mot ion world Metal meets Medical The Magazine for CNC Automation Solutions for the entire process chain Volume 9 1/2010

Transcription

1 mot ion world The Magazine for CNC Automation Volume 9 1/2010 Solutions for the entire process chain Metal meets Medical

2 Contents motion world W. Geyer DLR KSMS Page 6 Sinumerik MDynamics produces perfect surfaces in the machining of freeformed surfaces Page 12 Laukhuff utilizes state-of-the-art Sinumerik technology for the manufacture of organ components Page 16 Spirit AeroSystems benefits from retrofit of its machine tools for aircraft component machining Cover CNC in Medical Technology 4 Metal meets Medical Solutions for the entire process chain Technology Sinumerik MDynamics 6 Partners for Greater Performance Heller Maschinenfabrik GmbH, Germany Collaboration with Siemens 9 Win-Win Situation Sinumerik Solution Partner Job Shop CNC 10 A Real Global Player Sinumerik 828D Milling 12 Musical and Technical Masterpieces Laukhuff GmbH & Co. KG, Germany Industry Aerospace 14 Controlled, Stable Processes Composite production with CAD/CAM 16 Do-it-yourself Retrofit Spirit AeroSystems, USA Service After-Sales Support 18 More Service Benefits Online Registration 19 Dialog, Imprint 2 motion world

3 Editorial Dear readers! Uwe Häberer Global Head of Machine Tools at Siemens AG A. Kradisch Medical part manufacturing is a future growth market. Due to increased life expectancy and high expectations in terms of mobility, particularly the demand for artificial joints such as knee and hip implants is guaranteed to increase. We will also see a rise in the demand for surgical instruments and dental implants. Efficient production of these parts is essential if we are to ensure high-quality, yet affordable medical care. Our solutions for medical part manufacturing, which span the entire process chain, have put us on course to succeed in these areas. From data generation in CAD/CAM with NX from Siemens PLM, which can be perfectly integrated into the Sinumerik CNC, to simple programming and setup of the control system and through to the finished workpiece, the user experiences an integrated solution. Our new Sinumerik MDynamics software option ensures high machining speeds and perfect surfaces regardless of whether it is individual, highly-complex implants that are being produced or serial parts in large quantities. You can experience the complete production process at METAV at our Metal meets Medical special interest booth in Hall 9 (booth D09). There, Siemens and its partners machine tool manufacturers, tools and measurement technology will unveil a digital factory illustrating the entire process chain for medical part production. In the technology arena, we will be giving a live demonstration of medical part manufacturing using various procedures. In addition, the Device Med forum will have exciting discussions of medical part manufacturing topics. This new issue of motion world magazine contains a wealth of information about medical part manufacturing with Sinumerik. I hope you enjoy this issue. Combine this with the education initiative and all our machine tool innovations, and it s clear that we are making a positive contribution at METAV during the current difficult economic climate. You ll see: it s well worth a visit. Sincerely yours, motion world

4 Cover CNC in Medical Technology Innovative control technologies and an integrated CAD/CAM/CNC process chain ensure seamless processes and safety for successful high-speed machining in medical part production. Pictures: Siemens AG Medical part production specifically demands high quality in the production of medical devices. In the field of orthopedics and prosthetics specifically (knee and hip implants, instruments, bone plates and screws), high-precision machining, perfect surfaces and excellent process reliability are absolutely imperative. Orthopedic and prosthetic parts are expected to have a long life, so highly resilient materials such as titanium and cobaltchromium are used. Siemens supports an integrated, state-of-the-art process chain for the production of medical devices and implants. With NX CAM from Siemens PLM, the CAD/CAM system for the complete design and production process, the virtual world of surgical scheduling can be integrated into the physical world of production on the shopfloor. Siemens will have a special booth at the METAV trade fair where it will unveil the entire process chain. The company will be working together with its partners from the fields of machine tools, along with tools and measurement technologies such as DMG, Renishaw, Index, Zoller, Schütte, Iscar and Star. With presentations on machining technology and fire protection products, users will experience an integrated solution for the medical technology sector (see sidebar). The right solution no matter the requirements Solutions for the entire process chain Metal meets Medical A key factor in the success of the various machining procedures used in medical part manufacturing is the CNC technology that is used. High costs for storage and raw materials have led to small batches and single items being produced alongside large batches. With its Sinumerik CNCs, Siemens offers a solution for every area of application. The new Sinumerik 828D is just as suitable for the efficient production of large batches in the three-axis applications as it is intended for single-part production. It is available in two versions for turning and milling. Key features are the impressive performance it delivers despite its compact size, plus easy operation and maintenance. The Sinumerik 828D offers simple machine setup functions to tackle the frequent changeovers associated with small batch sizes. 4 motion world

