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Composite, Reinforced, & Structural Components

  • Composite, Reinforced & Structural Components
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The number of component parts made from advanced composite materials has been rapidly increasing over the past decade: reinforced composite materials providing structural strength as well as durable internal support surfaces.

The wide range of parts is matched by the broad range of demands for "just-in-time" machining capability, multiple part production, rapid change over, high accuracy, speed and reliability, and the increasing concern with the elimination of dust and carcinogenic particulate thrown off by machining processes. CMS' deep technological capability to provide solutions for each customer's specific need, years of experience in working with the world's leading automotive manufacturers and unique solutions for dust collection, have resulted in long term relationships among the automotive industry's leading companies.

 

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machine

Monobloc
CNC's

Antares - Flexible, high speed, 5-axis machining for composites

Antares - Flexible, high speed, 5-axis machining for composites

ANTARES, CMS' moving bridge class CNC machining center, is a small footprint, 5-axis, laterally enclosed structure for safety with controlled opening of its doors, perfectly adapted for machining composite parts, providing important options for dust control.

Antares comes with machine strokes of:

For fast nonstop work cycles, as seen in the bottom to the photo, Antares can be equipped with CMS' TR system (Table Rotating), by which the operator can be loading and unloading the table in complete safety, while work is being carried on within the machine.

As seen in the photo to the top right, Antares' structural design also makes it possible for it to take advantage of CMS' total enclosure system, by which Antares closes and seals off its top from the ambient and creates a downdraft to pull any dust inside Antares into the dust extraction system, away from the machine and the operator.

Antares makes composites machining work safe, fast and accurate.

  • 2600 mm (102.4") X axis,
  • 1500 mm (59.1") Y axis,
  • 1200 mm (47.2") Z axis
  • +/- 135° B axis, and +/- 270° C axis. Antares' well sized working envelop and powerful 5-axis working unit makes it an ideal beginning point for composites machining requirements with:
  • spindle power of 12 kW (16.1 hp) power at 12,000 rpm, 24,000 rpm maximum, S1 rating, optional 6 kW (8 hp) working unit available,
  • full perimeter safety enclosure with automatic opening and closing door system,
  • optional linear and rotary scales
  • optional dust hood for 5-axis working unit (as seen in the photo to the bottom) optional carbon fiber/composite dust protection kit for composites machining work
ARES - additional options for machining composites

ARES - additional options for machining composites

ARES, CMS' moving bridge class CNC machining center, extends the range of available work envelop sizes and options for machining composite materials and dust control.

ARES has a range of large work envelop sizes, all with full, free form, 5 axis capability:

As seen in the photo to the top, ARES is available with CMS' APC (Automatic Pallet Changing) tables for unobstructed nonstop load and unload cycles from 3 sides of the table.

ARES' TR (Table Rotating) system for nonstop cycles is also available for the 3618 version Dust control options:
The bottom left picture shows ARES with it optional total enclosure and special internal downdraft system for capturing and controlling carcinogenic dust that might otherwise be released into the ambient.

The bottom right photo shows the inside of the total enclosure roof with sound deadening material, lighting system and inflow air supply for the downdraft ducting system.

CMS' unique dust hood for 5-axis work capturing dust at the spindle is available. A high velocity dust extraction system connected to the dust hood, for maximum efficiency, is also available.

  • X axis 3600 mm (141.7"), 4800 mm (188.9") or 6000 mm (236.2")
  • Y axis 1800 mm (70.9") or 2600 mm (102.4")
  • Z axis 1200 mm (47.2")
  • +/- 120° B axis and +/- 270° C axis
  • CMS' PX5 working unit with 12 kW (16.1 hp) power spindle at 12,000 rpm, 24,000 rpm maximum, S1 rating, liquid cooled, or optionally equipped with 6 kW version (8 hp) power spindle at 18,000 rpm, 27,000 rpm maximum, S1 rating, liquid cooled
  • Central protection divider, for nonstop work cycles and independent control of vacuum and compressed air for either side
  • CMS' standard steelwork flat table with threaded hole grid or optional phenolic multilayer or aluminum gridded vacuum table, as well as vacuum table with steel t-slots
  • waste conveying chutes on the back and both sides of the table for easier cleanup Nonstop work cycle options:
Poseidon K & Cronus K - more power and precision for composites machining

