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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

METAL REMOVAL PROCEDURES


AND LIMITATIONS
Contract Number F33657-88-C-O037

Releasability of this material under the Freedom of


Information Act is subject to the restrictions on release in
DoD Regulation 5400.7-R and DoD Directive 5230.25.
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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

METAL REMOVAL PROCEDURES


AND LIMITATIONS

Prepared and Approved By:


.,, . -,, .- ..

/wfk’’tlL/ —
.——
S. B. Klehl, Chief
Structural and Environment
Materials & Processes
LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

CHANGE INDEX

Revision “E” incorporates the requirements of amendments 1 through 9. The only new requirement is the
addition of 3.8.5, which defines allowable anodize clamp marks.

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-30170

I AtILt Ul_ GUN 1 ENTS

Para Page
1 SCOPE 1
1.1 REQUIREMENTS 1
1.2 LIMITATIONS 1
2 APPLICABLE DOCUMENTS 1
2.1 MILITARY SPECIFICATIONS 1
2.2 LFWC SPECIFICATIONS 1
3 REQUIREMENTS 2
3.1 RAW STOCK CLEANUP 2
3.1.1 Removal of Mill Decarburization 2
3.1.2 Removal of Mill Skin from Titanium, 10 Nickel, and PH/CRES Alloy Products 2
3.1.3 Removal of Mill Skin from Aluminum 2
3.1.4 Skin Milling Parameters 2
3.2 INITIAL CUITING OPERATION 2
3.2.1 Flame Cutting 2
3.2.2 Abrasive Cutting 2
3.2.3 Friction Sawing 2
3:2.4 Circular Sawing 3
3.2.5 Laser Cutting 3
3.2.6 Electrical Discharge Machining (EDM) 3
3,2.7 Plasma Arc Machining (PAM) 3
3.2.8 Abrasive Water Jet Cutting 3
3.2.9 Aluminum Hand Forgings 3
3.2.10 Matte Finishing of Aluminum Parts 3
3.2.11 Machining Of Fully Heat Treated Alloy And Carbon Steel Parts 3
3.3 GRINDING 3
3.3.1 Grinding of Steel Parts 3
3.3.2 Grinding of Chromium Plated Low Alloy Steel Parts 3
3.3.3 Grinding of Titanium Parts 3
3.4 BENCH WORKING OF METAL PARTS 4
3.4.1 Deburring of Metal Parts 4
3.4.2 Hand and Power Tools 4
3.5 HOLE PREPARATION 4
3.5.1 High Strength Steel 4
3.5.2 Chamfering and Spot Facing 4
3.5.3 Close Tolerance Holes 4
3.6 HOLE DEBURRING 4
3.6.1 Fastener Holes in Aluminum 4
3.6.2 Fastener Holes in Metals Other Than Aluminum 5
3.6.3 Non-fastener Holes 5
3.7 CORNER RADII 5
3.8 SURFACE INTEGRITY 5
3.8.1 I Surfac& lntegrityForNon~FatiguwArrd-Nom-Fracture Critical Parts 5
3;8.2 Surface Integrity For Fatigue And Fracture Critical Parts 5
3.8.3 Surface Integrity For Holes 5
3.8.4 MOO1 5
3.8.5 Anodize Clamp Marks 5
3.9 MATERIALS HANDLING 5
3.9.1 Corrosion Protection 5
3.10 COOLANTS 6

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

TABLE OF CONTENTS

Para Page
4 QUALITY REQUIREMENTS 6
4.1 PARTQUALITYAND lNTEGRllV 6
4.2 SURFACEINTEGRITY 6
4.3 DIMENSIONALTOLERANCES 6
4.4 EXAMINATION 6
5 PREPARATION FOR DELlVERY 6
6 ACKNOWLEDGEMENT 6
7 REJECTIONS 6
8 NOTES 6
8.1 EDGE 6
8.2 CORNER 6
8.3 EDGE BREAK 6
8.4 CLOSE TOLERANCE HOLE 6
8.5 FASTENER HOLE 6
8..6 CHIPLOADFORMULA 6
9 ENVIRONMENTAL HEALTH AND SAFETY 7

LIST OF FIGURES

Figure Page
1 Polishing Requirements Around the Mold Line of Formed Sheet Metal 7

