'Large Dimensions Models

Large Dimensions Models

The requirement for very large scale models and molds has given impetus to the development of CNC machining centers of a truly large scale as represented by the need for full sized boats, yachts, windmill blades, nacelles, spinners, full sized vehicle bodies, and so forth. CMS' basic CNC families for such large scale models are POSEIDON, POSEIDON MAXI and CRONUS. CMS' unique engineering capabilities provide full 5 axis machining centers with envelops reaching up to 60+ meters (200'+) in length, 10 meters (~33') in width and 5+ meters (~16.5') in height including consideration for vertical height encumbrances with CMS' special telescopic Z axis. Even large models and molds requiring unusually high orders of precision can be obtained with CMS' linear scale technology on all these families and, in particular, on its critically designed, high order of precision, specialized series, CRONUS, including Torque5 technology.

At the upper end of dimensional requirements, CMS' 5 axis machining centers, used for mold and model making applications, benefit from the following:

  • speed, modularity, dynamism, precision
  • adaptive control of processing speeds
  • 5 axis dust collection
  • closed circuit video camera
  • automatic re-qualification of the 5-axis working head and cutting tools (available across the range of CMS' machine families)
  • automatic surface surveying and probing
  • possibility of a telescopic Z axis (on the Poseidon family)

Products Used

Poseidon, Poseidon Maxi, and Cronus - massive 3D working envelops for model and mold machining

Poseidon, Poseidon Maxi, and Cronus, CMS' range of very large format, moving bridge CNC machining centers, provide massive 3D working envelops with powerful, full, free-form, 5-axis working units, making it possible to carry out precise, flexible, powerful machining work on large scale models and molds, perfect for large to very large dimensional projects.

POSEIDON -

Poseidon strokes:

  • From X axis 2.5 m to 41.0 m (8.2' to 134.5'), longer lengths available by request up to 60+ meters (200'+)
  • From Y axis 2.6 m to 8.5 m (8.5' to 27.9'), wider widths available by request up to 10 meters (~33')
  • From Z axis 1.3 m to 4.0 m (4.3' to 13.1'), taller heights available by request up to 5+ meters (~16.5'), non-telescopic version standard and telescopic versions available where reduced height limitations exist
  • available with optional linear and rotary scales
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)

CRONUS -

Cronus' defined higher precision provides control over many accuracy factors, including thermic expansion, yet with axes strokes of significant length.

  • 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°
  • C axis +/- 300°
Cronus 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
Cronus 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 compressed air capability through the cutting tool, and incorporating rotary scales for high precision accuracy, high rotational speed, high rigidity, and with high torque drive technology
  • 16 place tool changing magazine standard, with additional expansion possible

Poseidon and Cronus have the fast positioning speeds and high speed acceleration/deceleration characteristics required for optimum mold and model machining work:

  • Poseidon: quick positioning speeds of 85 m/min (3346"/min) X and Y axes, and 45 m/min (1772"/min) Z axis, 9000°/min B axis & 9000°/min C axis
  • Poseidon: quick acceleration speeds of 3.0 m/s2 (118.1"/s2) X, Y and Z axes, and 500°/s2 B & C axes
  • Cronus: quick positioning speeds of 85 m/min (3346"/min) X and Y axes, and 45 m/min (1772"/min) Z axis, 36000°/min A axis & 24000°/min C axis
  • Cronus: quick acceleration speeds of 3.0 m/s2 (118.1"/s2) X, Y and Z axes, and 2500°/s2 A & C axes
Controllers:
  • FANUC 31i or SIEMENS controller -- Full digital technology
Poseidon and Cronus are also available with optional:
  • compressed air through the cutting tool
  • carbon fiber/composites dust protection kit
  • dust hood for 5-axis work
  • high velocity dust extraction system connected to the dust hood, for maximum efficiency
  • CMS' total full surround dust enclosure or CMS' unique, flexible roof, total dust enclosure, connecting from both sides of the moving bridge to the ends of the machine, detachable via CNC control command and powered in either direction, to or from the bridge, to permit overhead or end loading.

