Transforming Aerospace Challenges into Success

Since 1935, Bell has been a pioneer in aviation. Its rotorcrafts are used not only in civilian applications but also for transportation, medical, rescue and military services. In special mission and emergency operations, these helicopters are used to deliver supplies to hard-to-reach areas and, above all, to carry out rescues in challenging situations. “We want people to know that Bell is laser focused on quality to ensure we get our customers back on the ground safely and home to their families” says Kendall. 

“When your machines last over 30 years, that’s a pretty good stamp of approval for a quality machine”, emphasises Kendall. In recent years, Bell has gradually replaced the older machines with new VX 59 models. For Kendall and his team, it was a clear decision: “Over the lifetime of the older machines, they’ve proven themselves. They lasted beyond what they were expected to.” 

One of the machinists at Bell is Scott Phillips. “I think the VX machines are very versatile. All our helicopter models from the past four decades have been fitted with gears ground on KAPP NILES machines. In recent years, most of these parts have been produced on VX 59s within the tolerances we expect.” 

The latest generation of machines are equipped with an optional zero-point clamping system. This allows set-up times for grinding spindles and additional grinding heads to be reduced by around 85 % compared with the original duration. “It speeds up the set-up time significantly. We’ve also noticed that there are no differences between operators anymore. It’s more plug-and-play.” 

One of the most significant projects was the introduction of an integrated measurement system (AMS) in the 1990s. “This project established the way we work today and has since gained broad adoption, helping to lead the aerospace industry”, Phillips explains. Arnt Lachetta, Area Sales Manager at KAPP NILES, recalls: “Bell reached out and asked for a special function on the machine to measure and document workpiece characteristics. In a close collaboration, we developed the AMS function.”

With an onboard Renishaw measuring system, AMS is used to measure multiple points along the profile and lead direction of the gear. This inspection process is performed before and after grinding. The procedure ensures that the gear surface is properly finished at every point and that excessive material is not removed from the hardened layer.

“AMS was an important development. Pretty much every gear that we grind nowadays is AMSed”, adds Phillips. “It brings reliability and significant time savings. Not just in cycle time, but by eliminating the need to move parts between machines for measurement. As we’ve been using AMS for more than 30 years, the time we saved isn’t measured in hours or days, but in months.” Due to the significant benefits of this function on VX machines, KAPP NILES has recently revised and improved it based on Bell’s requirements.

The approved production process requires the gear to be CBN-ground during the finishing cycle. “So, we came up with the idea of combining both tools”, explains Lachetta. “With our KX 500 FLEX, we found the ideal combination: rough machining is done using generating grinding, resulting in significant time savings, while finishing with CBN profile grinding wheels delivers the usual high-quality finish.”

Bell and KAPP NILES share many years of experience and a strong drive to move forward together. “Sometimes Bell comes with requirements that are challenging for us”, notes Lachetta. “These tasks push us to our limits – and beyond. This is incredibly valuable to us, as we not only support our partner, but also grow through these challenges ourselves. The fact that we are now a market leader in the aerospace sector is partly due to Bell’s requirements helping us improve.”

“We set high standards for ourselves and our products. That’s why we sometimes require special solutions”, says Kendall. “Bell does unique things, and we need a partner who truly cares. With KAPP NILES, we feel supported by a team that values our goals and growth as much as we do. We know we can rely on them, that’s why we keep coming back.”