FLEXIBLE EQUIPMENT FOR THE MACHINING OF AEROSPACE PARTS MADE OF COMPOSITE

Size: px

Start display at page:

Download "FLEXIBLE EQUIPMENT FOR THE MACHINING OF AEROSPACE PARTS MADE OF COMPOSITE"

Lily George
6 years ago
Views:

1 FLEXIBLE EQUIPMENT FOR THE MACHINING OF AEROSPACE PARTS MADE OF COMPOSITE Düsseldorf, November 29th 2016

2 CONTENTS COMPANY PROFILE 3 CMS FOR AEROSPACE 13 SOLUTIONS FOR AEROSPACE 20 WHEN FLEXIBILITY BECOMES PRODUCTIVITY 38 CONCLUSIONS 53 2

3 COMPANY PROFILE 3

4 FACTS AND FIGURES A corporate snapshot. Turnover 119 Mio EUR, Employees 600 Sales 86 % Service & Spares 14 % Production 470 Machines, Export 83 % Total Installed CMS Machines > 8000 Patents 58 Most Processed Materials (% of sales) Composites + Plastics 40 % Aluminum 15 % Wood 15 % Stone 14 % Glass 10 % Most Important Markets (% of sales) Aerospace 19 % Automotive 12 % Other Markets Buildings, Railways, Energy, Glass, Stone, Wood, Eyeglasses AEROSPACE DEFENSE ENERGY AUTOMOTIVE RACING RAILWAYS GLASS STONE WOOD 4

5 FACTS AND FIGURES Italian family-owned company with a global presence. CMS IN THE WORLD 5 international direct branches over 200 distributors 5

multi-axismachiningcentres, other machines and

6 HISTORY AND IDENTITY CMS hasbeenfoundedin 1969 The missionof CMS isto be a specialistin the manufactureof multi-axismachiningcentres, other machines and production lines, innovative, performant, accurate and reliable. 6

7 HISTORY AND IDENTITY The name CMS stands for Building of Special Machines CMS hasbeenseveraltimesthe onlybuilder ableto finda solutionto a problemneedinga special machine. Thanksto thisattitude, CMS hasbeenoneof the first builder of machine tools for the composite cutting. 7

HISTORY AND IDENTITY Customers satisfaction CMS machine toolsare

8 HISTORY AND IDENTITY Customers satisfaction CMS machine toolsare oftenusedin contextswhereproductivityand reliability are strictly requested. Many customers who have purchased CMS solutions, still choose CMS for other machines. Among CMS customers who work composites or aluminium, 1/3 has purchased more than one machine, 60% of companies with more than 50 employees has purchased 2 or more machines. 8

9 PARTNERSHIP Current partners 9

10 HIGHLIGHTS Machining of models and composite parts for Motorsport and Automotive 10

11 HIGHLIGHTS Machining of parts made of aluminium for Railways A SELECTION OF MODELS MANUFACTURED BY CMS SOLUTION FOR RAILWAYS 11

12 HIGHLIGHTS Restoration of monuments made of Stone THE PARLIAMENT OF BUDAPEST, RESTORED BY MEANS OF BREMBANA MACHINES. 12

13 HIGHLIGHTS Manufacturing of structural glass for Buildings ORIGINAL DESIGN OF "CANOPÉE DES HALLES" IN PARIS AND ITS CURRENT STATE. THE GLASS PARTS ARE MANUFACTURED BY MEANS OF BREMBANA MACHINES. 13

14 CMS FOR AEROSPACE 14

CMS FOR AEROSPACE Main references The following companies and brands have been provided by CMS or by CMS customers Applied Composites Engineering DACC Aerospace ORPE «Technologiya» ACITURRI DAHER

15 CMS FOR AEROSPACE Main references The following companies and brands have been provided by CMS or by CMS customers Applied Composites Engineering DACC Aerospace ORPE «Technologiya» ACITURRI DAHER RUSAVIAINTER AGC DEMA SAAB AgustaWestland DENEL SCALED COMPOSITES AIDC DOMAERO SPACEX AIP Aerospace Elbit Systems SPIRIT Aerosystems Airborne Aerospace EMBRAER SHANGHAI Aircraft Manufacturing ANTONOV GE Aviation ST Aerospace ATK Space Systems GENERAL ATOMICS SURREY SATELLITE Technology Aurora GKN Aerospace THOMPSON AERO SEATING AVCORP HAL Triumph Group AVIC SAC (Shenyang) IAI TsAGI AVIC XAC (Xi An) Ipeco UTC Aerospace Systems BOEING KUMAPP ZODIAC Aerospace Composite Industrie CTRM LOCKHEED MARTIN MARSHALL Aerospace 15

