Besides, it would have helped to see whether the French have EMALS or not, and from where they sourced the CAT's they currently have.
The U.S. Navy and the French Connection
Military pilots are a gutsy breed, regardless of which country they fly for. And carrier pilots? Well, just imagine trying to land a high-performance fighter plane on a runway the size of a football field – a constantly moving football field, no less. One that is pitching and rolling on the high seas.
In essence, it’s just controlled crashing: slam the plane down on the deck, snatch the arresting cable with the tail hook, and pray the plane stops short of the runway’s end – and a quick plunge to the ocean below. The last thing a carrier pilot wants to worry about is whether the parts for the arresting mechanism were manufactured to the proper specifications.
DCN International, the commercial arm of Direction des Constructions Navales (DCN), France’s naval shipbuilding company, is putting its final touches on construction of the 38,000 ton, nuclear-powered aircraft carrier Charles de Gaulle. Construction started in May 1994, sea trials commenced July 1998, and the ship is due to be commissioned in 2000.
The French carrier, which is approximately half the size of an American nuclear-class Nimitz carrier, is equipped with two USN Type C13 catapults, rated to launch aircraft weighing up to 22 tons at a tempo rate of one aircraft per minute. When operational, the ship will have a fleet of 40 Rafale M combat aircraft, the Super Etendard, the Hawkeye E-2C airborne early warning aircraft, and the AS 565 Panther helicopter. The de Gaulle’s manning will be approximately 1200 ship’s company and 600 air wing personnel, for a total compliment of 1800.
With aircraft launch and recovery operations scheduled for May 1999, the ship had a lot of preparation ahead. The Rafale jet had been to the Naval base at Lakehurst, NJ, for carrier suitability development in the past, and was scheduled to return to Lakehurst for support equipment integration later this year. Still, actual real time launching and arresting on a new ship presents many challenges.
Counting down weeks to go before actual at-sea tests posed an excellent time for carrier equipment experts to review the French program. During the time frame of March 22 to 24, 1999, Mr. George DiBiase and Rear Admiral Joe Dyer visited the DCN Brest naval shipyard in Brittany. They were briefed on the progress, installation and check-out of all of the ship’s subsystems. Discussions followed, allowing an exchange of information beneficial to both countries.
The French highlighted several concerns they were having with the aircraft arresting gear on their new ship. DiBiase, venerably titled “Mr. Catapult” by the French for his contributions and help in developing the de Gaulle, took a heightened interest. Most of the problems encountered with the gear probably had been experienced in the past, and if any one person has this level of knowledge, it would be the Navy’s Chief carrier engineer, George DiBiase.
The island on the de Gaulle is forward of the location used on US Navy carriers. Due to the shorter deck, the “runout” span of the arresting cable was changed from 345 feet for U.S. carriers to 320 feet for the de Gaulle. Lakehurst engineers had performed worst case analysis that indicated an E-2 aircraft with an off-center, maximum run-out arrested landing would put the E-2 Hawkeye’s nose wheel at or over the upwind end of the angle deck. Although recognized to be safe, pilot apprehension of not seeing enough deck in front of him was an issue of great concern to the French.
After the program reviews, DiBiase and Admiral Dyer were flown by helicopter from Brest to the de Gaulle at sea. While reviewing the technical data from arrestments, DiBiase concluded the constant runout valve cam was not manufactured to the proper specification for a runout of 320 feet. This cam controls the amount of runout cable permitted to arrest an aircraft. A cam that is not properly set or manufactured could cause an aircraft to go too far on an arrestment and go overboard.
Without having the proper equipment on board to measure the exact size of the suspect cam, the French sailors removed the cams from the other two arresting engines and stacked each on one another so as to visually identify differences between the cams. The French engineers concluded the cam was different, and fretted that without any spares, delivery of a new cam would take months and interfere with their upcoming sea trials. “I’ll have you a new cam by next Monday,” promised DiBiase.
With the astonished French crew nearby, DiBiase called the manufacturing department at Navy Lakehurst and ordered a specially made cam: Lakehurst part number 626664. “I’ll need that delivered to France by April 5,” DiBiase said.
The call was received by Kellie Borrero, a program manager in the manufacturing facility. The navy maintains this core capability to provide prototype manufacturing support, producibility analysis, drawing package validation and the application of new manufacturing technologies to the design, development and product verification of flight critical aircraft launch and recovery equipment and support equipment. It is also used to complete the work of contractors that default, and, when an emergency arises in the carrier fleet, respond as quickly as possible to keep the ships operational.
