Ares - Moving Bridge

Ares model 3618

Ares model 3618, CMS' compact, accurate and versatile machining center for advanced materials applications. In this photo can be seen Ares' robust enclosed structure and frontal doors which are automatically controlled via the CNC program. The Ares 5 axis milling machine's safe working environment provides an envelop capable of exploiting its flexibility, power and rigid work surface on which fixtures, molds or projects can be directly anchored, or to which can be added T-slot or vacuum table arrangements, as needed.

In addition, Ares' powerful PX5 head for full 5-axis, freeform, movement for surfacing, trimming or various machining processes can be seen.

Also shown, to the right in this photo, is Ares' optional 16 place tool changing disc for additional tool storage and Ares' B&C alignment device for automatic verification and correction of the B&C rotary axes prior to work beginning or tool length measurement.

Ares model 4818

Ares model 4818, CMS' midsized, multipurpose, 5-axis CNC machining center. The midsized Ares model is the most often requested since its dimensions are perfect for many businesses, making it possible carry out a work cycle on single larger sized items while permitting a pendular cycle on midsized components. In this picture can be seen - between Ares' CNC controlled, telescoping, safety doors - its central divider which makes it possible to carry out a pendular (nonstop) work cycle in complete safety. In Ares' nonstop cycle one side of the machine is open permitting the operator to unload and reload a part while on the other side of the central protective barrier Ares is carrying out a work cycle.

When the operator finishes his load/unload work - or even changing out a fixture - he pushes the "close door" button on the pendant located in front of the door followed by the "cycle ready to begin" button and when Ares finishes it work cycle it is permitted to move into the other work zone. In this way, if the length of cycle time permits, the machine never waits for the operator and both operator and machine can work in complete safety with each other.

When parts are so large that no nonstop cycle can be carried out, the central shield is easily removed along with its interlock letting the CNC know that there is now no central barrier in the way for its complete and unobstructed work cycle in a single zone.

Ares model 6018

Ares model 6018, CMS' large 3D format, 5 axis CNC machining center. The Ares 6018 makes it possible to work throughout truly long spans for parts with lengths up to 6 meters (just short of 20'), while its depth of 1800 mm (70.87") can be increased, optionally, to 2600 mm (102.36") with a Z axis height of 1200 mm (47.24"). The Ares model 6018 vertical machining center also comes with a central protective divider making it possible to carry out a nonstop cycle on parts of even larger size.

Since the Ares model 6018 is a very long machine from which it’s possible to load and unload through the same wide opening, it is provided with a heavy, precision, CNC controlled central support column at the center of this opening, eliminating potential flexion or vibration during work. In the picture on the right the CNC controlled central support (in yellow) is shown in its "down" and working position, in the picture to the right it is seen in its "up" position to permit - if part size requires it – load and unload work or changing of a fixture.

Ares 6018 with APC tables

In this picture is shown an Ares 6018 5 axis milling machine with APC tables (Automatic Pallet Changing). Ares with APC tables makes it possible to fully extract the work table from the work area and permit the operator to work without obstruction from 3 sides of the table, as can be seen with the table on the right in this picture. Ares APC tables also work in synchronization with the operator for a complete nonstop cycle. When the operator has finished with his load/unload work, he pushes the cycle ready button and Ares understands that it may begin work in that zone as soon as it finishes the cycle its working on. The APC tables also come complete with their own protection keeping both the operator safe from entry to the table's moving parts and the table's moving systems safe, covered and free from obstructions.

Ares 4818 with APC tables and downdraft system

Ares 4818 5 axis CNC machining center with APC tables and downdraft system. Ares can also be equipped with an optional downdraft dust collection capability along its sides, back and between the APC tables, when present, to enhance dust collection efficiency. Since Ares is already enclosed on its 4 sides, and the downdraft dust collection points are located just below the work table surface, it can take advantage of the air movement to direct the dust away for the work area. Downdraft dust collection is a perfect solution for 5-axis work where the relationship between tool length, head inclination and dust hood design can make it difficult to always obtain maximum efficiency in dust collection near the cutting tool tip.

To the right of this picture, Ares’ downdraft dust collection system placed around the sides, back and between the APC tables can be seen.