5 The Sinumerik 840D sl CNC the premium numerical control from Siemens has been perfectly adapted for high-speed cutting in five-axis machining. The flexible CNC system is suitable for use in the most diverse range of technologies, making it ideal for the machining of challenging orthopedic and prosthetic implants. It allows even complex parts to be machined in a cost-effective manner, with maximum precision, and great speed. Key workpiece-specific data such as tools, cutting values, program information or zero offsets can be saved and then accessed again at a later time. The open nature of the HMI and NC Kernel supports compliance with specific requirements in the medical technology sector. Easy operation, mirror-smooth surfaces Thanks to the new, intuitive Sinumerik Operate user interface, Sinumerik impresses with its speed and ease-of-operation. Convenient graphical programming and simulation from ShopMill/ShopTurn workstep programming to Sinumerik high-level language with programguide to DIN/ISO programming make it just as easy to excel with large batch sizes as with single items. The interactive Animated Elements assist operators in their daily work routines, as they provides look-ahead displays of every machining step as an animated simulation. When it comes to medical part manufacturing, optimum machining results with perfect surface quality, precision and quality, all at higher machining speeds, are particularly important. With 80-bit precision in positioning, speed and current control, Sinumerik is up to even the most stringent surface quality requirements. In addition, the Sinumerik MDynamics technology package ensures optimum results in threeaxis and five-axis milling. A highlight of Sinumerik MDynamics is the innovative Advanced Surface motion control functionality, which guarantees perfect surface quality even during high-speed milling of hip or knee joints that require pinpoint accuracy. Before the knee joint is milled on the machine, the operator can create a model in NX CAM and simulate the machining process Special Siemens fair presentation: Metal meets Medical A digital factory will be presented at the special interest booth entitled Metal meets Medical to highlight the integrated planning and implementation of the main production steps associated with the workpiece, the efficient use of resources, and the standardization and continuous improvement of the process. Workpieces will be developed and programmed in NX and will then be available to all components involved in the process within the shared database of the Teamcenter PDM software. The machine tools will be connected to the digital factory via MCIS software solutions to enable access to production data and a direct transfer of NC programs and tool data. In the technology arena, medical devices will be machined live on various machine tools. Using various machining technologies to illustrate the process, Siemens will give visitors the opportunity to learn about the technical possibilities of medical part manufacturing. The technologies covered include: five-axis grinding, turning/milling and high-speed cutting (HSC) milling. In addition, Siemens will be showcasing the Sinorix al-deco STD fire protection system. Due to high cutting speeds, cooling oil and, particularly, the hard materials, fire protection plays a large role when it comes to machine tools. Working together with the leading partners from the machine tools industry, the Siemens special interest fair booth will present an integrated solution for medical part manufacturing. Sinumerik MDynamics offers other innovative functions in addition to the new, optimized motion control functionality: new tool and program management features, innovated measurement functions in JOG for simple machine setup, innovative technology and measurement cycles, and efficient cycles for highspeed cutting. The package is completed by simple data and program handling with additional Compact Flash (CF) card memory, spline interpolation and workpiece simulation for multi-side machining. This technical equipment leaves manufacturers ideally equipped to machine medical parts and devices in all other technological aspects, enabling them to meet the stringent requirements of the sector. info contact karsten.schwarz@siemens.com motion world

6 Technology Sinumerik MDynamics Photos: W. Geyer Heller Maschinenfabrik GmbH, Germany Partners for Greater Performance A development partnership with Siemens brings new, marketdriven machine solutions for efficient five-axis machining. 6 motion world

7 With its finger on the pulse of relevant industry trends and with Siemens engineers as development partners by its side, Heller Maschinenfabrik has made targeted additions to its range of machines. The new F-series in the company s machines business offers additional made-to-measure, five-axis machining centers with the Heller trademark performance and efficiency. Now, these benefits are also available for tool- and moldmaking as well as for single-part production. The foundations for this launch were laid with the development of the H-series, which saw Heller become one of the first machine tool manufacturers in the world to adopt the Sinumerik 840D sl the latest generation of controllers at EMO The response was phenomenal, with more than 150 H-series machining centers being commissioned within a very short time. Taking a deliberately phased approach to ensure easily manageable steps for developers and users alike, Heller has also spent a number of years migrating the operating and programming interface, from Sinumerik HMI Advanced to the current integrated Sinumerik Operate operating concept. Today, even the basic versions of the machines in the F-series are equipped with the comprehensive Sinumerik MDynamics technology package for five-axis milling (see sidebar). The innovative functions of this package give machine manufacturers a clear market advantage over their competitors and provide maximum userfriendliness. Complementing the innovative spirit of this approach, the package provides full compatibility and continuity for both hardware and software, so pallets, equipment and the NC programs of the H-series and its predecessors can still be used on the new F-series machines. Two models with a single objective: maximum milling efficiency The Heller F-series will initially comprise two models, with each model offering two sizes of work area (2000/ 4000). The FP model is designed for maximum production output and availability and is therefore, ideal for serial production with five-axis machining. The FT model with manual table loading is a classic workshop machine ideal for use in tool- and moldmaking, where its flexible, high-precision five-axis machining of complex components caters for even the smallest batches. The proven Heller spindle technology features on both models. The high-torque Power Cutting Unit (PCU 63) is offered as a swivel head for users in the high-performance cutting industry. For high-speed The new F-series from Heller offers five-axis machining centers with manual table loading (FT) for use in moldmaking and workshops Sinumerik MDynamics The Sinumerik MDynamics technology package for five-axis milling comprises the Sinumerik 840D sl and a wealth of intelligent CNC functions as well as the full CAD/CAM/CNC process chain. The Advanced Surface intelligent motion guidance assures optimum surface quality even at high feed rates. It perfectly harmonizes the speed profiles of adjacent milling paths using an enhanced look-ahead capability, and the upgraded online compressor minimizes contour deviation. The result is even better surface quality and contour accuracy with no need for workpiece-specific optimization. MDynamics for five-axis milling offers the following functions: Advanced Surface Additional user storage on a Compact Flash (CF) card Spline interpolation (ASPLINE/BSPLINE/CSPLINE) Transmit and peripheral surface transformation Automatic measuring cycles 3-D simulation Simultaneous recording ShopMill/ShopTurn workstep programming Residual material detection Five-axis machining package (Tool Center Point programming/traori) 3-D tool radius correction (CUT3DC/CUT3DF) Kinematics measuring (Cycle996) Siemens AG Efficient HSC functions like the Cycle832 highspeed setting guarantee optimum precision and perfect surface quality motion world

8 Technology Sinumerik MDynamics Keeping it all under one roof Intelligent motion control with Advanced Surface produces perfect surfaces at high machining rates and maximum contour accuracy cutters, Heller offers the high-rpm Speed Cutting Unit (SCU 63), which is also a swivel-head unit. These spindles are also available as a Speed Cutting Tilt unit (SCT 63) with a fork head for efficient machining of any freeformed surfaces. Focus on user-friendliness One of the main aims in this latest round of development was to make operation and programming even more user-friendly and so further improve the operator-friendliness of the F-series machines. Newcomers and professionals alike can now use the diverse functions for five-axis machining with confidence, set up their machines quickly, program rapidly even on the shopfloor, and simulate and optimize machining steps. We looked very closely at the needs of our targeted market segment. We exploited the many years of experience offered by Siemens in relevant sectors such as aerospace and shopfloor programming, and in return, we played an active part in optimizing the current Sinumerik Operate HMI system, says Dr.-Ing. Hannes Zipse, authorized representative and head of Sales at Heller Machines. For years now, Heller has been an important pilot customer for Siemens, becoming regularly involved in the (further) development of Siemens drive and control systems. As a result, Heller s own control developers boast a high level of competence, which promotes a high level of interchange and accelerates the work process significantly. This close cooperation is of benefit to both sides, and ultimately of course to the user. For example, the new series features a number of functions that users of Heller machines have come to expect, such as integrated performance monitoring (IPM) and the tried-and-tested pallet management on the FP model, both of which are Heller inhouse developments. Sinumerik Operate, the new operating and programming interface for the H- and F-series, fuses the superb flexibility and functionality of Sinumerik HMI Advanced with the intuitive user guidance of ShopMill under a common environment. The operator essentially has two options when programming the controller: ShopMill, the graphics-aided workstep programming application that is very popular in shopfloor environments and achieves very short programming times especially when machining individual parts and small batches Programming in programguide, DIN/ISO and G-code with cycle support and clear cycle graphics. Programming with ShopMill and programguide is further aided by the Animated Elements function, which illustrates the input parameters using short animated sequences. This allows a confident assessment of the machining step to be made before the first chip is cut and offers added protection against operator error. Other features include enhanced, intuitive functions for machine setup, the tool and the workpiece, for example for measuring using different probes or swiveling in JOG mode, and for fast and simple handling of complex workpieces in a fixture. There are also functions for efficient tool and program management, such as the logbook required by Heller. Sinumerik Operate s new online help function, with its detailed description of all controller functions, has also been well received by first-time users. All functions come as standard under a common environment. This simplifies engineering for the machine tool builder and gives users freedom of choice combined with maximum operating convenience. The machine tool of tomorrow Machine manufacturers and Siemens will continue to work together to implement the innovative technologies and topics of today in the machine tools of tomorrow. One such topic is the broad field of energy efficiency, a goal that is being advanced with the use of frequency converters in machine tool ancillary components and peripherals, and also with energy-saving motors. In the future, the two companies will be looking to further deepen their long-lasting partnership by opening up new industries and applications and by training personnel from the Heller Training Center at the Siemens Technology and Application Center (TAC) in Erlangen, Germany. info contact reinhard.knoll@siemens.com hannes.zipse@heller.biz 8 motion world

