, has a working surface 37 inches high, and a maximum with of 48 inches. The unit's bulky size makes it unsuitable for shipboard installation.

3. New Development Introduction. Both the land-based and the shipboard HTBMs were introduced through new production.

4. Significant Interfaces. NA

5. New Features, Configurations, or Material. NA

H. CONCEPTS

a. Navy. The HTBM is operated and maintained by personnel in the Aviation Structural Mechanics, Hydraulic (AMH) and Aviation Structural Mechanics, Structural (AMS) ratings.

b. Marine Corps. The HTBM is operated and maintained by personnel in the Hydraulic Mechanic discipline.

a. Organizational. NA

(a) Land-Based Hydraulic Tube Bending Machine. Preventive maintenance of the land-based HTBM consists of servicing and testing the unit in accordance with the approved maintenance plan as described in Periodic Maintenance Requirement Cards, NAVAIR 17-600-158-6-2.

(b) Table-Mounted Shipboard Hydraulic Tube Bending Machine and Hydraulic Tube Bending Machine with Stand. Preventive maintenance of the HTBMs consists of servicing and testing in accordance with the maintenance plan identified in the factory manual.

(a) Land-Based Hydraulic Tube Bending Machine. Corrective maintenance of the land-based HTBM consists of fault isolation, removal, repair, replacement of defective components, and testing the tube bender in accordance with the Operation and Maintenance Instructions with Illustrated Parts Breakdown, NAVAIR 17-5-4.

(b) Table-Mounted Shipboard Hydraulic Tube Bending Machine and Hydraulic Tube Bending Machine with Stand. Corrective maintenance of the HTBMs consists of fault isolation, removal, repair, replacement of defective components, and testing the tube bender as described in the factory manual.

c. Depot. Depot level maintenance on the HTBMs includes repair, rework, and overhaul of the bending machine, repair of components beyond the capability of the intermediate level of maintenance, and the manufacture of items coded as depot level. The manufacturer will perform depot level maintenance, if required.

d. Technical Assistance. NATEC personnel provide technical assistance, including on-site training.

e. Interim Maintenance. NA

f. Life Cycle Maintenance Plan. NA

3. Manning Concept. No changes to current AIMD manpower or Marine Aviation Logistics Squadron (MALS) manpower are required.

4. Training Concept

a. Initial Training. The contractor (Teledyne Pines) provided initial training for the Land-Based HTBM in May 1988. No initial training was conducted for the table-mounted shipboard HTBM or the HTBM with Stand.

b. Follow-on Training. NATEC Engineering Services Division provides follow-on training for the Land-Based HTBM on an as requested basis. The command requesting training must submit a request for technical assistance to NATEC Engineering Services Division.

c. Student Profiles. HTBM training is usually for AMH personnel. They are responsible for aviation flex hose and rigid tubing fabrication. 'A' school completion is not a prerequisite for attending HTBM training.

d. Training Pipelines. There are no formal training tracks that include HTBM operator-maintainer training, and none have been identified for future development.

a. Maintenance Training Improvement Program. Training associated with this system is not covered by the Maintenance Training Improvement Program (MTIP) criteria.

b. Aviation Maintenance Training Continuum System. The Aviation Maintenance Training Continuum System (AMTCS) will provide career path training to the Sailor or Marine from their initial service entry to the end of their military career. AMTCS is planned to be an integrated system that will satisfy the training and administrative requirements of both the individual and the organization. The benefits will be manifested in the increased effectiveness of the technicians and the increased efficiencies of the management of the training business process. By capitalizing on technological advances and integrating systems and processes where appropriate, the right amount of training can be provided at the right time, thus meeting the Chief of Naval Operation's mandated "just-in-time" training approach.

Included in the AMTCS development effort is the Aviation Maintenance Training Continuum System - Software Module that provides recording of training [Electronic Training Jacket], and a Feedback system. The core functionality of these AMTCS tools are based and designed around the actual maintenance-related tasks the technicians perform, and the tasks are stored and maintained in a Master Task List data bank. These tools are procured and fielded with appropriate Commercial Off-The-Shelf hardware and software, i.e. Fleet Training Devices - Laptops, PCs, Electronic Classrooms Learning Resource Centers, operating software, and network software and hardware.

Upon receipt of direction from OPNAV (N889H), AMTCS is to be implemented and the new tools integrated into the daily training environment of all participating aviation activities and supporting elements. AMTCS will serve as the standard training system for aviation maintenance training within the Navy and Marine Corps, and is planned to supersede the existing MTIP and Maintenance Training Management and Evaluation Program (MATMEP) programs.

2. Personnel Qualification Standards. NA

3. Other Onboard or In-Service Training Packages. Marine Corps onboard training is based on the current series of Marine Corps Order P4790.12, Individual Training Standards System and MATMEP. This program is designed to meet Marine Corps, as well as Navy OPNAVINST 4790.2 series, maintenance training requirements. It is a performance-based, standardized, level-progressive, documentable, training management and evaluation program. While HTBM training is recorded as part of intermediate level maintenance training qualifications it does not result in the assignment of a Military Occupational Specialty (MOS) for Marine Corps personnel.

a. Land-Based Hydraulic Tube Bending Machine. The Land-Based HTBM ILSP, ILSP-CSE-0525-AA, was prepared by the Naval Air Engineering Center and approved in June 1987.

b. Table-Mounted Shipboard Hydraulic Tube Bending Machine. The contract for 86 table-mounted shipboard HTBMs was approved in 1986 with delivery starting in late 1987. No ILSP was developed for the table-mounted shipboard HTBM.

c. Hydraulic Tube Bending Machine with Stand. The contract for the ten HTBMs with Stand was awarded in 1997 and were designated EL-215. No ILSP was developed for the HTBM with Stand.

a. Land-Based Hydraulic Tube Bending Machine. The contractor provided all technical manuals required for support of the Land-Based HTBM. Technical manuals are in work package format, and both the technical manuals and the Maintenance Requirement Cards (MRCs) support the approved maintenance plan. Technical Manuals are listed below:

b. Table-Mounted Shipboard Hydraulic Tube Bending Machine. The contractor provided all technical manuals required for support of the Table-Mounted Shipboard HTBM.