LIST OF TABLES

Table Page
1A Mill Decarburization Removal Amounts 8
IB Titanium Mill Skin Removal Amounts 8
Ic 10 Nickel and CRES Mill Skin Removal Amounts 9
11A Minimum Material Removal After .Flame Cutting ,, . 9
IIB Recommended Flame Cutting Speeds 9
[11A Abrasively Cut Surface Layer Removal 10
IIIB Recommended Abrasive Blades and Cutting Speeds 10
Iv Maximum Feeds for Grinding Titanium Parts 10

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LOCKHEED FPS-3017E
FortWorthCompany Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

METAL REMOVAL PROCEDURES


AND LIMITATIONS

1 SCOPE
1. REQUIREMENTS - This specification establishes the requirements for metallurgically damage-
free and acceptable surfaces on metallic parts and components from which metal is removed bv. anv. of the
common metal removal methods.
1.2 LIMITATIONS - This specification does not cover chemical machining methods. Refer to FPS-
1051 and M039 for chemical milling requirements.

2 APPLICABLE DOCUMENTS - The following publications shall be applicable to the


extent specified herein, or as defined in the contract or purchase order. These publications shall be the
revision listed in 16PR711, except in cases where a particular revision is specified in this specification.
Compliance with any other issues of these publications requires prior written approval from LOCKHEED
Fort Worth Company (LFWC) Materials and Processes Technology (M&PT). If any of the publications
referred to herein conflict with the requirements of this specification, this specification shall govern.

2.1 MILITARY SPECIFICATIONS - Available from Commanding Officer, Naval Publications and
Forms Center, 5801 Tabor Avenue, Philadelphia, PA 19120.

MI L-P-3420 Packaging Materials, Volatile Corrosion Inhibitor, Treated, Opaque

MlL-C-l6173 cOrrOSiOt_I PfWE?ntiVe Compound, Solvent Cutback, Cold


Application

2.2 LFWC SPECIFICATIONS - Available from LFWC Service Library, P. O. Box 748, MZ 1519, Fort
Worth, TX 76101.

FPS-1051 Chemical Milling of Metals

FPS-1089 Grinding of Steel Parts and Chromium Plated Steel Parts Heat
Treated to 180,000 psi and Over

FPS-1 098 Drilling and Reaming of Alloy Steel Parts Heat Treated to 180,000
psi and Above

FPS-3014 Heat Treatment of Steels (Aerospace Practice, Process For)


FPS-3018 Forming of Aluminum Alloys
“FPS=3086 ‘“ ‘ ‘ Composite?vtachining Procedures and” Requirements
FQPL-3017 Fort Worth Division Qualified Material List for FPS-3017

NDTS 9111 Nital Etch Inspection

M039 Dynamic Etch Process, Aluminum Alloy Roughness and Radius


Tolerances For

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

MOOI Surface Roughness and Tolerances for Machined Surfaces

M333 Installation of Bushings, Interference Fit

16 PR711 F-1 6 Materials Procurement and Processing Specifications


Applicable Issues

3 REQUIREMENTS
3.1 RAW STOCK CLEANUP - The surface finish after skin milling shall be 125 RMS maximum.
3.1.1 REMOVAL OF MILL DECARBURIZATION - Carbon and alloy steels shall have all hot worked
surfaces machined to remove mill decarburization, unless otherwise specified on the engineering
drawing. Refer to Table 1A for material removal amounts. This requirement is not applicable to 10 Nickel
(HY 180) steels.
3.1.2 REMOVAL OF MILL SKIN FROM TITANIUM, 10 NICKEL, AND PH/CRES ALLOY PRODUCTS -
Material not deskinned at the mill shall be machined to remove oxide, scale, or contaminated skin before
the surface is in a satisfactory condition for use as the surface of a finished part. Titanium products maybe
chemical milled per FPS-1 051 in lieu of machining. Refer to Table IB for titanium material removal amounts
and Table IC for PH/CRES and 10 Nickel removal amounts. A286 and 300 Series stainless steels are
excluded from this requirement.
3.1.3 REMOVAL OF MILL SKIN FROM ALUMINUM - When skin milling aluminum, proper speeds and
feeds shall be maintained in order to achieve a chip load of .006 -.01 O“, with a preferred chip load of .008 -
.010”. Refer to paragraph 8.6 for instructions on determining chip load. Cutters used for skin milling must
have a positive axial rake angle and a positive radial rake angle for their cutters/inserts. In addition, the skin
milling operation must be run with coolant or microlube.
3.1.4 SKIN MILLING PARAMETERS - If only one side of a billet is required to be skin milled, the
amount of material removed shall not exceed 0.249. If the amount of material to be removed is 0.250” or
greater, equal amounts are to be machined from both sides. When only one side is to be skin milled but
the material size has been substituted with a thicker material, equal amounts shall be removed from both
sides until the final thickness is achieved.
3.2 INITIAL CUTTING OPERATION - Initial cutting operations such as flame cutting, abrasive
cutting, bandsawing, friction sawing, circular sawing, laser cutting, plasma arc machining (PAM), electrical
discharge machining (EDM), and abrasive water jet cutting are permitted provided that either a damage
free surface is maintained or the damaged surface layer is subsequently removed, unless otherwise
stated on the engineering drawing.
3.2.1 FLAME CUTTING - Steel with carbon content greater than .30% and all low alloy steels maybe
preheated at 500 ‘F* 25 ‘F prior to flame cutting to reduce cracking. After flame cutting, these materials
shall be stress relieved per FPS-3014 at 1175 ‘F* 25 “F for a minimum of 2 hours. When flame cutting 10
Nickel steel in section thicknesses greater than 2 inches, the material shall be preheated to 250 “F*50“F
prior to cutting. Refer to Table IIB for recommended cutting speeds. Do not flame cut aluminum. After
flame cutting, the damaged surface layer must be removed per Table II IA.
3.2.2 ABRASIVE -CU?77NG - Materia+-whict?is abrasively-cut must tiavethe damaged surface layer
removed per Table II 1A. Alloy steels which are subsequently hardened and tempered may be stress
relieved per FPS-3014 at 1175 “F * 25 “F for a minimum of 2 hours after abrasive cutting in lieu of the
surface removal requirements. Refer to Table IIIB for recommended blades and cutting speeds.
3.2.3 FRICTION SAWING - Friction sawing is not recommended for aluminum due to its high thermal
conductivity. Friction sawing is also not recommended for material greater than 1/2” in thickness due to
inadequate softening of the workpiece during the cutting operation.

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LOCKHEED FPS-3017E
FortWorthCompany Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

3.2.4 CIRCULAR SAWING - Circular sawing is not recommended for steel or titanium products due to
the slow cutting speeds which are required.
3.2.5 LASER CUTTING - Laser cutting is permitted for all alloys. A minimum of 0.01 O“ shall be
removed from all laser cut surfaces to ensure removal of the recast zone, the heat affected zone, and the
microcracks caused by the laser cutting. If the laser cut surfaces are to be subsequently welded, metal
removal after laser cutting is not required. Company specific deviations to the minimum metal removal after
laser cutting may be allowed as follows

(a) Manufacture specimens from (1) 2024-T3, T62, or T81, (2) titanium representative
of any titanium cut, (3) carbon steel representative of any carbon steel cut, and (4)
stainless steel representative of any stainless steel cut. Two specimens from each
material must be used. One specimen must be a cut edge, the other must be a cut
hole. After cutting, NO additional work may be preformed, i.e., deburring, polishing,
buffing. The specimens can be any convenient size or thickness, as long as they
can be sectioned and analyzed.

(b) The specimens must be submitted to an independent laboratory to determine the


thickness of the recast zone and the heat affected zone. A report, including original
photographs at 100X minimum, must be submitted to LFWC M&PT for analysis.
3.2.6 ELECTRICAL DISCHARGE MACHINING (EDM) - EDM is permitted for all alloys. A minimum of
0.01 0!’ shall be removed from all EDM cut surfaces to ensure removal of the recast zone, the heat affected
zone, and the microcracks caused by the EDM.
3.2.7 PLASMA ARC MACHINING (PAM) - PAM is permitted for all alloys. A minimum of 0.010” shall be
removed from all PAM cut surfaces to ensure removal of the recast zone, the heat affected zone, and the
microcracks caused by PAM.
3.2.8 ABRASIVE WATER JET CUTTING - Abrasive water jet cutting shall not cause any material
degradation.
3.2.9 ALUMINUM HAND FORGINGS - When machining fully heat treated/aged aluminum hand
forgings, care must be taken to minimize warpage. Parts shall not be finish machined on one side before
starting on the other.
3.2.10 MATTE FINISHING OF ALUMINUM PARTS - Machined aluminum parts which are not fracture
critical may be matte finished by the wet abrasive blasthlurry method. Wet abrasive blasthlurry systems
shall not cause any material degradation.
3.2.11 MACHINING OF FULLY HEAT TREATED ALLOY AND CARBON STEEL PARTS - Alloy and
carbon steels heat treated to Ftu = 180 ksi and over which are machined in the fully heat treated condition,
shall be nital etch inspected for burns per NDTS 9111 and baked at 50”F below the tempering
temperature for a minimum of two hours perFPS-3014.
3.3 GRINDING
3.3.1 GRINDING OF STEEL PARTS - Alloy or carbon steels heat treated to Ftu = 180 ksi and over
shall be ground per the procedures of FPS-1 089. If the material is in the fully heat treated condition, Ftu =
180 ksi and above, it shall be nital etch inspected for~rinder burns per NDTS 9111. 10 Nickel, PH Steels,
maraging steels, and alloy or carbon steel heat treated to less than 180 ksi are excluded from this
requirement.
3.3.2 GRINDING OF CHROMIUM PLATED LOW ALLOY STEEL PARTS - Grinding of chrome plated
low alloy steel parts heat treated to 180 ksi and above shall be performed per FPS-1 089.
3.3.3 GRINDING OF TITANIUM PARTS - Low stress grinding shall be performed on the last 0.010” of
material on exterior surfaces and the last 0.005” of material on internal cylindrical surfaces (0.01 O“ on the
internal diameter). Maximum feeds shall be per Table IV. All parts shall be visually checked for overheating

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LOCKHEED FPS-3017E ~
Fort Worth Company Date: 17 Januaty 1995
FSCM 81755 Superseding: FPS-3017D

after grinding. Parts which are bright silver, gold, or light blue are acceptable. All other colors shall be
cause for rejection.
3.4 BENCH WORKING OF METAL PARTS
3.4.1 DEBURRING OF METAL PARTS - Parts shall be deburred to eliminate sharp edges and
projections. It is unnecessary to deburr for cosmetic purposes only. Surface integrity shall be per
paragraph 3.8.
3.4.1.1 Parts which utilize an automatic sheet deburrer do not require the edges broken if they will be
broken in subsequent operations. However, if the sheet deburrer is used as the final operation, the
edges must meet the requirements of paragraph 3.4.1.
3.4.1.2 When planning specifies the use of vibratory deburr, hand deburring may be substituted. If
the planning specifies hand deburring, vibratory deburring may be substituted provided that the part
meets engineering drawing requirements. Special care must be exercised when vibratoty deburring parts
under .050” thick, parts in the annealed condition, or long, thin parts without stiffeners due to the risk of
deformation. It is recommended that parts not be run in the vibratoty deburring/finishing media longer
than 45 minutes due to work hardening effects. After removal, the parts shall be thoroughly rinsed and
dryed.
3.4.1.3 Sheet metal which is punched, blanked, or pierced shall be polished to remove smeared
metal where the mold line intersects a net edge of the part, see Figure 1. The polished area shall extend
to approximately 1/2” of either side of the mold line.
3.4.2 HAND AND POWER TOOLS - Hand and power tools may be used in the removal of minor flaws,
over tolerance areas, and surface marks which have been machined, ground, or them milled to drawing
dimensions. Scraping, filing, or grinding should be accomplished using gentle passes all in the same
direction, preferably the direction of grain flow. It is not necessary to blend two intersecting surfaces
unless the intersecting radius is less than 0.060”. Do not use scrapers on high strength steel parts. Do
not hand grind using stone grinding wheels or arbor mounted stones. Planned excess metal removal
during installation shall be accomplished by course grinding or sanding, tool routing, sawing, or using a
hand held shear. A 120 or coarser grit shall be used to avoid overheating. The part must remain within
blueprint tolerances after metal removal.
3.5 HOLE PREPARATION - Holes may be prepared by using methods such as reaming, boring,
honing, burnishing, and grinding. If drawing requirements can be met, the drilling of holes maybe used as
a finish machining operation. Regardless of tool type, the tool shall be kept rotating during withdrawal. A
withdrawal rate of less than one inch/second is preferred. When machining through both metal and
composites, refer to FPS-3086 for composites machining procedures and requirements.
3.5.1 HIGH STRENGTH STEEL - Preparation of fastener holes in steel heat treated to 180 ksi and
above shall be per FPS-1 098. Precipitation hardening steel and 10 Nickel are excluded from this
requirement.
3.5.2 CHAMFERING AND SPOT FACING - Oversize drills shall not be used for chamfering with hand
power tools. Adequate tooling shall be used for chamfering and spot facing.
3.5.3 CLOSE TOLERANCE HOLES - Metal removal for close tolerance holes used for bearing and
bushing applications shall. follow
, .the provisions
,, of this specification and M333.
3.6 HOLE DEBURRING - When deburring non-bonded stacks of metal, the stacks shall be
disassembled for hole deburring unless otherwise specified on the engineering drawing. Peel shim shall
not be deburred prior to assembly.
3.6.1 FASTENER HOLES IN ALUMINUM - Fastener holes in aluminum do not require deburring
unless specified on the engineering drawing, when required for fit or function, or if sharp burrs or
protrusions exist.

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

3.6.2 FASTENER HOLES IN METALS OTHER THAN ALUMINUM - Holes shall bedeburredto0.015“
chamfer maximum, unless otherwise specified on the engineering drawing. A radiusing tool may be used
when entrance and exit surfaces are normal within 2° to the hole. Otherwise, deburring shall be
accomplished by hand.
3.6.3 NON-FASTENER HOLES - All hole edges shall be chamfered or radius deburred, unless
otherwise specified on the engineering drawing. I
3.7 CORNER RADII - Undimensioned corners, both internal and external, on air surface skins shall
be square. On internal skins, the radii for undimensioned external corners for both hand routed and
machine routed aluminum sheet metal parts shall be .25” maximum. For parts produced on blanking dies,
permissible radii on external corners is 0.12“ maximum and on internal corners is 0.15“ maximum. A
dimensioned corner is a corner having a specified radius.
3.8 S U R F A C E I N T E G R I T Y
3.8.1 SURFACE lNTEGRllY FOR NON-FATIGUE AND NON-FRACTURE CRITICAL PARTS- Surface
marks do not need to be removed unless they are greater in depth than 10% of the material thickness,
.004” maximum.
3.8.2 SURFACE INTEGRITY FOR FATIGUE AND FRACTURE CRITICAL PARTS- Surface marks
which are discernible by touch shall be rejected. A fingernail or a plastic indicator shall be used to
determine the presence of a rejectable surface mark. A surface mark which is visible but cannot be
physically felt is acceptable.
I
3.8.3 SURFACE INTEGRITY FOR HOLES - Unless otherwise specified on the drawing, hole integrity
in parts and assemblies shall be verified as follows:

(1) Visually examine for processing flaws such as axial and spiral tool marks.

(2) Any visible flaw which cannot be physically felt is acceptable.

(3) Axial flaws which can be felt shall be rejected. Spiral or circumferential flaws
which can be felt shall be compared to a surface roughness comparator.
Spiral or circumferential flaws which compare to a surface finish of 125 RMS or
smoother are acceptable.

3.8.4 MOOI - MOOI defines the limits to which machined sutface roughness and mismatches may be
permitted in order to minimize hand finishing on machined parts, and is applicable when specifically called
out on engineering drawings.
I
3.8.5 ANODIZE CLAMP MARKS - Anodize clamp marks are excluded from the requirements of
Paragraph 3.8. For machined parts, anodize clamp marks shall meet the requirements of MOOI, with a
maximum depth per side of .004”. For formed parts, anodize clamp marks shall meet the thinning
requirements of FPS-3018.
3.9 MATERIALS HANDLING - Care shall be taken to avoid damage to materials and parts during
storage, work, and transportation. Parts shall not be left on machines covered with residual coolant when
not running for longer than 2.days without being removed-and cleaned. In addition, all parts shall be
cleaned after machining. Cleaning shall be accomplished by a parts washer, alkaline cleaning, or caustic
etch.
3.9.1 CORROSION PROTECTION - After machining, and during transportation and storage, parts
shall be protected from atmospheric corrosion. Paper or plastic may be used to cover the parts. In
addition, MIL-P-3420 vapor phase inhibiting (VPI) paper maybe used on aluminum and either MIL-P-3420
VPI paper or Ml L-C-l 6173, Grades 2 or 3 Oil may be used on non-corrosion resistant steel. Do not use
MIL-P-3420 to protect cadmium plated surfaces.