16 CMS FOR AEROSPACE Position Industrial processes where CMS machines are used CUTTING, DRILLING, MILLING PARTS OF CIVIL AND MILITARY AIRCRAFT, HELICOPTERS, DRONES, ROCKETS, SATELLITES Wings, Empennages, Fuselage Sections, Nose Cones, Doors, Flooring, Interior Bulkheads, Other Structural Parts, Engine Inlets, Nacelles, Thrust Reversers, Turbine Engine Blades, Radomes, Interiors, Seats. Processed Materials: Aluminum, Composites, Core Materials, Titanium. 16

17 CMS FOR AEROSPACE CMS solutions for Aerospace Overview WIDE RANGE OF POSSIBLE CONFIGURATIONS DIFFERENT Y-STROKES DOUBLE WORKING UNIT SAME SHOULDERS SINGLE WORKING UNIT SINGLE BRIDGE DOUBLE BRIDGE DIFFERENT X-STROKES SAME MODULES 17

18 CMS FOR AEROSPACE CMS solutions for Aerospace Overview STANDARD CUTTING TOOLS AND MORE ABRASIVE WATERJET 5-AXIS CUTTING HEAD ENGRAVING LASER ULTRASONIC KNIFE 18

19 CMS FOR AEROSPACE CMS solutions for Aerospace Overview HIGH-TECH INTELLIGENT HOLDING FIXTURES 19

20 CMS FOR AEROSPACE CMS solutions for Aerospace Overview TO COVER THE WIDEST AREA OF PRODUCTION DEMANDS CUTTING OF AIRCRAFT STRUCTURAL ALUMINUM COMPONENTS OBTAINED FROM SOLID MATERIAL CUTTING OF STACKED ALUMINIUM SHEETS ALUMINIUM SKIN THICKNESS REDUCTION SCRIBING OF MASKANT IN THE CHEMICAL MILLING CUTTING, DRILLING, COUNTERSINKING OF COMPOSITE PARTS CUTTING OF CORE MATERIALS AND SANDWICH PROCESSING OF WINDSHIELDS, WINDOWS AND CANOPIES ABRASIVE WATERJET CUTTING OF ANY METAL PART 20

21 SOLUTIONS FOR AEROSPACE 21

22 CMS SOLUTIONS FOR AEROSPACE Composite Materials CUTTING, DRILLING, COUNTERSINKING OF COMPOSITE PARTS High Speed Cutting of aircraft components made of CFRP, AFRP, any other FRP. 22

SOLUTIONS FOR AEROSPACE Composite Materials MACHINES DESIGNED TO CUT COMPOSITES Machine

working units. Large working area and double cutting zone.

Available worktables: Cast-iron table with T slots; Vacuum table; Shuttle table; Vacuum cups table

High Speed and Finishing Quality Travel feed up to 85 m/min. Accelerations up to 5 m/s 2.

23 SOLUTIONS FOR AEROSPACE Composite Materials MACHINES DESIGNED TO CUT COMPOSITES Machine configurations available Single and double mobile bridge, with single or double 3- or 5-axis working units. Large working area and double cutting zone. Modular structure, wide range of configurable strokes. Available worktables: Cast-iron table with T slots; Vacuum table; Shuttle table; Vacuum cups table (each single vacuum cup is managed independently). High Speed and Finishing Quality Travel feed up to 85 m/min. Accelerations up to 5 m/s 2. Spindle rotation speed up to 40,000 rpm. Spindle power from 12 to 32 kw Integrated dust extraction devices Dedicated devices for the dust extraction. Full environment protection Protection cabin with automatic doors. Sliding roof for loading/unloading. 23

24 SOLUTIONS FOR AEROSPACE Composite Materials MILLING OF PATTERNS, MOULDS AND FIXTURES The CMS machine tools may be used not just for trimming, drilling, milling of the final moulded parts, but also in the previous steps of the related manufacturing processes. MOULDED PARTS PATTERNS (AUTOCLAVE, VARTM, RLI, etc.) MOULDS FIXTURES 24

25 SOLUTIONS FOR AEROSPACE Composite Materials CMS INTELLIGENT HOLDING FIXTURES 25

dust generation. Can be combined to standard working units, equipped with electrospindle.