Poseidon K & Cronus K - more power and precision for composites machining

The Poseidon K, see photo to the left, and Cronus K, see photo to the right, range of CNC machining centers, each monobloc versions of the larger members of their respective families, extend the performance and processing capabilities required for composites machining. Each is available with:

  • length (X stroke) of either 2600 mm or 4000 mm (102.4" or 157.5")
  • depth (Y Stroke) of 1500 mm (59.1")
  • Z stroke of 1300 mm (51.2")
  • +/- 110° B axis, +/- 300° C axis (called A and C for the Cronus)

Poseidon's working unit is a KX5 with either 15 kW power (20.1 hp) at 12,000 rpm, 24,000 rpm maximum, S1 rating, or 28 kW power (37.5 hp) at 4,300 rpm, 24,000 rpm maximum, S1 rating, and pneumatic brakes on the B & C axes. Poseidon also is available with optional:

  • linear and rotary scales compressed air through the cutting tool, if required
  • CMS' total enclosure with 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


Cronus' working unit is a Torque5 with either 15 kW power (20.1 hp) at 12,000 rpm, 24,000 rpm maximum, S1 rating, or 28 kW power (37.5 hp) at 4,300 rpm, 24,000 rpm maximum, S1 rating, and pneumatic brakes on the A & C axes. Cronus comes standard with:

  • linear and rotary scales
  • enhanced for high accuracy work with Torque drive technology on the working unit
  • double opposing linear drives for reduction of backlash to zero
  • a required heavier structure for higher accuracy demands for sliding ways and torsion stability
  • thermic expansion structural mechanisms


Cronus is also available with optional:

  • compressed air through the cutting tool
  • CMS' total enclosure with 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


Poseidon K and Cronus K offer expanded possibilities for power, accuracy and size for composites machining.

Moving
bridge CNC's

 Poseidon - Composites machining for mid to very large sized components

Poseidon - Composites machining for mid to very large sized components

Poseidon's range can expand significantly to incorporate increased axis length requirements, making it possible to machine composite components requiring very large work envelops, which makes Poseidon perfect for large dimensional parts. The photo to the left shows a smaller Poseidon, easily accommodating small to mid-sized components, while the photo to the right shows a large Poseidon with CMS' total enclosure system completely surrounding the machining center, with natural light panels assisting the internal lighting, high volume dust extraction capability and internal fire safety control system.

Poseidon's work envelop sizes:

  • 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°, B 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°, B 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°, B 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) Optional:
  • Linear and rotary scales
  • Compressed air through the cutting tool
  • CMS' total enclosure with 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
Cronus - Composites machining for mid to large sized components, ultra precision

Cronus - Composites machining for mid to large sized components, ultra precision

Cronus, CMS' moving bridge class CNC machining center, provides the maximum in precision, power and performance for composites machining and can be combined with CMS' special CNC controlled Flexible Table System, FTS, with total automated fixture setup capabilities to accomplish a range of Aerospace machining tasks, as for example the CNC controlled setup, holding and machining of composite wing surfaces.

Cronus' defined higher precision provides a reduced work area, in comparison to Poseidon, to maintain control over many accuracy factors, including thermic expansion considerations; yet its actual stroke lengths are still considerable.

Cronus 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°
  • C 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 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 Dust Control:
  • CMS' optional 5-axis patented dust hood
  • CMS' optional total enclosure for complete ambient dust control CMS' carbon fiber/composites dust protective kit

Note: the photo's to the bottom of this picture show 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.

5 axis
dust technology

5-axis dust hood technology for composites machining

5-axis dust hood technology for composites machining

CMS provides a range of dust hood extraction solutions for 5-axis composites machining applications.

In the photo to the top left can be seen CMS' "clam shell" dust hood, with the dust hood having been opened under CNC program control to permit changing of the cutting tool, use of an aggregate, or to permit a closer approach to the part when in a constrained area. In the photo to the top right the "clam shell" hood has received the command to close.

In the photo to the bottom left is seen CMS' "extendable" dust hood with CNC selection of 3 projected distances in order to match as closely as possible to the actual distance of the cutting tool from the spindle nose. In addition, the "extendable" dust hood is combined with CMS' patented extraction manifold technology for maximum freedom of dust hoses while working in 5-axis interpolated moves. The picture to the bottom right shows the extraction manifold from another view in which 2 extraction hoses join in a flow balanced Y connection for uniform vacuum draw and volume.

