Faster, More Efficient CNC Machining Center

By on November 10, 2018 in PROCESSES & FABRICATING

The CMS IKON Is Easily Modified to Meet Customer Needs

Background
Established in 2014, Kangde Composite Materials Co., Ltd., is the core enterprise of the carbon fiber lightweight ecological platform that was jointly developed by the Kangde Group and Kangdexin Group. It provides customers with design, research and development for carbon fiber composite parts. This includes lightweight solutions ranging from trial production, inspection, small-batch production to large-scale supply and service.

Situation
Kangde Composite was looking for a more efficient and reliable production machine to trim a CFRP (carbon fiber reinforced plastic) automotive component. The part’s dimensions required the total length be less than 1300 mm while maintaining less curvature and complexity than the previous part.

An advantage of the IKON is being able to easily integrate a robotic load/unload cell, eliminating the need for an attending operator.

Solution
The new IKON, currently being used by Kangde Composite, features the same intuitive programming capabilities as earlier ARES models, but is now capable of trimming very light, strong parts for the automotive industry with greater speed and performance. This new CNC (computer numerical control) machining center can be tailored to each customer’s unique machining requirements while adhering to strict safety standards.

Kangde Composite configured their IKON machine to include a vacuum fixture, heat-shrinkable tool holder, hydraulic-tool holder, carbide-milling cutter, polycrystalline-diamond (PCD) milling cutter, diamond saw blade and an angular milling head. Modifications are made to meet the specifications of a customer’s individual process.

An additional advantage of the IKON is being able to easily integrate a robotic load/unload cell, eliminating the need for an attending operator. Placing two IKON machines face to face with a robotic cell between them also increases the efficiency of auto loading/unloading the tables.

When processing these CFRP parts using the IKON, two identical CFRP panels are trimmed simultaneously in the first step of the operation while the machine’s two heads are used in harmony to create a more intricate trimming in a secondary stage. While one or two parts are being trimmed inside the housing, one or more other parts can be set up on the other side of the double-sided work table. This leads to maximum efficiency and reduced cycle time.

Beyond these capabilities, what makes the IKON more efficient than other CFRP machinery is its automatic debris take-away system. Parts are mounted on the machine table at 5 degrees off vertical so that trimmed-away material falls into an automatic takeaway system. That means operators don’t have to worry about performing any cleanup between trimmings.

The machine is totally enclosed so that harmful carcinogens like dust won’t reach the operators. When there is a vertical table for dust removal, twin spindles that are capable of working simultaneously, and having X/Y axes moving parts outside the working area, are instrumental in avoiding dust pollution. That environmental ingenuity was one reason Kangde Composite Co. decided to invest in the machine.

The machine is totally enclosed so that harmful carcinogens like dust won’t reach the operators.


Results

The IKON not only creates consistent, functioning pieces, but does so in a timely and effective manner. With this higher level of efficiency and safety, the CMS IKON elevated Kangde Composite’s competitive edge. Kangde Composite just went into a significantly larger production phase, which was one of the key reasons for purchasing the CMS IKON. The machine’s advancements have made continuous large production convenient and proficient, leading Kangde Composite to recommend the CMS IKON as it has quickly become a highly valuable addition to their production facility.

Featured Machine Orientation
The CMS IKON is a very flexible, high-speed milling machine. It combines the typical CMS characteristics of precision, reliability and high safety standards with sturdiness, speed and handiness for carrying out any kind of milling, windowing, contouring, finishing, drilling and tri-dimensional machining with up to five reciprocally interpolated axes. It is numerically controlled with two movable vertical bridges and a vertical rotary table for clamping parts on two sides.

This machine is a completely selfcontained CNC machining center that has two heads for performing two identical jobs, two separate jobs or one job faster. The IKON contains a double-sided work table so that one job can be loaded on the outside of the enclosure while another is being completed inside.

Structure and Carriage Movements
The IKON is an open-structure CNC machining center with a rotary vertical working plane. The machine bed is made of very thick, welded and stabilized steel for quick displacements and to give the structure maximum stiffness. The carriages run along high-precision, long-life hardened and ground guides (BOSCH), using four-way track bearings with ball recirculation. All linear guideways have a forced-grease lubrication system, so there is no oil leakage.

