AERO-ENGINES I PISTON PRODUCTION
Cosworth to produce forged
pistons at competitive rates for
a much broader range of niche
applications.
The fully automated piston line
it intends to use for the job is
made up of two sets of Takisawa
TC-200CM CNC lathes with
driven tools, a Takisawa MAC-V40
vertical machining centre and a
Takisawa TPS-3400 elliptical and
round profile turning and grooving
machine.
Each machine will have a CNC
overhead gantry loader to load/
unload, a transfer station will be
positioned between each machine
Lycoming IO-540 engine | Powering high performance unlimited-class aerobatic aircraft
to allow each gantry loader to
output a piston and then the next machine’s gantry loader will small and large volume piston producers use Takisawa, not
collect the piston ready to load it for the next process. Also only for elliptical turning on the TPS series of machines
included is a washing station and a weight measuring station but with our ongoing development, we have solutions for
which will record the piston weight, calculate how much more round and elliptical gudgeon pin bores and piston ring
material to remove to ensure the piston is within the weight profile machining. There are many users worldwide and most
tolerance of 9 grams when the machining process is finished. Formula One, Indycar and Nascar pistons are produced on
The line will be delivered as a full turnkey package for four our machines.” ❙
different pistons, included will be all necessary cutting tools, www.takisawauk.com
work holding chucks, fixtures and programmes. Cosworth www.cosworth.com
Chief Executive, Tim Routsis, comments: “We are very www.lycoming.textron.com
pleased to have secured this long term supply agreement with
Lycoming Engines. This contract is testimony to our ability to Lycoming: The piston engine powerhouse
provide high quality, precision engineered components for the Building on a proud heritage of more than 75 years in business,
aerospace sector.” Lycoming says it remains the clear leader in the aircraft
Cosworth Sales and Marketing Director, Jog Lall, adds: “We piston engine market, producing more for general aviation
continue to focus on winning new business in the aerospace manufacturers than any other company in the world. The
industry, one of our target market segments. From a capabilities company claims to power more of the world’s general aviation
standpoint, Lycoming recognised Cosworth’s ability to provide fleet, both fixed wing and rotary, than all other power plants
high quality products supported by in-house engineering, combined.
manufacturing, material science, testing and supply chain Headquartered in Williamsport, Pennsylvania, Lycoming
management. Everyone in Cosworth is looking forward to specialises in the engineering, manufacturing, assembly, test
further develop the business relationship with Lycoming.” and support of piston aircraft engines. Lycoming’s factory
Cosworth is a renowned manufacturer of engine and engine produces the most complete line of horizontally opposed,
components, particularly for the motor sport sector, but the air-cooled, four-, six- and eight-cylinder engines available
transition into the aerospace sector started just twenty four including the only FAA-certified aerobatic and helicopter
months ago. Over this period Cosworth has secured contracts piston engines on the market. The company has built more
with three tier one customers in the global aerospace sector. than 325,000 piston aircraft
According to Takisawa, most large- and small-volume piston engines and powers more
producers use its machines. “Our TPS range is famous around than half the world’s general
the world and Takisawa is the world leader in non-round aviation fleet.
turning by CNC control,” comments UK General Manager
David Evans.
“Many of our machines have been developed for elliptical Lycoming Thunderbolt engined | Castrol
turning of piston profiles and other non-round shapes. Most
competition aircraft, the Extra 300SHP
AEROSPACEMANUFACTURING 33
AM_jul07_p32,33_cosworth.indd 33 29/6/07 11:03:44
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