Ares model TR - Rotating Tables

Ares model TR (Rotating Tables). As shown in this picture, the Ares vertical machining center can also come equipped with Rotating Tables (TR). Ares' Rotating Table version can be a perfect solution for a range of manufacturing requirements. Ares model TR provides a fast nonstop cycle (rotation time 7 seconds), requires a small floor footprint, provides a safe work environment for the operator behind the see-through protective barrier (which rotates with the tables), can be supplied with a variety of table types, or even be placed in an automated work cell with robotic load/unload integration.

Ares totally enclosed

Ares totally enclosed. As shown in this 3D engineering drawing, the Ares 5 axis CNC machining center can be supplied in a totally enclosed version, with the addition of its optional roof enclosure. The optional roof enclosure perfectly complements the downdraft dust collection system to prohibit the movement of dust particles back into the plant or operator's work environment. Air movement is directed from the top of the enclosure to the downdraft dust collection points below. In addition, the roof enclosure comes equipped with internal lighting and noise dampening capabilities.

Ares' rigid monobloc structure

In this picture can be seen the basics of the Ares 5 axis milling machine's rigid monobloc structure developed with the following disciplines applied:

• A cellular (honeycomb) style design made from folded steel plate for high torsional stability
• Structural dimensioning through finite element computation (FEM)
• The application of FEM to ensure high stiffness with reduced weight which results in high acceleration and superior finish quality
• Accurate analysis in the design/planning stage regarding first resonance frequency to ensure vibration free machining
• Heat treatment normalization of all structures to ensure maximum stability
• All machined surfaces created in one machine set up so as to ensure total accuracy and alignment Attention to the machine's support mountings using large leveling supports to ensure ease of alignment

Ares' bridge and Z axis mast structure

A picture of the Ares vertical machining center's bridge and Z axis mast on which is mounted its PX5 head with full, freeform, 5-axis movement.

CMS uses the highest quality drive systems which are hardened and precision ground; giving smooth and precise movement with long-life characteristics. During the assembly phase, laser systems are used to ensure the highest possible alignment standards: rack/guide parallelism is set to within +/- 0.01 mm.

Ares' rack/pinion systems are specifically oversized to exceed the design life of the machine and additional durability is guaranteed by the use of high-pressure automatic grease lubrication and innovative ball-bearing cage protection systems.

During machine assembly rectilinearity of the rack is adjusted to less than a hundredth of a millimeter (0.01 mm) and clearance to less than 2 hundredths of a millimeter (0.02 mm). This approach means that Ares' fundamental, raw, performance is set mechanically without the need to resort to backlash compensation systems to resolve inherent design and assembly deficiencies, resulting in Ares being able to continue maintaining its maximum rigidity.

Ares and CMS' patented dust collection hood for 5-axis work

Ares can be supplied optionally with CMS' patented dust collection hood for 5-axis work. In this photo, the Ares 5 axis machining center is shown on the left with its dust hood open (via CNC control) for a tool changing operation or even to pick up and use an aggregate during a machining cycle. On the left Ares is shown with its dust hood closed for use during a machining process. In addition, Ares' unique rotary joint can be seen, which allows the PX5 head to rotate in any manner while permitting dust collection to work unimpeded.

Ares' standard tool holder rack and options

The Ares 5 axis CNC machining center comes standard with one 8 place tool holder rack under the bridge for fast automatic tool changing with its PX5 head. As seen in this photo, Ares can also optionally be equipped with a second 8 place rack under the bridge and with an additional 16 place disc located to the side of its work envelope. When utilized, it opens its protective doors and enters Ares' work envelope and provides a place where the PX5 head can store a tool and rotate its disc to the next required tool. In this arrangement 32 tools are available for a wide variety of work processes. Ares has a number of other tool holding arrangements to meet various requirements for either number of available tool holders, location of tool storage or tool holder weight related concerns.

Ares' table structure

The Ares 5 axis CNC machining center's table structure provides the foundation for rigid anchoring and precision work processes. In this picture can be seen on the left an Ares' APC table and on the right Ares' standard fixed steel flatwork table with threaded hole grid on 600 x 300 mm pitch. Both of these tables are also provided with Ares' optional high efficiency downdraft dust collection capability.

Ares' tables are based on a steel webbed, continuous weld structure ensuring high rigidity across the whole table surface which is normalized by heat treatment to ensure maximum stability for the lifetime of the machine. The tables are designed for machining processes requiring high precision and a total absence of vibration during work.

Ares' table surface options

The Ares vertical machining center's table structure has a number of surface options available.