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

3.10 COOLANTS - Coolants shall be used during all machining operations on steel and titanium
products and when necessary to prevent overheating when machining aluminum. Coolant is
recommended for machining aluminum. Coolants shall not cause pitting, corrosion, or staining of I
machined parts. Coolants shall be cleaned from parts per 3.9. Water soluble cutting fluids shall be
maintained at a ratio of 1 part concentrate to 30 parts or less water. Deionized water or distilled water may
be used. Clean tap water is permissible when machining steel or aluminum.

4 QUALITY REQUIREMENTS
4.1 PART QUALITY AND INTEGRITY- Machining practices shall not induce metallurgical
degradation to the metal surface. Surfaces shall not exhibit visual evidence of overheating, shall not be
smeared or galled, and shall be visually free from contamination and defects. I
4.2 SURFACE INTEGRITY - Surface roughness shall be in accordance with the drawing callout.
When surface roughness is not specified on the drawing, machined parts roughness shall be 250 AA
maximum. The length of the surface roughness measurement taken shall be 0.03 minimum, unless
otherwise specified on the face of the drawing. Surface marks and edges shall meet the requirements of
paragraph 3.8.
4.3 D I M E N S I O N A L T O L E R A N C E S - Parts shall meet the dimensional tolerances of the
engineering drawing.
4.4 EXAMINATION - One of the first five parts produced when establishing a new, fixed set of
machining parameters shall be checked and meet the requirements of paragraphs 4.1, 4.2, and 4.3. This
examination shall be repeated after significant changes in machining parameters.

5 PREPARATION FOR DELlVERY - This section is not applicable to this specification.

6 ACKNOWLEDGEMENT - A vendor shall mention this specification number and its


revision letter in all quotations and when acknowledging purchase orders.

7 REJECTIONS - Product not conforming to this specification, or to modifications authorized


by the purchaser, will be subject to rejection.

8 NOTES
8.1 EDGE - The edge is the intersection of two surfaces.
8.2 CORNER - The corner is the intersection of three or more surfaces.
8.3 EDGE BREAK - An edge break is the amount of material removed from the theoretical
intersection of two surfaces. This may be chamfered or radiused. The chamfer shall be burr free.
8.4 CLOSE TOLERANCE HOLE - A close tolerance hole is one with tolerances equal to or less
than A .002”. . ..:- .>
8.5 FASTENER HOLE - A fastener hole is a hole which any type of fastener goes in including, but
not limited to, bolts, screws, rivets, and blind rivets.
8.6 CHIPLOAD FORMULA - The formula for computing the chipload is as follows:
(1) Chipload = Inch Per Inserl
(2) Number Of Inserts= Number Of Inserts In Face Mill Or Number Of Flutes Per Endmill

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

(3) Table Feed Rate = Inches Per Minute


(4) Inch Per Insert X Number Of Inserts X RPM= Table Feed Rate
(5) RPM = Spindle Speed

9 ENVIRONMENTAL HEALTH AND SAFETY - Appropriate persona] protective


equipment is required when melting, forging, machining, forming, or otherwise processing metals. The
nature of the processing activity will determine what equipment is necessary, i.e., glasses, respirator,
protective clothing, and/or ear protection. Contact an occupational health professional to make the
appropriate determination.

Deburred Area

I 1/2” I 1/2” I
FIGURE 1: Polishing Requirements Around the Mold Line of Formed Sheet Metal

.. ,. ..- .,

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

TABLE 1A: Mill Decarburization Removal Amounts

NOMINAL DIAMETER OR MAXIMUM MINIMUM AMOUNT OF STOCK


DISTANCE BETWEEN OPPOSITE FACES REMOVAL FROM EACH SURFACE
t c .188” None
.188” 5 t c .250” .010”

.250” s t < .375” .015”


.375” s t < .500” ,020”
.500” < t c .625” .025”
.625” < t < 1,00” .030”
1.00” < t c 2.00” .055”
2.00” s t < 3.00” .070”
I 3.00” s t c 4.00” I .085” I
4.00” s t < 5.00” .115”
t > 5.()()” .150”

TABLE IB: Titanium Mill Skin Removal Amounts

MINIMUM AMOUNT OF STOCK


PRODUCT
REMOVAL FROM SURFACE
Forged Bar and Billet .040”
Hot Rolled Bar .030” I
Condition “A” Piate .020” I
Condition “RA” Plate .025”
Condition “Beta Annealed” Plate .025”
Extrusions .015”
Die and Hand Forgings .040”
No. 2D Surface Finish Sheet &-Plate Not Required

