cincinnati pmt product presentation

ConfidentialMetal Cutting | Composites

Metal Cutting | Composites

Cincinnati PMT Gantry Mill (Precision Mill-Drill-Trim)

May 2015Prepared by: John Hardin

ConfidentialMetal Cutting | CompositesCincinnati PMT Gantry Mill (Precision Mill-Drill-Trim) 2

Product Introduction

• PMT (Precision Mill, Drill, and Trim machine) is Fives’ latest high speed, 5-axis, gantry mill

• Designed for increased productivity, the PMT provides high-performance and precision machining capability

• PMT technology replaces Cincinnati legacy machine designs that have served the industry for over 30 years

• Performs high-speed milling, drilling and trimming operations on aerospace panel parts

• Establishes an industry standard for precise, high-speed machining of large parts

Precision Mill, Drill and Trim (PMT) : Introduction


Fives Precision Mill & Trim Experience

Legacy Systems – more than 30 shipped, many still in use


PMT Introduction

PMT – The new standard for precise, high-speed machining of large parts


PMT Overview

PMT provides speed, accuracy and performance to those manufacturers producing large complex parts from:

• Fiberglass• Graphite composite • Stacked composite layups • Aluminum• Non-ferrous alloys • Aircraft mold materials


PMT Overview

Design Strategy • Modular design

• Proven component designs • Mix & match to permit “build to order” configurations that best fit customer applications • High-performance capability for a broad range of precision machining application

• Engineered for reduced maintenance & lower operating costs

• Designed with “voice of customer” feedback• Price & Delivery• Better accuracy • Integrated dust and chip collection systems• High axis rates • Minimized hydraulics


PMT Configurations

High-rail, Concrete (Standard basic)

High-rail, Stanchion

Low-rail

ConfidentialMetal Cutting | Composites 8

Gantry Mount

Floor or Work Zone Mount

48 tool pockets, 2 x 24 tool diskscrossrail mount

24 tool pockets, single disccrossrail mount, one or two modules

24 tool pockets, single disc

Tool Exchanger Alternatives

18 tool pockets, single disc low-rail slide mount only, one or two modules

• Work plates• Flexible fixturing

system• Pallet system

Chip & Dust Systems

Auxiliary System Alternatives

• Coolant pump-tank-filter• Chip conveyor• Mist collection• Dust collection

Work Holding

Siemens 840 sl

Fanuc 30 i

CNC Control Alternatives

X

Y

Z

Axis Orientation

XYZ Digital Scales- Option

Positioning / Drive Alternatives

1m

1.5 m

2m

Z-axis Ram & Saddle Alternatives

High-railslide

X-axis Slide Alternatives

Modular rail system - Unlimited travel - 1 m increments

X-axis Rails

2m 3m 4m 5m 6m

Y-axis Cross Rail Alternatives

X-axis Rail Support Alternatives(Height to suit Z-axis)

Poured Concrete Steel Stanchions

48 tool pockets, dual discs

Continuous C-axis

+/- 300o C-axis

18k rpm / 20 kW / 30 Nm

Spindle Options

24k rpm / 42 kW / 23 Nm

24k rpm / 34 kW / 39 Nm

30k rpm / 42 kW / 23 Nm

30k rpm / 34 kW / 39 Nm

+/- 360o C-axis

A/C Head Alternatives

24k rpm / 20 kW / 22 Nm

Work zone end doors

X-axis side panels

Flexible roof

Machine Enclosures Alternatives

XYZ axis way covers

2m w/roof

Tool / shroud exchange racks

Pressure Foot

Low-rail slide/riser

Accuracy Packages

Standard

Precision option

Volumetric option

Servo-Tune Alternatives

Acceleration tuneSpeed tune

Multiple modules can be added


PMT Features & Benefits

5-Axis and 5-Sided Flexibility

Benefit: Provides capability to process complex parts• Part molds - detail machining • Part fabrications - detail machining • Post-cured, graphite composite parts - milling, trimming, drilling, cutouts • Fiberglass, stacked composite layups - milling, trimming, drilling, cutouts • Non-ferrous alloy parts - detail machining • Aluminum skins - milling, trimming, drilling, cutouts • Aluminum structural panels - shallow pocket machining



Design is based upon 130 years of precision machine tool manufacturing experience

Benefit: Excellent dynamic stiffness • Provides optimal cutter path response

• Results in precise feature geometries • Results in accurate dimensional tolerances

• Permits aggressive acceleration, deceleration and directional changes during cutting, even with the ram extended

• Designed to permit full spindle power utilization

Benefit: PMT design• High speed machining with the precision expected from a performance machine tool• Provides a balance between performance and economy



Selection of machine configurations

Benefit: Easily customize PMT configuration to match requirements • Z-axis travels: up to 2m (6.6 ft) • Y-axis travels: up to 6 m (19.7 ft)• Unlimited X-axis travel; 1 meter (3.3 ft) increments

Benefit: Provide ranges to process extremely long, wide and tall parts• Examples: aluminum skins, wind turbine blades, boat hulls, aerospace composite structures, light-rail train

structures, etc.



Modular design and optional features

Benefit: Increased productivity with custom configurations• Reduces labor costs & part variability • Selection of spindle speed, power, and torque combinations • Automatic tool storage & exchanger options • Integrated, high-efficiency chip & dust collection vacuum system • Chip & coolant systems appropriate for specific work piece materials • Work piece holding options

Benefit: Automate large part processing

• Improves efficiency, part quality & consistency


PMT Technical Highlights

Precision machine tool design

Robust PMT structural design• Provides adequate dynamic stiffness necessary for accurate,

high speed machining

• Provides optimal cutter path response at high acceleration rates

• Ram section : 475mm x 500mm

• Cross-rail section : 980mm x 1070mm

High speed machining with the precision expected from a performance machine tool

• Produces precise feature geometries

• Provides accurate part dimensions



Basic PMT – Linear Axes Standard Features

• Drive systems are designed to deliver a balance of high-performance and responsive control

• Precision roller-type, linear guide ways on XYZ • Y & Z ways: ISO class 45

• X ways: ISO class 55

• Rack-and-pinion drive system on XYZ axes • Y-axis way covers are included in basic PMT package

• Way covers for X and Z are available as options

Y cover – std.



Basic PMT – Linear Axes Standard Features (continued)

• All electric drive systems on XYZ• Dual servo motors on each X-axis rail • Dual servo motors on Y-axis • Single servo motor on Z-axis (no hydraulic

counter-balance)• XYZ feedback

• Rotary encoder, motor feedback standard on XYZ axes • Linear scale feedback is optional for the XYZ Axes

• XYZ feed rates up to 60 m/min (2360 i/m) • Choice between two standard rate setup packages



Two alternatives for linear axes rate characteristics

Acceleration Servo-Tune package (standard)• X-axis & Y-axis

• Feed rate = 40 m/min (1575 in/min)• Acceleration rate = 0.35 g

• Z-axis • Feed rate = 40 m/min (1575 in/min)• Acceleration rate = 0.35 g

Speed Servo-Tune package (optional)• X -axis & Y-axis

• Feed rate = 60 m/min (2360 in/min)• Acceleration rate = 0.20 g

• Z-axis • