Aluminum Structural Components

Poseidon K - precision CNC monobloc design, power & precision

Poseidon K is CMS' monobloc, precision, moving bridge class CNC machining center for high speed machining of structural aluminum components with high precision, high accuracy, and heavy duty cutting power.

Poseidon K provides a:

• monobloc frame in
• 2600 mm (102.4") or 4000 mm (157.5") X stroke, with
• 1500 mm (59.1" Y stroke,
• 1300 mm (51.2") Z stroke,
• +/- 110° B axis and
• +/- 300° C axis rotation, as well as
• pneumatic brakes on the B & C axes for increased rigidity when not interpolating
• CMS' KX5 working unit with either 15 kW (20.1 hp) power at 12,000 rpm, or 28 kW (37.5 hp) power at 4,300 rpm, maximum 24,000 rpm, liquid cooled, S1 rating, with optional cutting fluid capability through the cutting tool as well as around the cutting tool
• 30 place tool changing magazine for storage of HSK63E toolholders
• available with optional linear and rotary scales
• FANUC 31i A5 controller - Full digital technology, standard
• cast iron tables optional, in place of standard fixed steel work table with aluminum gridded vacuum table and steel T-slots waste removal with liquid recycling and treatment

Poseidon K's heavy duty KX5 working spindles provide the power during high speed machining to remove between 3.5 to 4 inch³ of aluminum per minute, at that rate KX5 15 kW removes between 70 and 80 inch³ per minute (MRR, Material Removal Rate) and KX5 28 kW removes between 131 and 150 inch³ per minute (MRR).

Poseidon K is the starting point in CMS' complete range of heavy duty, high speed machining centers for structural aluminum components.

Cronus K - ultra-precision CNC monobloc design, power & precision

Cronus K is CMS' monobloc, ultra-precision, moving bridge class, CNC machining center for high speed machining of structural aluminum components with linear scale precision, high accuracy, and CMS' Torque5 technology for heavy duty cutting power.

Cronus K provides a:

• monobloc frame in
• 2600 mm (102.4") or 4000 mm (157.5") X stroke, with
• 1500 mm (59.1" Y stroke,
• 1300 mm (51.2") Z stroke,
• +/- 110° A axis and
• +/- 300° C axis rotation, as well as
• pneumatic brakes on the A & C axes for increased rigidity when not interpolating
• guide-way axes double opposing servomotors for elimination of backlash
• enhanced structural stiffness required for Cronus' ultra-precision characteristics
• design elements for elimination of thermic structural growth
• CMS' Torque5 working unit with either 15 kW (20.1 hp) power at 12,000 rpm, or 28 kW (37.5 hp) power at 4,300 rpm, maximum 24,000 rpm, liquid cooled, S1 rating, with optional cutting fluid capability through the cutting tool as well as around the cutting tool incorporating rotary scales for high precision accuracy, high rotational speed, high rigidity, and with high torque capability
• 30 place tool changing magazine for toolholder storage
• complete with linear and rotary scales
• FANUC 31i A5 controller - Full digital technology, standard
• cast iron tables optional, in place of standard fixed steel work table with aluminum gridded vacuum table and steel T-slots waste removal with liquid recycling and treatment

Cronus K's heavy duty Torque5 working spindles provide ultra-precision accuracy with high power during high speed machining to remove between 3.5 to 4 inch³ of aluminum per minute, at that rate Torque5 15 kW removes between 70 and 80 inch³ per minute (MRR, Material Removal Rate) and Torque5 28 kW removes between 131 and 150 inch³ per minute (MRR).

Cronus K is the starting point in CMS' Cronus range of ultra-precision, heavy duty, high speed machining centers for structural aluminum components.

In the picture to the right, Cronus K is shown with its waste removal, chip conveyor, and liquid recycling and treatment system.

Poseidon range - precision, small to very large format, high speed machining

Poseidon's range expands significantly to incorporate increased axis length requirements, making it possible to machine structural aluminum components requiring very large work envelops and making Poseidon perfect for large dimensional projects.

Strokes:

• From X axis 2.5 m to 41.0 m (8.2' to 134.5')
• From Y axis 2.6 m to 8.5 m (8.5' to 27.9')
• From Z axis 1.3 m to 4.0 m (4.3' to 13.1'), non-telescopic version standard and telescopic versions available where reduced height limitations exist Working units:
• From PX5 working unit with 12 kW power (16.1 hp) at 12,000 rpm, maximum 24,000, liquid cooled, S1 rating, A axis +/- 120°, C axis +/- 270°
• To KX5 working unit with 15 kW power (20.1 hp) at 12,000 rpm, maximum 24,000, liquid cooled, S1 rating, A axis +/- 120°, C axis +/- 270°
• To KX5 working unit with 28 kW power (37.5 hp) at 4,300 rpm, maximum 24,000, liquid cooled, S1 rating, A axis +/- 120°, C axis +/- 270°
• 16 place tool changing magazine standard, with additional expansion possible Bridge configuration:
• From a single bridge, with single Z mast and working unit
• To a double bridge, each with a double Z mast, each with a working unit (4 independently CNC controlled working units in total) Controllers:
• FANUC 31i or SIEMENS controller -- Full digital technology Working tables available:
• Cast iron
• Special steelwork tables
• Flat aluminum tables, gridded vacuum, t-slots, precision gridded hole pattern matrix with steel bushings Additional:
• Linear and rotary scales
• Cutting fluid through the cutting tool, as well as around the cutting tool
• waste removal with liquid recycling and treatment and much more...