9 Technology Collaboration with Siemens Sinumerik Solution Partner Win-Win Situation Within the framework of the Siemens Solution Partner Program, a sales and technology partnership with Siemens, merge the strengths of Siemens with the application and industry expertise of the solution partner. As a result, perfect solutions are created for every requirement, as the following examples demonstrate. Cycles according to customer requirements Founded in 1974, R&D Steuerungstechnik (Control Technology) GmbH & Co. KG has made an important contribution to the NC technology in the machine tool industry. The company s technology center has become a major foothold, offering extensive expertise in Sinumerik solutions for machine tools and automation systems. Since the mid-1990s, R&D has been the Sinumerik development partner for user interfaces in job shops and provides operation, installation and configuration of Siemens shop- R&D specializes in user-specific cycles such as special cycles for profile threads floor software. Recently, the company was registered as the Sinumerik Solution Partner for the development and commissioning of user-specific cycles for Sinumerik 840D, which are geared towards the technological and technical requirements of machining tasks. Above all, this includes special cycles for profile threads and cambers, as well as the pocket milling cycle on the lateral face (without Y-axis). As R&D is very familiar with the open nature of Sinumerik CNC, the company is able to program and install a suitable custom solution, including a user interface, for each application. As a result, Siemens can now also fulfill special requests from customers with respect to cycles. R&D for machine tools from a wide range of industries. The VM25 measurement and control system for grinding machines from Balance Systems S.r.l. has been successfully certified for use on Sinumerik controls. Thanks to this solution, the VM25-HMI user interface can be easily integrated into the Balance Systems developed a measurement and control system for grinding machines for use on the Sinumerik application program by the user, or activated as an independent task. A large number of functions are available to the operator: Balancing the grinding disk on one or two levels using extremely precise balancing bodies without torsional impact for a maximum surface quality of the ground workpiece Determining the grinding disk contact to optimize machining and smoothing cycles and for handling the normal acceptance curves for monitoring and signaling process irregularities using acoustic, hydrophonic and power sensors Comparative in-process measurement of the workpiece with immediate correction feedback to the CNC/PLC for the diameter, lengths and current positions, as well as for roundness deviations to avoid rejected parts and to ensure consistent production quality Thanks to a complete programming interface, the Sinumerik-integrated program interacts with the devices and the operator to manage these functions. With its certified solution, the new Sinumerik Solution Partner, Balance Systems, expands and enhances the Sinumerik functionality in the grinding machine industry. Balance Systems Improvement in grinding process quality Balance Systems S.r.l., founded in 1975, specializes in the balancing of rotating bodies. The company, located near Milan, Italy, receives orders from grinding machine manufacturers, automotive suppliers or machine tool component manufacturers, among others, info contact yalcin.delioglan@siemens.com motion world

10 Technology Job Shop CNC Siemens AG Sinumerik 828D A Real Global Player The compact and strong Sinumerik 828D is perfectly suited for global machine tool manufacturers. Compact, strong, simple simply perfect! This was the theme under which Siemens presented its new Sinumerik 828D numerical control to the world at the EMO 2009 trade fair in Milan, Italy. With its open and modular structure and its flexibility, the Sinumerik 840D sl supports almost every conceivable machine concept in the premium segment. By contrast, the job shop demands a smaller variety of machines that offer simpler commissioning and handling when servicing. These requirements are best met by the Sinumerik 828D, as confirmed by the extremely positive feedback received at EMO. Perfect for global marketing The Sinumerik 828D provides machine tool manufacturers with a tailored solution that enables them to market their globally-usable machines with a single CNC system. The Sinumerik 828D fulfills a major prerequisite for a Global CNC : the combination of all the required operating and programming functions in a single control system. ShopMill/ShopTurn workstep programming offers job shop users a well-established solution, while the Sinumerik 828D provides an extremely flexible CNC high-level language, which makes it possible to market machines, even in the automotive supply industry. Lastly, Sinumerik 828D can also be programmed with ISO commands a programming language used widely throughout Asia. This means that this particular market can also be covered by a single CNC system. However, marketing machines on a global scale also requires the global provision of services by the machine tool builder or dealer. The Sinumerik 828D addresses these requirements perfectly. PLC programming and online diagnostics are performed in the 10 motion world