26 SOLUTIONS FOR AEROSPACE Composite Materials STANDARD CUTTING TOOLS + ABRASIVE WATERJET Abrasive Waterjet 5-axis Cutting Head For the trimming of large composite parts, without dust generation. Can be combined to standard working units, equipped with electrospindle. Abrasive catcher with original design by CMS. Pressure intensifiers with original design by CMS. 26

27 SOLUTIONS FOR AEROSPACE Aluminium HIGH SPEED CUTTING OF AIRCRAFT STRUCTURAL ALUMINUM COMPONENTS OBTAINED FROM SOLID MATERIAL 27

SOLUTIONS FOR AEROSPACE Aluminium LARGE WORKING

configurations available Single and double mobile

units. Large working areas and double milling zone.

28 SOLUTIONS FOR AEROSPACE Aluminium LARGE WORKING SPACES AND CUSTOMIZED CNC SOLUTIONS Machine configurations available Single and double mobile bridge, with single or double 3 or 5 axis working units. Large working areas and double milling zone. Modular structure, wide range of configurable strokes. Standard worktables: cast-iron table with T slots; vacuum table; shuttle table. UHF (Universal Holding Fixture). Integrated swarf extraction systems. Protection cabin with automatic doors. Sliding roof for loading/unloading. 28

29 SOLUTIONS FOR AEROSPACE Aluminium THE CMS HIGH-SPEED CUTTING High Speed and Accuracy Travel feed up to 85 m/min. Accelerations up to 5 m/s 2. Dual opposed drive on linear axes. Direct drive on rotating axes. CMS working units: power and control Wide choice of working unit spindles: from 20 kw up to 45 kw. Spindle rotation speed up to 24,000 rpm. Automatic working unit change. L-type and Fork- type milling units. 29

SOLUTIONS FOR AEROSPACE Aluminium CUTTING OF STACKED ALUMINIUM SHEETS High productivity of aluminum parts from stacked sheets (without using rivets or screw) High Productivity Sheet stacks up to 14

. High Speed and Finishing Quality Travel feed up to 100 m/min. Accelerations up to 5 m/s 2. Spindle rotation speed up to 24,000 rpm.

30 SOLUTIONS FOR AEROSPACE Aluminium CUTTING OF STACKED ALUMINIUM SHEETS High productivity of aluminum parts from stacked sheets (without using rivets or screw) High Productivity Sheet stacks up to 14 mm. Bridge cut technology Dedicated device for external contouring without using rivets or screws. No sacrifice of top sheet. Depth of scratches lower than mm.. High Speed and Finishing Quality Travel feed up to 100 m/min. Accelerations up to 5 m/s 2. Spindle rotation speed up to 24,000 rpm. Integrated swarf suction devices Dedicated suction devices for the total swarf evacuation. Integrated and dedicated nesting CAD-CAM software Automatic nesting, with possible manual intervention. Import-export of DXF IGES DWG files. Sheet Optimization. Postprocessor for bridge cut technology. 30

SOLUTIONS FOR AEROSPACE Aluminium TOTALLY OPTIMIZED SOLUTIONS Machine configurations available Fixed bridge with single or double table, for tandem cycle.

Working unit power from 15 kw up to 20 kw, to advantage of flexibility and productivity. Medium sized sheets. High productivity.

31 SOLUTIONS FOR AEROSPACE Aluminium TOTALLY OPTIMIZED SOLUTIONS Machine configurations available Fixed bridge with single or double table, for tandem cycle. Mobile bridge and fixed, medium to-large clamping table with single or double cutting zone. Wide choice of working unit spindles Single or double independent working unit. Working unit power from 15 kw up to 20 kw, to advantage of flexibility and productivity. Medium sized sheets. High productivity. Multi purpose machine By removing the pressure ring, the machining centre may be used for other applications (i.e. solid aluminium plates, sandwich panels, etc.). Options Bar code reader. Special clamping systems. Loading / unloading units. Large sized sheets. 31

32 SOLUTIONS FOR AEROSPACE Aluminium THE PATENTED CMS SOLUTION FOR ALUMINIUM SKIN THICKNESS REDUCTION 32

33 SOLUTIONS FOR AEROSPACE Aluminium THE CMS SOLUTION FOR THE SCRIBING OF MASKANT IN THE PROCESS OF CHEMICAL MILLING 33

34 SOLUTIONS FOR AEROSPACE Core Materials and Sandwich CUTTING OF CORE MATERIALS AND SANDWICH 34

Can be fitted in the standard working units with automatic tool change, Automatic change of knives and/or saw blades.