Cronus range - ultra-precision, small to large format, high speed machining

Cronus' range expands to incorporate increased axis length requirements, making it possible to machine structural aluminum components requiring large work envelops and making Cronus perfect for very tight accuracy, large dimensional projects.

Strokes:

• From X axis 2.5 m to 20.5 m (8.2' to 67.3')
• From Y axis 2.6 m to 5.0 m (8.5' to 16.4')
• From Z axis 1.3 m to 2.0 m (4.3' to 6.6')
• A axis +/- 110°
• B axis +/- 300° Structure:
• Guide-way axes double opposing servomotors for elimination of backlash
• Enhanced structural stiffness required for Cronus' ultra-precision characteristics
• Design elements for elimination of thermic structural growth
• Included linear and rotary scales for high precision Working units:
• CMS' Torque5 working unit with either 15 kW (20.1 hp) power at 12,000 rpm, or 28 kW (37.5 hp) power at 4.300 rpm, maximum 24,000 rpm, liquid cooled, S1 rating, with optional cutting fluid capability through the cutting tool as well as around the cutting tool incorporating rotary scales for high precision accuracy, high rotational speed, high rigidity, and with high torque capability
• 16 place tool changing magazine standard, with additional expansion possible Bridge configuration:
• From a single bridge, with single Z mast and working unit
• To a double bridge, each with a Z mast, each with a working unit (2 independently CNC controlled working units in total) Controllers:
• FANUC 31i or SIEMENS controller -- Full digital technology Working tables available:
• Cast iron
• Special steelwork tables
• Flat aluminum tables, gridded vacuum, t-slots, precision gridded hole pattern matrix with steel bushings Additional:
• Cutting fluid through the cutting tool, as well as around the cutting tool
• waste removal with liquid recycling and treatment and much more...

High speed machining methodology

In addition to the high power and precision control of either Poseidon or Cronus, CMS employs an updated machining methodology, applicable in a number of processing situations, which increases the processing performance of "high speed" aluminum machining. Traditional conventional methods have employed high powered working units, with large diameter cutting tools, working at lower rpms, at a significant cutting depth, which resulted in slower cutting progress, though still removing a lot of material. CMS' unique, updated methodology, utilizes larger diameter cutting tools, at reduced cutting depths, high rpms, and high feed speeds, removing lots of material quickly. At the same time, and where possible, CMS executes a cutting cycle with a depth of 2 to 3 mm at high speed, in which the rib walls may be created at the same time as the roughing work is being carried out, meaning that real time is saved by not needing to return and "re-trim" the rib wall after the roughing operation, resulting in optimum side wall finish, without steps, high accuracy and high efficiency.

Full flood machining, waste removal, filter coolant recirculation system

CMS provides complete waste removal system capabilities, in conjunction with the working tables, to handle the large amount of chips produced during machining cycles, working in tandem with complete fluid filtration recovery and recirculation, in which the system automatically advances new filter media when the filter no longer efficiently works.

Structural components - fuselage

A wide variety of curved structural aluminum components are used throughout aerospace construction, such as components involved in various locations throughout the fuselage.

Structural components - support

Structural aluminum components provide intermediate support between other various components and require precise machining while removing the bulk of the material, thus reducing component weight, and providing high design strength.

Heavy nested fuselage components

This photo shows an example of heavy structural aluminum components used for the fuselage, which are nested in a large sheet and machined with CMS' high precision, high speed cutting methodology.

Wing Spars

Wing spars represent large structural components with the vast majority of the heavy aluminum plate removed and a web of ribs remaining to provide a light weight, yet very strong, structural element, which requires smooth wall surfaces to avoid surface fatigue. CMS' Poseidon and Cronus range of CNC machining centers are perfectly paired to these requirements.

Heavy machining vertically and horizontally

Regardless of the required part orientation for machining, vertically, horizontally or uniquely positioned, Poseidon or Cronus, provide robust structural support, powerful working units, precise control with high accuracy, resulting in perfect parts.

Nose faring - structural component

A complex, structural aluminum, nose faring component is being machined from heavy aluminum plate, using CMS' high speed machining methodology on a Poseidon class CNC machining center.

Aerospace - aluminum structural component overview

CMS presents an overview of high speed machining of structural aluminum components. CMS' Poseidon, double mast version, is shown with 28 kW working spindles, full flood machining, and processing of:

• wing spars - large and heavy, executing processing cycles for milling, surfacing, roughing, rib wall machining and drilling operations
• nose faring - heavy plate, high speed, roughing, rib wall creation, openings, reaming, chamfering, finishing milling and drilling
• wing components - simultaneous, concurrent, left and right machining operations support spans - heavy horizontal machining, rib wall creation in high speed machining methodology

Structural component machining - high integrity required

Poseidon is shown machining a structural ring component from a heavy aluminum block, which cannot be cast or formed for reasons of higher structural integrity. The cycle incorporates an A, B and C positioning for all processing operations, which include roughing, milling, special edge machining, horizontal milling and drilling, and finishing.

Aerospace, CNC solutions

Aluminum Structural Components Sector and HAL Case Study