Large boat models - EPS foam machining, paste application and milling or Frame Construction

To produce exceptional boat hull and deck surfaces requires a high quality mold surface, which will be the mirror image of the finished surface. Good molds can be used to build hundreds of boats, or even one, if high-end custom boat or luxury yacht making is the sector involved. The better the plug (the positive male surface), the better the mold that comes from it, and all the subsequent boats made from that. Although it is also possible, that certain mold surfaces may be obtained by direct CNC machining of the mold surface (the negative female surface), bypassing the plug preparation phase. It all depends on the objective and whether a working model is important.

In this photo a rendering of Poseidon is shown, providing a real perspective of the machine and its size for the molds and models produced in its working envelop.

In the photo to the top, Poseidon can be seen with its "walk-way", providing an overview to operators and managers, during the processing of an EPS substrate core on its far end for a large boat deck. Poseidon's working envelop is so large that it's possible for the paste preparation to be done on its other end and allowed to cure - Poseidon has a protective barrier between the side where work is currently taking place and that where operators prepare a model for its next phase - following which Poseidon will receive a new program and mill the hard cured paste surface to a high quality finish.

In the photo to the bottom, Poseidon is shown machining one half of a boat hull's surface using the direct CNC machining to mold approach, the support structure for which has been prepared, a catalyzed polyurethane (PU) mixture sprayed on it, and precisely machined, resulting in a high quality mold surface, which by-passes the need for the preliminary plug development phase.

Poseidon with APC tables - machining nacelle molds

Poseidon or Cronus can be equipped with CMS' APC (Automatic Pallet Changing) tables. In this photo a large nacelle mold, providing turbine cover components for the wind energy sector, is being machined with one of CMS' full, free-form, 5-axis working units. CMS' APC tables provide both the work surface on which the mold is fixed as well as easy movement of the mold in and out from the work envelop.

Poseidon - APC tables, special fixtures for Wind Blades

Poseidon's APC tables can be supplied in long narrow versions, which are perfect for wind blade mold production. In this photo to the left is shown Poseidon with a pair of long narrow APC tables providing a complete work table with reference grid for fixture placement and compressed air connections, where a project can be prepared and setup on one table, while the other is being used for machining, capable of nonstop production, as well as avoiding delays due to setup, with easy accessibility around the APC tables, which are protected from the machine so that the operator may work around the table while the machine is working. The photo to the left shows a Poseidon with a special fixture for holding wind blade molds during machining, while leaving lots of room in Poseidon's work envelop available for other projects.

Poseidon - wind blade mold production

This photo shows, to the left, the CAD work for a wind blade layup mold. The information in the CAD is converted by CAM to that required to carry out the various machining processes needed to create the blade mold's surfaces. In the picture to the top right is shown the substrate, which has already been milled to the approximate surface required, to which the curable paste is being applied under CNC control by Poseidon. The picture in the middle shows the mold with the applied paste curing, while the photo to the bottom shows Poseidon machining the cured paste to the required final, precision blade mold surface.

Very large mold machining

Poseidon machines very large, massive in scale, molds. This picture gives a sense of perspective to just how large such projects can be. In the top photo, part of a very large boat hull structure is seen, complete with port holes, there is a man standing to the back of the picture, almost un-noticeable, to the bottom is seen another large component for the project, with a young lady standing to the front of it. Poseidon's massive structure, with attention to precision, speed and power, result in opportunities never before possible.

Additional Images

Molds - Boat and large components

Molds and models of massive proportions can be made in one piece, or large sections, in CMS' large format, 5-axis, CNC machining centers. As shown in this photo, Poseidon is machining the various required features for a boat deck in an EPS foam substrate over which will be applied a curable paste, later to again be machined by Poseidon and milled to a high quality mold surface. The EPS processing will take place with high speed roughing passes followed by tighter step-over finishing passes, both of which will benefit from CMS' high speed acceleration/deceleration characteristic. To the right side is shown a large mold component in the position in which it has been machined within the work envelop, the horizontal and vertical machining occurring as placed, the bottom picture showing its surface following the roughing passes and the top following the tight finish passes prior to the paste application.