Lakehurst has its manufacturing department located in six different buildings. Two of the buildings, which are old dirigible hangars, house large machines for heavy machining, cutting and welding. One smaller building is used primarily for working in a concurrent engineering environment where integrated product teams can work together to design, prototype and test equipment. It is an environmentally controlled building with state-of-the-art machines, that allows engineers and technicians to share thoughts and ideas more readily than the larger hangars. Manufacturing one cam to precise measurements is an ideal task for this building.
Moments after the call on March 25, a team was assembled. Joe Delano would provide the CAD/CAM support, while Chris Arkenau would machine cut the cam. Bob Wigginton would be the quality assurance expert. “We need to take a three month schedule and compress it into nine days,” said Borrero.
A piece of 4340 pre-hardened steel was identified that was suitable for the cam. Delano and Arkenau started to transfer over 500 data points from the three prints to the computer, using Mastercam software. Mike Buppert from the producibility group developed a manufacturing process for manufacturing fixtures, jigs and test specimens. With the process plans agreed to, Delano wrote 18 software programs, some with more than 2700 lines of code, that would shape a blank piece of steel into the heart of a carrier’s arresting engine. The machine assigned to tackle the job was a Haas VF-4 vertical machining center. “Although the programs were large, the Haas VF-4 is user friendly and can easily receive programs from other computers, store in memory and execute these programs when required,” said Arkenau.
Kellie Borrero, program manager, gets a perfect view of the French cam as it is machined on the Haas VF-4. The cam is for one of the arresting engines on the aircraft carrier Charles de Gaulle.
According to Joe Delano there wasn’t anything easy about this. “When you get a part like this that has incredibly tight tolerances measured to one thousandth of an inch, you have to think everything through. Fixtures, tools, gauges all have to be perfect. You plan everything, and then you keep going through in your mind how it will work. Every working moment, until the cam is finished, you’re thinking about it.”
The team members, who had never made a cam of this size before, all agreed this was a “ten” on a scale of one to ten for determining complexity. “When you envision a cam, you think of a small gear. But there is nothing small about this cam, which begins with a blank piece of steel weighing more than 60 pounds, and the final weight is 40 pounds,” declared Arkenau. “It is not the kind of task you wish for, especially because of the tight schedule. But that is what we are here for, to solve fleet problems. If anyone can make critical ship items within these tight schedules, it’s us here at Lakehurst,” said Wigginton. “We are the heart of Naval aviation.”
Listening to Delano and Arkenau explain the manufacturing steps helps understand why management refers to these employees as artisans. “You have to sneak up on the last cut of the transitional surface in order to hold a 63 profiled finish,” quipped Delano, referring to the almost mirror like surface on the final cam which was achieved by using a 1 1 / 2" inserted carbide endmill. “We came up with a novel way to position pre-located and measured spindles to let us know how close we were to the final desired width,” uttered Arkenau.
Borrero prepared a detailed program plan identifying all of the steps necessary to complete the job, from obtaining the raw material to final check-out. Each step was assigned a time measure in order to provide instant recognition of each stage of completion. “I wanted to be prepared to respond to the U.S. Navy and French government if any programmatic questions were raised,” expressed Borrero.
But no questions were forthcoming. Arkenau and Delano surpassed even the most optimistic schedule, and by Friday afternoon, April 2, Wigginton was dimensionally inspecting over 300 data points on the cam. “I’ve inspected a lot of cams in my lifetime, and this was the finest cam I ever saw,” said Wigginton.
The cam was prepared for shipping and sent to France on Easter Sunday.
“It is not the kind of call you like to receive; however, it demonstrates how absolutely critical Navy Lakehurst is to maintaining the fleet and military readiness. Whether it is a supply systems shortage, contractor default or fleet emergency, we are here to respond. It is nice to see our capability being extended to other countries that have a strategic relationship with the U.S.,” said Rich Headley, manager of the prototyping and manufacturing department.
“The Navy launches $60 million airplanes off its carriers every day, every night and regardless of the weather conditions. These aviators have to know that the equipment that launches them, and the equipment that catches them after their sortie, will do its job. This is accomplished by designing and making equipment correctly every single time. We at Navy Lakehurst take great pride in our people and work. But our people are only half of the equation. It takes great equipment like Haas to complete the job.” — Mark Gindele
Mark Gindele is the manager in charge of quality assurance and material for prototyping and manufacturing at the Naval Air Warfare Center, Aircraft Division, in Lakehurst, New Jersey.