Each of these dust hood units can be provided with a CMS supplied high velocity dust extraction system for maximum optimized performance, achieving about a 4 fold improvement in extraction speed over traditional factory systems, and important considering the high kinetic particle energy to be overcome within the small area of the dust hood close to the cutting tool.

Images

Carbon fiber structural rib for Aerospace

Carbon fiber structural rib for Aerospace

Significant interest, development and implementation has occurred during the past decade regarding the new generation of composite materials, and particularly the application of carbon fiber technology in Aerospace components, such as this internal structural "rib", which provides a high strength to weight ratio over traditional materials, resulting in real operating cost and performance benefits. CMS' know-how and technical innovation has kept pace with this development, providing high speed, accurate, machining capabilities with special fixturing systems, safe working environments and dust extraction and containment technology for a clean ambient air around the machine.

 Large structural composite components

Large structural composite components

Carbon fiber, along with other composite materials, has provided technological benefits for large component design and development. As a fiber it is weaved together in various patterns and combined with plastic resin resulting in a high strength to weight ratio, high tensile strength, and unaffected by normal thermic expansion concerns, all properties which make it an excellent choice for large component design, several of which are shown in this photo. CMS' large format machining centers, with their high speed and accuracy, take the challenge out of machining precise large format components.

 Composite bodies in automotive design

Composite bodies in automotive design

As seen in this photo, composite and carbon fiber applications have entered the high performance automotive industry being taken advantage of in designs ranging from sports car bodies to Formula One cockpits to meet the continuing demand for materials with higher strength/weight ratio and performance. CMS is proud to work with such world leaders as Lola Group of the UK, providing them with the high performance 5-axis machining technology required for F1 development and manufacturing.

 Molded Fiberglass components

Molded Fiberglass components

In this photo a fiberglass shell is shown. Providing high quality finished surfaces and strength, fiberglass molded components make beautiful sweeping surfaces possible, which are functionally strong. CMS, in addition to providing the 5 axis machining technology to process fiberglass parts, also provides special protection for its machining centers from the damaging effects of composite dust machining, as well as special dust hood and total enclosure technology for dust extraction, to provide a safe, dust free working environment.

 Decorative, functional, automotive composite components

Decorative, functional, automotive composite components

Various interior automotive components have also been developed and built with composite techniques, which provide the look and feel of real wood, composed of layers of wood and aluminum molded together into strong functional components and beautifully finished, adding interior appeal to some of the world's finest cars. An area in which CMS has been proud to provide such machining solutions for many years.

Structural composite automotive components

Structural composite automotive components

Composite structural components have allowed automotive companies to reduce vehicle weight, as well as take advantage of its energy absorbing benefits, avoiding the damage due to low speed impact events with traditional bumpers or components made from steel. Composite glass mat polypropylene material started replacing traditionally manufactured automotive components in steel in the late 1990's, when it was seen that they offered overall cost savings by as much as 25%, lower tooling and assembly costs by as much as 20% and would meet crash standards, which required that there be no permanent deformation, in the case of a bumper, at speeds of less than 5 mph. CMS has been providing its CNC 5-axis solutions for machining such components to many of the world's well known automotive companies for many years.

Videos

Composite Components - Automotive Applications

A number of composite components with automotive applications are presented in this video, ranging from 5 axis surfacing and machining of the shift knob, to the machining and trimming of the decorative interior trim pieces based on solid wood and aluminum sheet laminates, several composite reinforced structural components, one of which features CMS' rotating table system for high speed nonstop cycle production and equipped with a double 5-axis independently controlled CNC solution permitting the work cycle to be simultaneously executed on the same part and utilizing CMS' special software for division of labor of the CAM program, a car bumper being processed on an ARES with APC tables for nonstop production, and a variety of carbon fiber components being machined.

Aerospace - fiberglass tank machining

CMS' ARES 6018 with APC (Automatic Pallet Changing) tables for nonstop production cycles, and CMS' special downdraft dust collection system for composites machining, is shown processing an aerospace fiberglass composite front tank sectional panel. The curved part is placed on a special fixture. The cycle begins with a large saw blade being used in a 5 axis manner to remove the excess flashing from all sides, following which a router bit machining horizontally is used to trim the side wall height to the correct dimension and then carry out the drilling of the required connection holes along the walls on both sides.

Files

Solutions for Composite Materials Machining
(click folder on the left to download)

 

Advanced Materials Highlights - 4 Composites Case Studies
(click folder on the left to download)

 

BMW/Oracle Selects CMS for Composites Machining
(click folder on the left to download)