The movement of the axes is controlled by AC brushless and digitaltype servomotors. The movement of each axis is produced by a hardened and ground precision rack in which a precision pinion meshes. The machine also contains guide protections that include bellows and double scrapers on the X and Y axes, double scrapers on the Z-axis guides and a package that gives protection from abrasive dust. It is also important to note that accuracy and repeatability will be guaranteed with an operating condition of 20 degrees Celsius +/- 2 degrees.

Axes Strokes and Rapid Transverse

 

 

 

 

 

Precision and Repeatability
CMS assures positioning precision and repeatability according to VDI/DGQ 3441 rules. These controls are achieved using laser measuring systems. A copy of the relevant certificate is given to the buyer.

WORKING VOLUME

Working Units

5-Axis Heads PX5
Two universal heads with F axes all simultaneously controlled by NC (numerical control) provide the inclination and orientation of the tools in any direction. Besides the three basic axes of the machine, the units are also oriented on two rotating axes, the fourth and fifth, freely controlled by NC.

The heads are equipped with special CMS electro-spindles with automatic tool-changers that have a particularly strong shaft on which two pairs of preloaded bearings are mounted, specifically designed for high speeds and performances.

All mechanical components are dimensionally ground, and the rotational parts are dynamically balanced. The fourth axis rotates the unit around the horizontal axis, and the fifth axis inclines the spindle in the vertical plane. The rotating axes are moved by AC motors coupled with highprecision reduction units. The working units are equipped with pneumatic brakes for fixing the A1/A2 and C1/C2 axes position during the machining, which do not require these axes be interpolated. This allows higher system stiffness.

Three Working Functions
• Single operating unit (the other one parked away)
• Two coupled operating units (the heads work on two identical pieces at the same time)
• Fully independent units (the operative units can run two different programs or work on the same part at the same time)

NR.2 16-Position Rotary Tool Magazine
Nr.2 Rotating CNC-controlled disc magazines with 16 stations positioned in the left/right side of the basement structure. The tool magazine is completely isolated from dust, and the operator is able to control the manual introduction of tools during the active working cycle due to an external access.

 

 

 

 

 

 

 

 

WORKING PLANE

Vertical Rotary Table
The table fully rotates in approximately seven seconds.

Top surface: 2 aluminum vertical planes
Size: 3100 x 1800 mm each
Max. load: 1000 kg each

Table surface can be inclined 5 degrees for convenient part loading/unloading.

Vacuum System for Part Clamping
The high-suction pressure vacuum system is generated by a rotary vane pump mounted on a special frame and complete with filters.

 

 

 

Vacuum on/off push buttons and vacuometers.

Full Enclosure (Integral Cabin with Roof)
The machine’s roof guarantees noise reduction and dust dispersion.
• Steel-plate structure with suction inlets integrated
• Lighting plant, protection level IP67

Dust-Suction Inlets
Three dust-suction inlets are installed on the roof and connected to a dust-suction system. These systems efficiently extract dust from the working area.

Chip Conveyor
A conveyor is located on the floor under the part being cut with a slipway from the machine side.

The extraction system is approximately 900 mm high.

Numerical Control Siemens 840 D Solution Line

CNC hardware specifications
• NCU 730.2 with PLC 317-2DP
• PLC 512KB Profibus DP
• NC user memory (RAM) 3 MB for parts programs, tool compensation, offsets
• Diagnostics functions from interface, PLC and NC with plain-text displays on screen
• Driving system: SINAMICS 120 (high-performance control)
• Position inspection: fully closed loop for each axis • Working and processing times displayed
• Advanced surface (COMP CAD)
• Traori (RTCP)
• Five axes spline interpolation
• Transmit and transform peripheral surface
• Measuring cycles
• Five axes machining package
• 3-D tool radius correction
• Operating surface: Sinumerik Operate v.2.6 SP1 in EN, GER, FR, IT, SP, CH