Large molds, models and plugs - EPS foam substrate with curable paste surface

Production of large models and molds can now benefit from CMS' large format combined CNC machining and paste application technology. As shown in this photo to the left, Poseidon has two different, full sized, boat deck plugs, each in a different process phase. That to the back is in the first phase, in which the EPS foam substrate is being machined, while that to the front has had a curable paste applied over the nominally dimensioned EPS surface, cured and ready to be milled to the required final dimension. The pictures to the right show the application of the curable paste on the EPS foam substrate under CNC control, and that to the bottom, the milling of the cured paste surface. The result is a large mold, model or plug, prepared with a greatly reduced total cost and with a high quality, durable, surface.

Large boat hull molds - direct to surface CNC machining

In this photo, to the top, can be seen the two halves of a boat hull mold using a support frame structure, over which a catalyzed polyurethane (PU) has been sprayed on it, and will use the direct CNC machining to finished surface methodology, bypassing an initial plug (and prototyping) phase. Poseidon is shown machining the high quality finish surface on the mold, a process which greatly benefits from its high end feed speeds and highly responsive acceleration/deceleration characteristics. With the mold machining work done, the halves can be assembled and the work of producing a hull take place. The photo to the bottom shows the resulting very large hull structure with a symmetrical, sleek, high quality surface.

Wind blade mold creation

As with other large objects requiring a mold for their production, wind blade mold manufacturing benefits from Poseidon's very large work envelop format. With some wind blade designs reaching lengths of 200', Poseidon's massive work envelop is a perfect match for such demanding requirements. Wind blade mold technology also benefits from Poseidon's combined technology capabilities of CNC machining and paste application. In the photo to the top is shown Poseidon's application of a curable paste on the substrate surface it previously prepared, while to the bottom is shown Poseidon's machining work, bringing the cured paste to its final dimensioned, high quality surface... even though that surface be on a blade 200' in length.

Poseidon - production of the varied wind energy generation components

Wind energy generation technology requires mold and machining work for a number of parts, for which CMS' Poseidon and Cronus range of large format CNC machining centers is perfectly suited. Creation and manufacturing of large size mold components includes such items as: nacelles, spinners (on the bottom), and wind blades, as well as machining work for the root to which the blades attach as shown in the photos to the top.

Poseidon - machining very large molds

Although very large, this boat hull mold is easily contained with Poseidon's massive work envelop. For perspective, a man standing toward the back of the picture is almost lost from view. Poseidon's full, free-form, 5-axis reach to all areas of the work, along with its high feed speeds, high acceleration/deceleration performance characteristics, and massively rigid structure, ensure high quality mold surfaces.

Videos

Boat Deck EPS & Paste machining at Ferretti - Poseidon

CMS presents Ferretti Yachts, well known and world famous for its premier boat and yacht building reputation, and their large format, CMS Poseidon, CNC 5-axis machining center. Poseidon is viewed in its overall size, with access to upper walk way for operator and management overview, double protected work zones and dust cleanup system.

Poseidon is shown roughing and finish milling the EPS foam deck substrate to its nominal surface, over which will later be manually applied a curable paste, also shown. Following which, Poseidon is shown machining the cured paste surface with roughing and finishing passes resulting in a smooth, high quality plug mold surface.

More information about Ferretti Yachts can be found at their website: www.ferretti-yachts.com

Numarine boat hull, direct negative mold CNC machining - Poseidon

Numarine Performance Motoryachts is presented with their large format CMS Poseidon, machining the prow mold hull section of a large, 102' yacht. The process involves the steel structure preparation, the CNC machining of the wood frame applied to the structure, over which the sheets are attached and then the spray application of the catalyzed polyurethane (PU), which will be machined by Poseidon to the final mold surface. The process is a direct CNC to negative mold surface, bypassing the positive plug surface phase, and benefiting from time, material and labor cost savings in the process. The video starts with some circular interpolation machining for a part of the project and then moves quickly into the roughing phase with a flat end mill for high speed removal of the excess material, followed by a large ball end milling tool with tight step over passes for a high quality finished mold surface.

More information on Numarine is available from their website: www.numarine.com

Downloads

BMW/Oracle Selects CMS for Composites Machining

(click folder on the left to download)

Marine Industry

(click folder on the left to download)

CNC Solutions for Wind Energy

(click folder on the left to download)