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LOCKHEED FPS-3017E
FortWorth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

TABLE IC: 10 Nickel and CRES Mill Skin Removal Amounts

MINIMUM AMOUNT OF STOCK


PRODUCT REMOVAL FROM SURFACE
Forged Bar, Billet, and Hand Forgings .040”
I Hot Rolled Bar and Plate I .030” I
Extrusions Per Engineering Drawing
Die Forgings Per Engineering Drawing

I No. 2D Surface Finish Sheet & Plate I No Removal Required

TABLE 11A: Minimum Material Removal After Flame Cutting

MATERIAL MINIMUM CLEANUP A~ER FLAME CUTTING


THICKNESS 10 NICKEL STEEL TITANIUM
t c 1.00” .15” .15” .15”
1.00” < t < 2.00” .20” .20” .20”
2.00” <t s 7.00” .40” .25” .30”

TABLE IIB: Recommended Flame Cutting Speeds

MATERIAL CUITING SPEED


MATERIAL
THICKNESS (lN./MlN.)
3“ 33 - 36
4“ 30 - 33
Titanium
5“ 27 - 30
6“ - 7“ 20 - 27
3“ 6 - 6.5

10 Nickel

~
, ,, 14 - 20
2“ 10 - 14
Steel
4“ 7-12
6,, - 7,, 5 - 8

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LOCKHEED FPS-3017E
Fort Worth Company Date: 17 January 1995
FSCM 81755 Superseding: FPS-3017D

TABLE IIIA: Abrasively Cut Surface Layer Removal

I MINIMUM CLEANUP AHER


MAXIMUM MATERIAL
THICKNESS
l%??=

t < 1.00” .10” .15”


1.00” s t c 2.00” .15” .20”
I 2.00” s t < 3.00” I .20” I .30” I

I 3.00” < t s 7.00” I .25” I .30”


I

TABLE IIIB: Recommended Abrasive Blades and Cutting Speeds

WHEEL SPEED
MATERIAL BIADE TYPE (RPM)

Steel Aluminum Oxide 5500 - 6500


Titanium Silicon Carbide 3000 - 6000

TABLE IV: Maximum Feeds for Grinding Titanium Parts

PASS
EXTERIOR
SURFACES
INTERIOR CYLINDRICAL
SURFACES I
I Initial Low I .001” per Pass to Within .0005” per Pass to Within I
Stress Passes .002” of Finish Surface .002” of Finish Surface
3 Passes @! .0004”
Finishing Low 4 Passes @ .0002” 10 Passes @ .0002”
Stress Passes Final Pass with No Feed
Final Pass with No Feed
I I I I

10
LOCKHEED MARTIN Amendment 1 to FPS-3017E
Tactical Aircraft Systems Date: 9 September 1999
FSCM 81755

AMENDMENT 1 TO
FPS 3017E

METAL REMOVAL PROCEDURES


AND LIMITATIONS

Releasability of this material under the Freedom of Information Act is subject to the restrictions
on release in DoD Regulation 5400.7R and DoD Directive 5230.25.
LOCKHEED MARTIN Amendment 1 to FPS-3017E
Tactical Aircraft Systems Date: 9 September 1999
FSCM 81755

This amendment incorporates and supersedes all previous amendments. This amendment forms a part
of and shall be attached to Lockheed Martin Tactical Aircraft Systems Specification FPS-3017, Metal
Removal Procedures and Limitations, dated 17 January, 1995. This amendment is effective
immediately upon issuance.

Paragraph

1.3 Change: Add the following new paragraph 1.3:

1.3 ALUMINUM-LITHIUM ALLOYS


Aluminum-Lithium (Al-Li) alloys are aluminum-based alloys such as FMS-4097
which contain intentional additions of lithium above 0.15% by weight.
Requirements for metal removal of Al-Li alloys are identical to those for
conventional aluminum alloys, EXCEPT WHERE OTHERWISE NOTED
HEREIN.
Reason: To define Al-Li alloys as used in this document.

3.1.3 Change: Add the following new sentence to the end of paragraph 3.1.3:
Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9,
Materials Handling.
Reason: To highlight the requirements for scrap segregation of Al-Li alloys.