PC hardware specifications
• PC type: PC HP ProDesk 400 G1 SFF
• Processor: Intel Celeron G1820a 2.7 GHz 64 Bit 2 Mb Cache L2
• Memory: 4 GB DDR3 DIMM PC3-10600 Dual Channel a 1.600 MHz
• Hard Disk: 500 GB SATA 7.200 rpm
• Graphic card: Intel HD Graphics
• DVD—Rom
• DVD
• Net card: Ethernet RJ45 10/100/1000
• Expansion slot: (1) PCI Express x16 graphics connectors, (3) PCI Express x1 accessory connectors, Bays (1) 2.5” internal storage drive bay, (1) 3.5” internal storage drive bay
• Keyboard: Standard HP PS2
• Mouse: PS/2 2 buttons optical scroll mouse
• External port I/O: N.4 USB 2.0, N. 1 VGA, N. 1 DVI-D, N. 1 RJ-45, N. 1 RS-232 serial, RS485
• Modem: 56K V9
• Operative System: Windows 7 Pro 32 bit multilanguage

Main Functions
• Display of multi-windows created by the constructor
• Communication windows between CNC and machine
• Dynamic “Ladder” display
• Tool path graphics
• Position display
• Self-diagnosis
• Output signals display (NC ready, drives ready, etc.)
• Alarms
• Display of all executed operations
• Display of PLC messages for the operator
• PLC
• Oscilloscope function for wave monitoring of drives
• Information on machine maintenance

CNC Main Functions
• Standard drilling and milling cycles
• Handling of operating modes: MDI, JOG, EDIT
• Background editing
• Software end-of-stroke control before moving
• Linear and circular interpolation by means of radius programming
• 5 axis spline controlling (high-speed machining)
• Tangent speed control
• Compensation of screw reversal
• Tool offset
• Tool change control
• Axes controlled by PMC
• PMC
• Tool compensation
• RISC SW for AI high-precision, contour control
• 3-D cutter compensation
• Rotation tool center point (RTCP) control
• Program rotation and translation
• Spindle control
• Program restart
• Axis limit protection
• Scaling and mirror function
• SIMATIC STEP 7

Remote Control
Siemens portable console with micrometrical hand wheel for the manual displacement of axes

Sinumerik Handheld Terminal HT2 Compkete With:
• Emergency button
• Safety button (dead man)
• ON/OFF switch
• LCD 16-character display on two lines
• LCD 16
• Centesimal hand wheel
• Feed override switch
• Keyboard with LED for the following functions:
– One axis selection
– Axes “zero” selection
– Wheel mode
– Jog mode
– Positive and negative movement
– Quick speed movement
– Automatic mode
– Single block mode
– Dry run mode
– Start cycle
– Stop cycle
– Reset
– Increment selection
• Standard cable 10 m.
• Magnetic hand wheel

Air-Conditioning System
Fitted on the electrical cabinet to keep internal temperature below 35 degrees Celsius.

Equipment
Compressed-air requirement
Centralized compressed-air system equipped with filter group, pressure regulator, greasing device and minimal pressure control.

Operating pressure 6 bar

Lubrication system

The carriages are greased by forced injection using the automatic centralized system, with pressure and minimum tank level monitoring.

Class3 safety circuits: Able to move the axes manually with reduced speed through the portable keyboard, with doors opened and idle electro-spindle.

N. 2 emergency push-buttons inside the machine

Machine Color CMS standard color—gray = RAL 7035

Peripheral Safety Cabin
The safety cabin is integrated with the basement front-sliding doors that are pneumatically operated and controlled by M code. The safety functions also reduce noise during the milling phase.

The machine complies with the applicable parts of the following directives:

Directive 2006/42/CE
Directive 2014/30/CE

For further information, please contact:
CMS North America, Inc.
Phone: 616-698-9970
Fax: 616-698-9730
Email: Info@cmsna.com
Website: www.cmsna.com

 

ABOUT THE AUTHOR
Ellie Jensen is the marketing assistant at CMS North America, specializing in content writing. She recently graduated with a bachelor’s degree in professional writing from Michigan State University.

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