Transcript Presentazione di PowerPoint - National Composites Network

High Speed CNC Machining of Composite
Materials for Aerospace
November 26, 2008
SCM Group
•650,000,000 € TURNOVER 2006
•3,800 EMPLOYEES
CMS: AT THE CUSTOMER’S SERVICE SINCE 1969
•FOUNDED IN 1969
•VISION: Construction of Machines Special
•MORE THAN 5,500 MACHINING CENTERS
PRODUCED
•EXPORT: MORE THAN 75%
•90,000,000 € TURNOVER 2006
•7 PRODUCTION PLANTS
•4 OFFICES FOR TECHNICAL
DEVELOPMENT AND QUALITY CONTROL
•500+ EMPLOYEES
•CERTIFIED ISO 9001:2000
IN THE WORLD
• CMS OFFICES WORLDWIDE
•CMS FRANCE – ANTB
•CMS GERMANY
•CMS NORTH AMERICA
•CMS UK
• MORE THAN 50 AGENTS ALL OVER THE WORLD
APPLICATION FIELDS
INDUSTRIAL SECTORS
•AUTOMOTIVE
•AEROSPACE
•PATTERNS AND
MOULDS
•WIND ENERGY
•FOUNDRY
•MARINE
APPLICATION FIELDS
MATERIALS PROCESSED
•COMPOSITES
•LIGHT ALLOYS
•ALUMINIUM
•CASTING SAND
•RESINS
•PLASTICS
AUTOMOTIVE
AUTOMOTIVE
Motorsport and Special parts
-Carbon fibre parts
-Special vehicles
WIND ENERGY
BLADES
NACELLES
SPINNERS
Manufacturing
pattern and
moulds
Milling parts
PATTERNS
AND MOULDS
Aluminium, light alloys, foams, EPS, epoxy phenol and PU resins,
solid wood, plywood, foundry sand, etc…
MARINE
MANUFACTURING
OF MOULDS AND
PLUGS
FOUNDRY
PATTERNS
DIRECT SAND
MOULDS
AEROSPACE
AEROSPACE
MILLING OF
SOLID
ALUMINIUM
STRUCTURAL
PARTS
AEROSPACE
STACK
MACHINING OF
ALUMINIUM
SHEETS
AEROSPACE
CUTTING OF
ALUMINIUM
EXTRUSIONS
AND FORMED
PARTS
AEROSPACE
MACHINING OF
CARBONFIBRE
AND
COMPOSITES
PARTS
AEROSPACE
MACHINING OF
HONEYCOMB
PARTS
EVOLUTION OF THE AIRCRAFT DESIGN AND
Other
MANUFACTURING
Steel
5%
10%
Weight saving for more efficient aircrafts
Extensive use of composites for the production of
primary aircraft structures
Evolution in the part manufacture for greater use
of automated processes
Titanium
15%
Aluminum
20%
Composites
50%
NEW REQUIREMENTS
The automised production of composites parts for aircraft involves
new challenges in terms of machining operations required and CNC
machine specification
5-axis large working envelope
High accuracies combined with fast dynamics
Machine and working environment protection from composite dust
High electro-spindle RPMs
Flexible tooling system and vacuum work holding
CMS SOLUTION
• CMS have designed and produced a range of 5 axis CNC machines
for machining composite and non ferrous materials
Ares-Antares
Poseidon
Cronus
CMS SOLUTION
Large working envelopes
From:
X= 2,600mm
Y= 1,500mm
Z= 800mm
To:
X= 25,000mm
Y= 10,000mm
Z= 5,300mm
CMS SOLUTION
Fast Dynamics
•24,000 RPM electro-spindle
•85,000 mm/min. rapid movement speed
•5 m/s2 acceleration
•Direct drive motors on the rotating axes
CMS SOLUTION
High Level of Accuracy
•Double servomotors on X and Y
axes to eliminate backlash
•Linear guides with recirculating
roller technology
•Linear feedback encoders
•Torque motors on the rotating axes
CMS SOLUTION
Machine Enclosure Systems
• Dust and noise containment
• Operator safety
• High level of electrical protection against carbon fibre dust
• Vision panels design to resist to carbon fibre dust abrasion
CMS SOLUTION
Extraction
• CMS designed extraction hood
• CNC controlled vertical setting for varying tool length
• Extraction hood auto-change system
• Dust extraction pipes in cable track
• Extraction take off points built into machine frame
• Swarf conveyors
CMS SOLUTION
Flexible tooling systems
• Suitable for one-off production
• Fast and automatic set-up
• Eliminates storage of conventional fixtures and tooling
• Reduced costs and time for fixture manufacture
CMS SOLUTION
Automatic pallet changers
CASE HISTORY
CASE HISTORY
BACKGROUND
• 1969: founded by the Brazilian President of the
Republic as a mixed capital company
• 1971: serial production of the Bandeirante
aircraft begins
• 1974: partnership with Piper
• 1977: exports of the Bandeirante to commercial
airlines begins
• 1984: first flight of the AMX prototype
• 1994: privatization of Embraer
CASE HISTORY
BACKGROUND
• 1999: launch of the new 170/190 family
• 1999: strategic partnership with EADS, Dassault, Thales
and Snecma
• 2005: delivery of the 900th jet of the 145 family
• 2005: delivery of the 1000th IPANEMA crop duster
• 2005: launch of light jet
• 2007: record delivery of 169 jets in one year
CASE HISTORY
Range of Products
Defence Aviation
Commercial Jets
Executive Jets
CASE HISTORY
New NEEDS
Approx. ten years ago they
started to use composites
materials
CMS CRONUS’ AND FXBs
Production based on traditional
CNC machines for metal
NEED FOR HIGHER
PRODUCTIVITY, FASTER
RETURN OF THE INVESTIMENT
CASE HISTORY
CMS MACHINES AT EMBRAER
2006: 2 x FXBs for stack aluminium sheets
2006: CRONUS 40/75 Z2000 TORQUE5
2008: CRONUS 40/200 Z2000 TORQUE5
CASE HISTORY
RESULTS
LARGER WORKING ENVELOPE – TANDEM MODE
CLEANER PRODUCTION ENVIROMENT
DRAMATICAL CYCLE TIME REDUCTION: -33%
COST OF THE MACHINE PER PRODUCED PART: -70%