11 » We have decided to equip our new EMCOMILL E350 CNC machining center for industrial use with Sinumerik 828D. It was the user-friendliness of the control system through its graphical user interface that really impressed us. We can also program in ShopMill and ISO, thus making us very flexible. «Dr. Stefan Hansch, CEO EMCO Group Emco Group easy-to-understand contact plan technology. Easy Extend offers a perfect solution, particularly for the retrofit of optional machine components, such as CNC rotary tables. This means that the required CNC parameters can be preconfigured in the factory. The subsequent installation of components is then accomplished at the touch of a button without any CNC expertise or software tools. Compact and strong Another advantage of the new Sinumerik 828D CNC is its compact design. Thanks to the small dimensions of the vertical and horizontal panels, it can be integrated into very compact control panel housings, without changing the machine design. The compact unit made up of control panel, keyboard and CNC electronics is also extremely robust since it has no interface ports. Together, the maintenance-free design is a central requirement in the job shop. The Sinumerik 828D is also maintenance-free; there is no hard disk or fan. The CNC data are also saved on modern NVRAM. That way, no expensive battery is needed and all data are retained even if the machine is transported or shut down for several months. A compact control system does not need to compromise on performance. The Sinumerik 828D offers users unique 80-bit accuracy of calculation in the CNC and drive control loops, thus permitting extremely precise machining. In addition, an extensive range of technology cycles support the production of highly complex workpieces. And with the new milling package, Sinumerik MDynamics, the Sinumerik 828D is also more than capable of machining challenging moldmaking workpieces. The system software versions are tailored specifically to the demands of challenging turning and milling machines that are typically used in the job shop. This significantly restricts the number of control parameters, which minimizes the commissioning time. State-of-the-art technology Setting new standards in CNC technology also means confronting the trends of modern communication technology. Thanks to its intelligent software architecture, the Sinumerik 828D supports all the modern communication media, such as USB, Compact Flash (CF) card or an unrestricted network capability. The new, convenient Sinumerik Operate user interface contains complete online documentation with numerous graphical diagrams or animated elements to support input with moving picture sequences. One highlight offered in particular by Sinumerik 828D is Easy Message, a process monitoring system that uses text messages. Information, such as workpiece counters, tool wear limits or upcoming machine services are transferred by text message (SMS) to the machine operator s mobile phone. This ensures maximum machine productivity, even in the job shop. info contact andreas.groezinger@siemens.com motion world

12 Technology Milling Laukhuff GmbH & Co. KG, Germany Musical and Technical Masterpieces The art of organ building at the highest level with modern CNC techniques: Laukhuff relies on a five-axis milling center from Spinner with Sinumerik 840D sl for small-series production. At Laukhuff in Weikersheim, Germany, tradition and modernity merge together in a way that cannot just be seen, but also heard. The family-run company, with almost 200 years of history, is the international leader in organ building as a supplier to the best-known organ builders and as a provider of its own complete developments. The company operates on a global level with 150 employees, considering itself a craft enterprise rather than an industrial company. Company CEO Hans-Erich Laukhuff emphasizes: In our carpenter s workshop, and when manufacturing organ pipes, we are hardly able to use any machines because 90 percent of the work has to be done by hand. When it comes to cutting, however, this is a different matter. Here we use modern milling and turning machines with innovative Sinumerik CNC equipment, so that we can keep productivity levels as high as possible. If required, the masters of organ building will supply everything from a single source. He explains: If requested, we will take on all the tasks involved in the design, the manufacture of individual parts and the installation on-site. We even make the bench seat and the key lights ourselves, as there are no usable solutions in the market. The high level of perfection shown by the organ builder is reflected in the optics, in the haptics and naturally in the sound of the instruments. It also has a positive effect on their reliability. After all quite unusually in these fast-moving times it is not necessary to plan the replacement of a Laukhuff organ for more than 100 years. However, a few spare parts will still be required. Despite the fact that this high quality is globally recognized, this family-run company is still facing constant cost pressure. To achieve a high throughput in cutting applications, the company uses five CNC turning machines and three CNC milling machines together with their latest acquisition: a five-axis CNC center (3+2) from Spinner s U-series, with modern Sinumerik 840D sl. Impressive price-performance ratio Company owner and CEO Hans-Erich Laukhuff and Production Manager Walter Rhein have already had positive experiences with Sinumerik. However, since mid-2009, they have been relying on the Spinner 12 motion world

13 Siemens AG Siemens AG Walter Rhein is very satisfied with the five-axis Spinner U5-620 with Sinumerik 840D sl With the Sinumerik-controlled Spinner U5-620, Laukhuff uses new options for the more productive manufacture of organ components, such as chimes machine tool factory in Sauerlach for the first time and using the U5. According to the production manager, this decision was based on the price-performance ratio and the small space required by the machine in contrast with comparable machines from other manufacturers. The U5-620 only needs 2,000 x 2,400 millimeters of surface area, but achieves travel distances of 620/520/460 millimeters in the X/Y/Z-axis direction. The new Spinner machining center has high-quality individual components, including 32 tools as standard, a double arm for rapid tool changes and linear axes on roller bearing guides. Michael Schulz, Spinner sales representative at Hollenbach GmbH, confirmed: This enables us to achieve rapid feed speeds of 48 meters per minute in all directions. Even in terms of accuracy and surface quality, our U-series sets a high standard. In terms of the productivity and quality increases that can be achieved, the organ builder expects the acquisition of the Spinner machine to be amortized within a short period of time. Ultimately an organ builder will often manage without time-consuming retooling, as Rhein confirmed: In the cutting applications for our organ pipe tuners, we used to have to retool three times and needed around 13 minutes just for clamping which doesn t even take into account the downtime while retooling. The five axes mean that production is now possible in a single clamping, within around eight minutes. All in all, we are at least twice as fast as a result. Graphically-animated user interface Like many medium-sized contract manufacturers, the organ builder s employees also program directly at the machine. CNC specialist Kurt Stüdlein is totally convinced about the Sinumerik 840D sl because it is powerful, safe to operate, user-friendly and reliable. But the CNC user interface, tailored to shopfloor programming, also scores highly: graphically-animated and logically-structured, ShopMill is great, particularly for beginners. Production Manager Rhein explains: Even a fitter who has only just finished his training, without any extensive programming experience, can work with it after brief instructions. CNC professional Stüdlein adds: Even on complex components using the 3+2 axis machining, I can create lots of programming steps with ShopMill. If I reach the limits when entering certain contours, or if» In cutting applications for our organ pipe tuners, we used to have to retool three times. Now it is possible in a single clamping and we are at least twice as quick as a result. «Walter Rhein, Manager of Cutting Applications at Laukhuff I am quicker with DIN, then I can switch from the graphic to the text-oriented DIN interface at the touch of a button. For additional employee safety, the Safety Integrated software solution is also integrated in the Sinumerik 840D sl. This means that it is possible for the user to safely track his program s production process in setup mode with the machine doors open. Laukhuff is certain, based on the experience gained, that he has made the right decision with the Spinner- Siemens combination. The technology and the continuously fast service from both companies, have convinced him: If there is a problem, we are helped very quickly which is not always a given with other manufacturers in this particular industry. info contact alois.penzkofer@siemens.com motion world