35 SOLUTIONS FOR AEROSPACE Core Materials and Sandwich STANDARD CUTTING TOOLS + ULTRASONIC KNIFE Ultrasonic Knife For the cutting of zero-radius internal corners. Can be fitted in the standard working units with automatic tool change, Automatic change of knives and/or saw blades. With the same CNC program, you may use the ultrasonic knife in the challenging cuts, toghether with the standard cutting tools, used for the removal of large volumes of material. The consumption of the cutting tools and the related costs can be optimized. 35

36 SOLUTIONS FOR AEROSPACE Other materials PROCESSING OF WINDSHIELDS, WINDOWS AND CANOPIES 36

37 SOLUTIONS FOR AEROSPACE Other materials CMS TECNOCUT ABRASIVE WATERJET CUTTING SOLUTIONS Abrasive Waterjet 3-5 axis cutting solutions For the cutting of parts needing no HAZ (Heat Affected Zones). For the precut of blanks. 37

38 WHEN FLEXIBILITY BECOMES PRODUCTIVITY 38

39 SALES > PRODUCTION = NEED FOR + PRODUCTIVITY The Aerospace sector is asking for improved productivity Source: 2016 Global aerospace and defense sector outlook Deloitte. 39

FROM FIXED TOOLINGS TO FLEXIBLE TOOLINGS Aerospace parts

They are light and subject to deformation and vibration

holding device has to be accurately coupled with the

40 FROM FIXED TOOLINGS TO FLEXIBLE TOOLINGS Aerospace parts to be machined must be carefully held in place. They are light and subject to deformation and vibration when machined Vacuum is used to hold them tightly The holding device has to be accurately coupled with the surface of parts to be machined Source: Global Tooling Systems, CMS Industries. 40

FROM FIXED TOOLINGS TO FLEXIBLE TOOLINGS Flexible tooling

With fixed toolings, a change of batch requires a

the machine and another one must be installed With UHF

41 FROM FIXED TOOLINGS TO FLEXIBLE TOOLINGS Flexible tooling integrated with the machine = great saving of time. With fixed toolings, a change of batch requires a considerable amount of time A tooling must be removed from the machine and another one must be installed With UHF Tablesto set the shapeof a new part isa matter of few minutes UHF = Universal Holding Fixture 41

42 WHY CMS UHF TABLES UHF Tables are competitive when batches are small-sized. P1 STANDARD FIXTURES Cost trends as a function of the variance of parts P2 P3 P4 Sections of parts to be manufactured. P1 P1+P2 P1+P2+P3 P1+P2+P3+P4 Amortization (Fixture's Manufacturing Costs) Logistics Idle Times In the example, to increase the types of parts to be manufactured also implies to dramatically raise the costs per manufactured part. The worst situation occurs with the size 1 batches. By using UHF Tables, the costs per manufactured part will remain steady, equal to the total Amortization+Maintenance. 42

Each module is independent and delivered calibrated, ready-to-use.

43 WHY CMS UHF TABLES CMS UHF Tables are competitive for their plug-and-play modules. CMS UHF Tables have a modular design and are independent by the machine. Each module is independent and delivered calibrated, ready-to-use. Robust and clean design for a long duration in heavy duty and dirty environment. A minimum area+depth of foundation pit is required. Few and simple connections, easy assembly operations, low skill needed. The whole table is self adjusting when a module is added or removed. industrial design low maintenance costs 43

Once stabilized, the cups are locked. 5X TABLE CUPS FIXED FLOATING TABLE CUPS FIXED 5X Automatic Z positioning.

44 RANGE A wide range of configurations, to meet any customer s need. CUPS FLOATING Automatic Z positioning. The PAN and TILT angles are given by the surface of the part to be machined, supported while the cups are idle. Once stabilized, the cups are locked. 5X TABLE CUPS FIXED FLOATING TABLE CUPS FIXED 5X Automatic Z positioning. Automatic PAN and TILT angles positioning. TABLE CUPS FIXED FLOATING, 5X BUTTERFLY RAILS FLOATING 5X TABLE CUPS BUTTERFLY FLOATING TABLE CUPS RAILS 5X 44

MODULES Floating Cup 0º 45º Plug-in connections for utilities only.

45 MODULES Floating Cup 0º 45º Plug-in connections for utilities only. All connections and mechanical lockings are accessed from the top. 750 Dust&Scraps-proof connections. All active components (valves, I/O, motors) are integrated in the sealed actuator s body. NO PLUMBING, PIPINGS AND WIRINGS UNDER THE GROUND. IT IS NOT NECESSARY TO GO IN THE ACTUATORS PIT FOR MAINTENANCE. all linear dimensions are in [mm] 45

46 MODULES 5X TILT 0º 90º extremely small actuator s head 750 Y + PAN Z Only 2 motors to manage 4 axis, thanks to the patented PAN & TILT system. Y PAN 360º Z + TILT HIGH POSITIONING ACCURACY, THANKS TO THE TWO INDEPENDENT AXES. all linear dimensions are in [mm] 46

MODULES Floating Cup + 5X Grinded and chrome stem (Ø 60 mm) Great wear resistance, even in aggressive environment. Does not need additional protections.