In this picture can be seen in the upper left an Ares' table surface with a 30 mm thick, solid, aluminum plate with steel T-slot inserts. This provides for quick, rigid anchoring of fixtures and templates, or the use of traditional mechanical clamping instruments.

In the upper right Ares is shown with 30 mm thick, gridded, multilayered, rexilon vacuum table, which in addition to anchoring fixtures can also be used for machining processes requiring vacuum holding of sheets.

In the picture at the bottom can be seen a version of Ares' Advanced Table System providing a range of vacuum modules of various sizes and shapes that fit easily into the gridded table, are orientable and include alignment stops and vices of various sorts. Modules that require compressed air have quick access ports provided in the table in close proximity to them eliminating the need for long runs of tubing to remote connection points.

Ares' optional B&C axis alignment device

In this photo the Ares 5 axis milling machine's optional B&C axis alignment device is seen.

Ares' B&C axis alignment device (located conveniently at the side of the work envelope) makes quick and easy work of several important tasks:

• Work process control verification, if required, that the B&C axes are in alignment before a machining process begins
• An automated re-adjustment of the B&C axes following an uncontrolled movement of the head against the machine, work or fixture Tool length measurement and its automatic insertion into the tool offset table

In the picture to the left Ares is carrying out an axis alignment check or adjustment; in the picture to the right Ares is checking tool length followed by its automatic insertion into the tool offset table.

Ares - model making projects

The Ares 5 axis milling machine makes accurate, quick, easy work of model making projects. In this photo Ares is seen machining tooling board for range of different models.

• In the upper left photo Ares is shown making high speed roughing passes.
• In the upper left Ares' PX5 head moves along at high speed making a series of finishing passes with a ball end mill to create a smooth swept surface on this model.
• In the lower left corner Ares is shown machining the fine details of a model car. In the lower right Ares is carrying out the finish work on this model's vertical surface with its PX5 head inclined horizontally and at a long distance from the spindle nose to give it reach into the deep recess areas, requiring vibration free cutting and well controlled smooth movements.

Ares - machining carbon fiber and fiberglass

Although there is a range of good cutting tools available for machining carbon fiber or fiberglass components, including PCD roughing and finishing bits, as well as carbide, one of the most significant concerns is collecting dust created during the machining process. The first concern is carcinogenic dust emission into the operator's or general environment and then the effect on the machine itself. The Ares 5 axis milling machine, as well as the entire range of CMS machining centers, has special provisions available for these situations. Ares can be optionally equipped with a special downdraft dust collection system and total roof enclosure to completely contain the dust created during the machining process and extract it preventing its emission into the ambient environment. In addition Ares also has an optional "carbon fiber" kit available to protect the machine's ways and electronics from "dust" created during the machining process and its negative effects on the mechanics and electronics.

In this photo on the left Ares is shown machining a carbon fiber part and on the right an example of a complex dashboard mask component.

Ares - mold and pattern machining, aluminum

In this picture Ares is shown machining a mold from a solid aluminum plate. Ares' PX5 full 5-axis, freeform, movement and power makes the roughing and finishing passes effortlessly.

Process: cutting with mist oil

Raw piece dimension: 900 x 400 x 70 mm

Material: Alcast

Total cycle time: 5 hr. 25 min.

Cusp tolerance: 0.01 mm

Roughing speed: 22,000 rpm; Feed: 8,000 mm/min.

Swarf removal rate: 30.5 cu"/min, 6 kW (8 hp) required out of 12 kW (16 hp) (5.08 cu"/kW, 3.81 cu"/hp)

Finishing speed: 24,000 rpm; Feed: 10,000 mm/min.

Ares routing honeycomb materials

The Ares 5 axis CNC machining center also excels in routing and trimming the range of honeycomb materials applications such as Nomex or aluminum. Developments in the last several years have made the option for special tools that can rout and trim these materials particularly interesting and effective, due to the fact they can work at a high rate of cutting speed with a clean cut edge without fuzz, burrs or dust problems. In this photo on the left is a typical Nomex honeycomb material and on the right is an aluminum honeycomb material: both showing cut edges free from fuzz, burrs or dust.

Ares - Ultrasonic Cutting Knife technology

Ares, as well as rest of CMS' range of Advanced Materials CNC machining centers, is also available with Ultrasonic Cutting Knife technology. In this photo Ares is shown applying Ultrasonic Cutting technology to Nomex honey comb. Ultrasonic cutting technology is also applied in various carbon fiber cutting processes as well.