14 Rubrik Industry Unterrubrik Aerospace Composite production with CAD/CAM Controlled, Stable Processes The composite manufacture of aircraft parts requires an integrated, tailored process chain. The CNC functionality of the Sinumerik 840D guarantees controlled, stable processes. The aerospace industry increasingly uses carbon fiber-based composite materials for wings, tail assemblies and fuselage segments. Tape laying and fiber placement have now become key technologies in aircraft construction. In the case of tape laying, 70- to 200-millimeter-wide tapes made from carbon fibers and composite resin are placed layer-by-layer on a flat support and are then cut off parallel to the edges of the workpiece. Where edges are complex, pre-cut tape segments are used, which requires the tape to be positioned precisely. The fiber orientation of the tape must, where possible, conform precisely to the direction of the point tension that will occur in the material during flight. For this reason, the tape must be applied without any tension or folds, and with precisely defined pressure. As a result, instead of wider tapes, components with complex curved surfaces, for example the segments of the aircraft fuselage, have several very narrow tows placed on the mandrel with fiber placement machines. To achieve the maximum strength and load capacity of the aircraft component, the tape layers must be applied to each other so that they adhere across the whole surface, without any air or dust entering. Therefore, the quality requirements for placement are uncompromisingly high. To prove the quality and safety, each composite component is subjected to an extensive, area-wide and nondestructive material test. If delamination is detected during this test, the entire part is normally rejected, which means a considerable amount of time and material is lost in the case of large-scale aircraft components. The economic and timely manufacture of wings and fuselage parts made from composite materials requires the reliable control of tape laying and fiber placement quality, as well as new solutions for drilling, cutting and trimming. High-performance CNC functions Different requirements are placed on the CNC for the building processes of tape laying and fiber placement, compared with cutting applications. To coordinate cutting control and motion control in the best possible way for fiber placement, the Sinumerik 840D offers synchronizing functions controlled according Z Y X Tool tip X..., Y..., Z... C1 A3=0 B3=0 C3=1 A Z Y X Tool tip X..., Y..., Z... C1 A3=0 B3=0 C3=1 A1 Part programs that are programmed in workpiece coordinates are advantageous for process security. This is enabled by CNC transformation functions C2 AN3=1 BN3=0 CN3=0 C2 AN3=1 BN3=0 CN3=0 A2 14 motion world

15 Siemens AG to actual positions, which synchronize the switch actions of the user or parts program with the motion control and position control. As a result, all the cuts sit precisely in their target positions, even at high laying speeds, which produces very clean laying edges. High-performance transformation functions are also integrated in the Sinumerik 840D, which make it possible for workpiece coordinates to be programmed in. This makes the part programs, in principle, independent from the machine kinematics and also improves clarity and the maintainability of the part programs. Even if an accurate axis-parallel mounting of the mold is not possible due to the size and weight of the mandrel, high-performance transformation functions guarantee the synchronous programming of the laying head movements and of the mandrel, as well as the appropriate alignment of the laying roller. It is necessary for it to be designed for genuine fiveaxis operation or, as in the case of fiber placement, for at least six or seven synchronous axes. and cycles for high quality In addition, the Sinumerik 840D supports composite material production with special cycles for composite drilling and other lightweight construction materials, for laser and waterjet cutting and for many other operations. High-performance open interfaces enable seamless logging of the actual values for all the process-relevant parameters and machine data for quality assessment. Again here, programming in workpiece coordinates is a key factor, in order to utilize the results of an automated material test with very little effort, or even automatically, for process optimization. Realistic process simulation In order to be able to precisely simulate the time-consuming production of large and complex aircraft components, not just geometrically, but also technologically including all process-relevant machine properties the Sinumerik 840D has a virtual NC kernel (VNCK). The real-time control software can be run on the Windows platform without any CNC hardware and enables a realistic simulation of all the CNC functions as a plug-in to conventional simulation systems. The production machine s data are also applied here. This means that the use of the simulation is no longer restricted just to the pure test of the part programs generated in the CAD/CAM system, but also enables an optimization of both the part program and of major process parameters. Controlled stable processes, which lead to perfect results, are an essential pre-requisite in economic aircraft construction with a high proportion of composites. That s why well-known system partners in the aerospace industry prefer to rely on Sinumerik-based machine automation solutions. info contact dirk.rabeneck@siemens.com As carbon-fiber tapes are almost completely non-elastic, they must be built up in twodimensional curved shapes from narrow carbon-fiber strips motion world

