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Aluminum Structural Components

  • Aluminum Structural Components
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High speed machining, high quality finish, and high accuracy of machined structural aluminum components is an essential requirement for Aerospace and related industries. CMS has supplied its unique machining center solutions to the world's top manufacturers encompassing parts such as wing spars, nose farings, seat supports and so forth. With high rates of material removal, resulting in smooth rib wall creation in the process, efficient cutting fluid filtration, chip waste removal, and much more, CMS provides serious solutions.

 

Choose
machine

Moving
bridge CNC's

Poseidon

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...

Cronus

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…

Monobloc
CNC's

Poseidon K

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…

Cronus K

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...

High Speed
machining

High speed machining methodology

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

Full flood machining, waste removal, filter coolant recirculation system

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.

Images

Structural components - fuselage

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 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

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

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

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

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.

Videos

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.

Files

Aerospace, CNC solutions
(click folder on the left to download)


 

Aluminum Structural Components Sector and HAL Case Study
(click folder on the left to download)