Ares - EPS foam and model making

Today's mold and model makers derive a great benefit from exploiting the use of EPS foam as a model substrate material followed up with an application of chemically cured two part paste, which is later milled to provide the model's hard finished surface. Large size models, or the need for lower cost, more quickly prepared molds, makes EPS substrate and chemically cured paste an increasingly preferred methodology. The Ares 5 axis milling machine also makes processing EPS foam (Expanded Polystyrene) an easy task, since roughing passes can remove large cross sections of material with little resistance and finish passes can take place at very high speed. Although machining polystyrene foam can generate huge amounts of airborne foam dust, the application of special hollow tool milling cutters in combination with Ares' downdraft dust collection system, relieves the problem of airborne EPS dust.

In the picture to the left can be seen a special hollow milling cutter attached to a dust collection system which is extracting the EPS dust through the center of the tool during the contour surface milling process. In the picture to the right the same tool is shown machining deep recess pockets in a large block of EPS foam. These hollow mill cutters come in a variety of sizes, shapes and lengths to carry out typical mold making processes.

Ares - applying paste to a model surface

In this photo, the Ares vertical machining center is seen applying a two part paste, mixed just before it enters the tube to the applicator head, to the surface contour that was previously milled with the hollow milling cutters. The same program that was used to create the surface contour is adjusted so that the paste can be applied by a special applicator head mounted in Ares' PX5 spindle. As Ares makes the passes back and forth on the surface, the paste flows together creating a seamless surface. The paste has a consistency that makes possible its use on sloping surfaces without sagging as well as vertical surfaces, meaning that the range of possible molds and models is not limited by its use.

After the paste has finished its chemical curing - in about 24 to 36 hours - the mold surface can be machined with normal milling tools to create the final finished surface.

Plan view - automated storage and retrieval work cell

This picture shows a plan view of an automated storage and retrieval work with Ares as the machining center for all just-in-time processing requirements. The cell incorporates at its ends entry for the parts to be processed and exit along with stacked vertical locations from which the work cell can obtain the necessary templates, fixtures or molds required for each part to be machined. The fixtures and molds have already been mounted to a fixture plate so that when they are taken from their storage location, they ready to be automatically received by the Ares 5 axis milling machine, centered and locked into position for machining to begin.

Ares - APC table extracted

A picture of the Ares 5 axis CNC machining center integrated into the automated storage and retrieval work cell. Here Ares is shown with the its APC table fully extracted from the machine and on the APC table is an exchangeable template on which each particular fixture or mold will be mounted along with the part to be machined.

Since this application involves the machining of carbon fiber components, as well as honeycomb parts, Ares is provided with an optional "carbon fiber dust kit" along with its special downdraft dust collection system, which can be seen along the sides and back of the photo. In addition, Ares' PX5 head has been equipped with its universal 5-axis dust collection hood and plenum system.

In this photo the CNC controlled door is in the raised position and the table has been extracted from the machine, ready for the template with its fixture and finished part to be taken away and the next template to be put in place.

Ares - APC table in the work position

In this picture the Ares 5 axis milling machine is shown with its APC table now within the machining center envelope, the protective door lowered and ready to work.

Ares - APC mechanism for exchangeable template system

A look at the mechanism on Ares' APC table which is used to position the exchangeable template system, center it and then hydraulically lock it into place during the work cycle.

Ares' APC table - close up

A close up of the Ares vertical machining center's APC table, which has been adapted to work with the requirements of the automated storage and retrieval work cell. Its downdraft dust collection system and additional cutting tool protected storage disc can also be seen at both ends of the work envelope.

Ares - working in Fastems' MLS (Multi-level System)

This photo shows a perspective view of a Fastems MLS (Multi-level System) in which the Ares 5 axis CNC machining center is performing the just-in-time manufacturing requirements for aerospace carbon fiber and honeycomb components. The picture to the left shows a rendering of the MLS and that to the right shows a view from the end and the stacker crane which services the racks and brings the pallet with its fixture to Ares.

Ares' CNC machining center - Fastems' MLS storage and pallet retrieval system

This photo shows another end view of Fastems' MLS. In the picture to the left can be seen the vertical storage locations on both sides of the stacker crane unit, which retrieves and stores the pallets which are brought to the Ares 5 axis milling machine. On the right is a photo of the stacker crane's forks which adjust themselves in width and then extend into the rack to retrieve or store the pallet requested for Ares.