The stem stay locked also when the machine is OFF or in case of unexpected power cutting. COMPRESSED AIR VACUUM Simple structure and kinematics No specific maintenance required.

47 MODULES Floating Cup + 5X Grinded and chrome stem (Ø 60 mm) Great wear resistance, even in aggressive environment. Does not need additional protections. Stem locking system Double brake system with normally locked stem: higher radial rigidity and axial loading capacity. Each stem is independently locked. The stem stay locked also when the machine is OFF or in case of unexpected power cutting. COMPRESSED AIR VACUUM Simple structure and kinematics No specific maintenance required. High reliability. Suitable for harsh environment. No additional encumbrance into the working area. High end-effector positioning accuracy. No hoses onto the end-effector. The inner pneumatic circuit Two independent lines for each actuator. 47

48 TABLES Fixed Z Y X A B Special interaxes may be designed. X, Y dimensions, number of modules and their arrangement are customized. Also the height of the working plan (Z) may be customized. The whole table is self adjusting when a module is added, removed or changes its position. No fixed and numbered positions for modules. Each module is identified by the system. THE FIXED TABLES ARE JUST HOST MODULES, LINES AND CONNECTIONS RELATED TO UTILITIES. THAT IS THE BASIC REASON OF THEIR FLEXIBILITY DURING THE DESIGN AND WHEN SOME CHANGES ARE NEEDED. all linear dimensions are in [mm] 48

49 TABLES Butterfly 0º 45º THE FUNCTIONS OF A BUTTERFLY TABLE ARE THE SAME OF THE FIXED ONE, MORE THE AUTOMATIC TILTING OF THE TWO WINGS. 49

TABLES Rails Z Y X A min B min 380 260 THE MOST FLEXIBLE UHF TABLE, ALLOWING TO PROCESS A WIDE RANGE OF PARTS BY USING THE

Also the height of the working plan (Z) may be customized.

50 TABLES Rails Z Y X A min B min THE MOST FLEXIBLE UHF TABLE, ALLOWING TO PROCESS A WIDE RANGE OF PARTS BY USING THE MINIMUM NUMBER OF MODULES. X, Y dimensions, number of rails and number of modules are customized. Also the height of the working plan (Z) may be customized. The whole table is self adjusting when a module is added, removed or changes it position. No fixed and numbered positions for modules. Each module is identified by the system. all linear dimensions are in [mm] 50

SYSTEM Visual Post-Processing Actuator ISO TOOLPATH

51 PROGRAMMING Architecture HARDWARE Tablet SOFTWARE PRO-E, UG-NX, CATIA, others SKIN SURFACE EtherCAT VPP SYSTEM Visual Post-Processing Actuator ISO TOOLPATH ACTUATOR / RAIL / WING MANAGING+POSITIONING PROGRAM Rail Wing 51

TOOLPATH POST-PROCESSOR VPP SYSTEM Visual Post-Processing Calculation of: Actuators position

52 PROGRAMMING VPP SYSTEM - Features PART, TOOLS AND EQUIPMENT LOCATION, ON VIRTUAL UHF TABLE. EXTRACTION SKIN SURFACE EXTRACTION ACTUATOR / RAIL / WING MANAGING+POSITIONING PROGRAM ISO TOOLPATH POST-PROCESSOR VPP SYSTEM Visual Post-Processing Calculation of: Actuators position (Y, Z, PAN, TILT) Rails position (X) Wings angle Toolpath Collisions Detection Virtual Simulation 52

53 CONCLUSIONS 53

54 CONCLUSIONS CMS is an Italian manufacturer of Machining Centres for Composites and Aluminium. CMS supplies the Aerospacewith an unparalleled variety of solutions for the machining of parts made of Composites, Core Materials, Aluminium, Titanium. Today the production demandin the Aerospace still exceeds production volumes and generates the need for improved productivity. By giving more flexibility to equipment you can increase the production rates, egwith a dramatic reduction of logistic operations. This is achieved with the new range of CMS UHF Tables. Fully automatic Plug & Play independent modules, ready-to-use with easy maintenance, simple connections, long duration in heavy duty and dirty environment. 54

55 YOUR TECHNOLOGY PARTNER THANK YOU FOR YOUR ATTENTION

CNC machining centres

CNC machining centres When competitiveness means maximum machining freedom Made In Biesse 2 The market demands a change in manufacturing processes that will allow companies to accept the largest possible