16 Industry Aerospace Kansas-based Spirit AeroSystems is a primary supplier to Boeing and other aircraft builders KSMS Spirit AeroSystems, USA Do-it-yourself Retrofit Spirit AeroSystems, a primary supplier to Boeing and other aircraft builders, utilizes the capabilities of Sinumerik 840D in the retrofit of its machine tools. Faced with the challenging economic situation and the resulting budget tightening, many aerospace component suppliers are seeking ways to improve their productivity and bottom-line results. At Spirit AeroSystems in Wichita, Kansas, the strategy to accomplish those goals has been in place for decades. Facility manager Ed Fenn and his team of retrofit and machine shop specialists are among the many reasons for this situation. Through a systematic predictive maintenance program and continuous upgrades to the controls, motors, drives and other components on the huge multi-axis gantry mills that produce many of the structures here, Spirit has realized substantial productivity gains without the capital investment of new machine tool purchases. Every retrofit planned or in progress and every machine tool in the facility, approximately 575 cur- rently, is monitored under a predictive maintenance program. Through this program, all machine parameters of wear, uptime, routine maintenance and even environmental impact are closely monitored, with an eye on the day when a planned retrofit or complete overhaul of the machine will be required. By doing this, Spirit has conserved millions in new capital expense, while actually improving the performance of its machine tool fleet. Exploiting control capabilities Several Cincinnati (now MAG/Cincinnati) gantry mills are key to the manufacture of the large metal aircraft components, as well as materials handling structures such as nacelles. Originally equipped with Siemens Acramatic controls, the forerunner to the advanced 16 motion world

17 Sinumerik 840D CNC platform that is now used on most of the machine tools here, these gantry mills machine the majority of the metal parts made, primarily from various grades of aluminum, titanium and tool steels. Because we have periodically upgraded our machine controls, along with the motor and drive packages, gear boxes, spindles, encoders and column structures on our gantry mills, we have tracked better productivity numbers on all of them. This is the result of newer controls, which have faster processing speeds, as well as the higher-accuracy positioning drives, linear motors and encoder technologies we utilize, Fenn explains. The performance and flexibility of the Sinumerik 840D makes it the perfect controller to be used in almost all retrofits. Other non-metal cutting equipment such as riveters, hydraulic presses and robotic materials handling devices equipment often get retrofitted with this CNC, as well as Siemens PLC and other control gear. On some of the largest machines at Spirit, such as our Brötje riveters, used to join the fuselage to the spars and ribs, all the axis and ancillary equipment control capability of the Siemens Sinumerik 840D comes into play, Fenn said in regards to the power and flexibility of the CNC technology. In process, there is also constant evaluation of the machine tool performance at Spirit. Through the onboard CNC, the VLAN and ICS protocols employed here, all machine parameters, including vibration and thermal characteristics, are monitored and entered into a database for evaluation by the CBM team engineers. In total, over 25,000 points are monitored throughout this 11,119,000-square-foot campus. Upgrading a Cincinnati machine with retrofit: one of the Spirit retrofit/machine shop specialists at work Therefore monitoring of machining processes in real time is possible for further documentation of the machine s performance, as needed. A cost-effective performance boost For cost comparison, the typical retrofit project on a large gantry mill at Spirit might run $1,000,000 or more, but that amount typically represents only about percent of the cost of a new machine. According to Fenn, We keep the steel and replace everything Siemens AG» The performance we are getting is every bit as good as a new machine s. «Edward Fenn, facility manager at Spirit AeroSystems else, though he noted a recent retrofit of a Z-axis column on a Henri Liné five-axis machine. However, The performance we are getting is every bit as good as a new machine s, he noted. Fenn notes that the onboard control is the top priority in gauging obsolescence on any machine at Spirit. The control technologies have progressed so far and so rapidly in the last 20 years that we would be foolish to remain in a fixed time mode for retrofitting any machine we operate here. Following the initial studies, a comprehensive assessment of the retrofit versus buy value proposition is conducted. Upon the decision to retrofit, the team develops a procurement package and initiates the buys through corporate purchasing. The scheduling of offline time for a machine tool at Spirit is a major responsibility, as the building of an aircraft fuselage requires the precise integration of many departments working in concert. As is true throughout the aerospace industry, composites technology is rapidly making a huge impact on machine builders, shop operations and controls personnel alike. Spirit is no exception and leads the way in advanced composites buildup and machining, according to Fenn. Not surprisingly, his retrofit team also plays a key role here, because there is a 25-yearold Cincinnati machine tool functioning perfectly on hard metal components that support the composite structures, having been retrofitted with a new control system, coolant system, hydraulics and all-new operator station. Another Cincinnati machine is on deck for retrofit with new ways, racks, control station, accelerometers and pressure transducers. Siemens AG info contact john.meyer@siemens.com motion world