3.2 Change: Add the following new sentence to the end of paragraph 3.2:
Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9,
Materials Handling.
Reason: To highlight the requirements for scrap segregation of Al-Li alloys.

3.2.1 Change: Add the word “alloys” to the next-to-the-last sentence of paragraph 3.2.1, so that
the sentence reads:
Do not flame cut aluminum alloys.
Reason: To affirm that no aluminum alloys shall be flame cut.

3.2.3 Change: Add the following new sentence immediately after the first sentence of
paragraph 3.2.1:
Friction sawing shall not be performed on Al-Li alloys.
Reason: To disallow friction sawing of Al-Li alloys.

3.2.5 Change: Add the words “except Al-Li alloys” to the first sentence of paragraph 3.2.5, so
that the sentence reads:
Laser cutting is permitted for all alloys except Al-Li alloys.
Reason: To disallow laser cutting of Al-Li alloys.

3.2.7 Change: Add the words “except Al-Li alloys” to the first sentence of paragraph 3.2.7, so
that the sentence reads:
PAM is permitted for all alloys except Al-Li alloys.
Reason: To disallow plasma arc machining of Al-Li alloys.

1
LOCKHEED MARTIN Amendment 1 to FPS-3017E
Tactical Aircraft Systems Date: 9 September 1999
FSCM 81755

2
LOCKHEED MARTIN Amendment 1 to FPS-3017E
Tactical Aircraft Systems Date: 9 September 1999
FSCM 81755

3.4.1 Change: Add the highlighted clause to the end of the first sentence of paragraph 3.4.1:
Parts shall be deburred to eliminate sharp edges and projections so that injury to
personnel and damage to equipment are prevented.
Reason: To clarify the intent of sharp edge/projection elimination.

3.4.1 Change: Add the following new sentence to the end of paragraph 3.4.1:
Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9,
Materials Handling.
Reason: To highlight the requirements for scrap segregation of Al-Li alloys.

3.5 Change: Add the following new sentence to the end of paragraph 3.5:
Scrap segregation requirements for Al-Li alloys are detailed in Section 3.9,
Materials Handling.
Reason: To highlight the requirements for scrap segregation of Al-Li alloys.

3.6.1 Change: Add the word “alloys” after “aluminum” in the first sentence of paragraph 3.6.1,
so that the sentence reads:
Fastener holes in aluminum alloys do not require deburring unless specified on
the engineering drawing, when required for fit or function, or if sharp burrs or
protrusions exist.
Reason: To clarify deburring requirements.

3.8.2 Change: Add the clause “typically greater than 0.001” deep on the bare metal” after
“touch” and add 3.8.2.1 so that the paragraph(s) read:
3.8.2 SURFACE INTEGRITY FOR FATIGUE AND FRACTURE CRITICAL
PARTS
Surface marks which are discernible by touch (typically greater than 0.001”
deep) on the bare metal shall be rejected. A fingernail or a plastic indicator shall
be used to determine the presence of a rejectable surface mark. A surface mark
which is visible but cannot be physically felt is acceptable.

3.8.2.1 Surface Integrity for Painted Fatigue and Fracture Critical Parts
When it is questionable on a painted surface whether a surface mark extends
into the metal, the paint and prime shall be removed from the area with fine
abrasive (e.g., "scotch-brite") by hand. A rejectable condition exists, if the
surface mark is discernible by touch on the bare metal. If the surface mark
extends only into the paint, a non-conformance does not exist. Touch-up and re-
apply prime and paint per the appropriate finish code elements.
Reason: To clarify how “surface marks” should be handled.

3.9.2 Change: Add the following new paragraph 3.9.2:


3.9.2 SCRAP SEGREGATION OF AL-LI ALLOYS
Scrap classified as solids, turnings, and borings where large amounts of scrap
material are generated shall be segregated from conventional aluminum alloy
scrap. Scrap classified as floor sweepings from bench working, drilling, or
assembly where scrap contamination typically occurs, does not require
segregation from conventional aluminum alloys.

3
LOCKHEED MARTIN Amendment 1 to FPS-3017E
Tactical Aircraft Systems Date: 9 September 1999
FSCM 81755

Reason: To highlight the requirements for scrap segregation of Al-Li alloys.

PREPARED BY: APPROVED BY:

_M. L. Polley____________ L. K. Austin________________


M. L. Polley L. K. Austin
F-16 Systems Engineering F-16 Systems Engineering
Materials and Processes Materials and Processes