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<p>This study presents an integrated engineering investigation of an Inconel 600 aircraft engine door cam spindle, focusing on manufacturing process improvement through dedicated jig design and thermo-mechanical reliability assessment under service-relevant conditions. To improve deep-hole machining stability and inspection efficiency, dedicated machining and inspection jigs were developed and applied to the production process. The redesigned process reduced the total machining time from 840&#xa0;min to 666&#xa0;min, corresponding to a 20.7% reduction, while the defect rate decreased from 6% to 2%. In addition, the process was successfully converted from outsourcing-dependent production to full in-house manufacturing. Dimensional and surface-quality verification of five fabricated specimens showed that all samples satisfied the specified tolerances for the slide outer diameter, cam-head outer diameter, and cam-head depth, while the average surface roughness (Ra) ranged from 0.613 to 0.712&#xa0;μm, which was well below the target value of 3.2&#xa0;μm. Furthermore, coordinate measurement of the deep internal bore confirmed that all five specimens satisfied the design tolerance of 0.070&#xa0;mm for both bore straightness (mean: 0.040&#xa0;mm) and concentricity (mean: 0.057&#xa0;mm and 0.051&#xa0;mm for the cam-head and slide references, respectively). To assess service reliability, thermo-mechanical and dynamic finite-element analyses were performed using a three-dimensional model based on the actual spindle geometry. The steady-state thermal analysis identified an allowable thermal limit of approximately 0.2&#xa0;W/mm², corresponding to about 301&#xa0;°C under air-cooled conditions. The static structural analysis confirmed safe operation with a minimum safety factor greater than 1.5 within the design load range, while the pre-stressed modal analysis revealed less than 0.7% variation in the first-mode frequency up to 20,000 RPM, indicating high dynamic stability against resonance. The thermo-structural coupled analysis further showed that, under the identical low-load condition, the maximum equivalent stress increased nearly fivefold from 34.8&#xa0;MPa to 169.0&#xa0;MPa when the thermal load was introduced, demonstrating that thermally induced stress governs the structural response at elevated temperature. These results show that the proposed jig-assisted process can improve manufacturability and product quality, while the finite-element analysis framework provides quantitative verification of structural reliability for high-temperature aerospace rotating components.</p>

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Manufacturing Process Improvement of an Inconel 600 Aircraft Engine Door Cam Spindle through Dedicated Jig Design and Thermo-Mechanical Analysis

  • 期刊论文

  • 发表日期：

    2026年5月28日

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  • Kyung Hwan Hwang,
  • Jin Yeong Song,
  • Dae Kyu Kwon,
  • Sang Min Park

摘要

This study presents an integrated engineering investigation of an Inconel 600 aircraft engine door cam spindle, focusing on manufacturing process improvement through dedicated jig design and thermo-mechanical reliability assessment under service-relevant conditions. To improve deep-hole machining stability and inspection efficiency, dedicated machining and inspection jigs were developed and applied to the production process. The redesigned process reduced the total machining time from 840 min to 666 min, corresponding to a 20.7% reduction, while the defect rate decreased from 6% to 2%. In addition, the process was successfully converted from outsourcing-dependent production to full in-house manufacturing. Dimensional and surface-quality verification of five fabricated specimens showed that all samples satisfied the specified tolerances for the slide outer diameter, cam-head outer diameter, and cam-head depth, while the average surface roughness (Ra) ranged from 0.613 to 0.712 μm, which was well below the target value of 3.2 μm. Furthermore, coordinate measurement of the deep internal bore confirmed that all five specimens satisfied the design tolerance of 0.070 mm for both bore straightness (mean: 0.040 mm) and concentricity (mean: 0.057 mm and 0.051 mm for the cam-head and slide references, respectively). To assess service reliability, thermo-mechanical and dynamic finite-element analyses were performed using a three-dimensional model based on the actual spindle geometry. The steady-state thermal analysis identified an allowable thermal limit of approximately 0.2 W/mm², corresponding to about 301 °C under air-cooled conditions. The static structural analysis confirmed safe operation with a minimum safety factor greater than 1.5 within the design load range, while the pre-stressed modal analysis revealed less than 0.7% variation in the first-mode frequency up to 20,000 RPM, indicating high dynamic stability against resonance. The thermo-structural coupled analysis further showed that, under the identical low-load condition, the maximum equivalent stress increased nearly fivefold from 34.8 MPa to 169.0 MPa when the thermal load was introduced, demonstrating that thermally induced stress governs the structural response at elevated temperature. These results show that the proposed jig-assisted process can improve manufacturability and product quality, while the finite-element analysis framework provides quantitative verification of structural reliability for high-temperature aerospace rotating components.