18 Service After-Sales Support Online Registration More Service Benefits The online machine registration equipped with Sinumerik CNC hardware and software enables extensive After-Sales Support. an automatically readable machine identity as standard (electronic type plate). Ultimately, all of these measures increase productivity during production. Online registration is also advantageous for the users of machines equipped with Sinumerik MDynamics, the new technology package for three- and five-axis milling, or for Sinumerik users who have a license for the NX CAM CAD/CAM software: they receive a free post-processor for NX CAM for the registered machine. In addition, an extensive Sinumerik documentation package is provided free-of-charge. Starting with pre-sales consulting for a machine equipped with Sinumerik, and all the way through after-sales service, Siemens makes a point of satisfying its customers and providing an optimal service. However, in the majority of cases, the location of machine tools after delivery to the operator remains unknown. In order to be able to improve service and support for these machines, as well as for all the other machines and equipment, customers can register their machine online. The advantage of online registration is better support services, as the location of the regional Siemens service is known and this office can react in a targeted way to service queries. In addition, it is possible to maintain efficient stock of spare parts and ensure service optimization as a result of cyclical checking of the registered machines. The integrated information base for service management allows faster reaction times to service inquiries. As the engineer has an exact overview of the components installed in the machine, service calls can also be planned in a targeted way. To make service even simpler, the system platform has Siemens AG Simple, fast and accurately recorded All the information about the machine can be directly recorded online. The machine identity includes: component lists and the machine s software information about the machine manufacturer and, if applicable, the dealer information about the end customer Registration is very simple: the information is automatically saved and read from the Sinumerik 828D and Sinumerik 840D sl (from SW 2.6) and transferred to the memory stick at the touch of a button. In the case of earlier controls, the parts list is simply imported onto the PC and uploaded. The machine manufacturer or dealer will carry out registration directly after commissioning. Operators can register their machine, if this has not already been done by the machine manufacturer or if changes have been made to the system. In this case, click on and upload the data. info contact service&support thomas.hamann@siemens.com 18 motion world

19 Dialog infos Do you want to find out more about industry automation and drive technology from Siemens? Then find your Siemens representative at: or visit us on the web: You will also find up-to-date newsletters as a free subscription; for example the Totally Integrated Automation Newsletter. Simply register your address at: See the return of job shop CNC online Point your web browser to: and download the latest issue as a PDF file. The elec tro nic archive enables access to all previous issues. You can also send suggestions and comments about the overall issue and the individual articles by . Take a close look now at the Sinumerik 828D If you are a job shop owner, now is the time to prepare for business recovery. Job shops around the world are escaping the limitations of G-code intensive Relic CNC, and so can you. See for yourself how the Sinumerik 828D can reduce operating costs, increase performance and boost the profitability of your business. Breakthrough CNC is the reason why more machine builders around the world are turning to Siemens. Seeing is believing. Take a close look now by visiting: Imprint: motion world Publisher Siemens Aktiengesellschaft, Gleiwitzer Str. 555, Nuremberg, Germany Division Drive Technologies CEO Klaus Helmrich Editorial Responsibility in Accordance with the German Press Law Arno Hoier Responsible for Technical Contents Bernd Heuchemer Concept Christian Leifels Editorial Committee Ivonne Luthardt Publishing House Publicis Publishing, Part of Publicis Pro P.O. Box 32 40, Erlangen, Germany Tel.: +49 (0) / Fax: +49 (0) / publishing-magazines@publicis-erlangen.de Editorial staff: Dr. Beate Bellinghausen, Gabriele Stadlbauer Layout: Jürgen Streitenberger, Stefanie Eger DTP: Mario Willms Copy editor: Sabine Zingelmann Job number: Cover picture: Siemens AG Printed by: Wünsch, Neumarkt, Germany Circulation: 8, by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper. The following products are registered trademarks of Siemens AG: ShopMill, ShopTurn, SIMATIC, SINAMICS, SINORIX, SINUMERIK, SINUMERIK HMI, SINUMERIK MDynamics, SINUMERIK Operate, SINUMERIK Safety Integrated If trademarks, technical solutions or similar are not included in the list, it does not imply that they are not protected. The information provided in this magazine contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Order number: E20001-MC110-B100-X-7600 Printed in Germany motion world

20 Looking for a better way to machine the perfect mold? SINUMERIK MDynamics: The expert milling package for perfect surfaces Answers for industry.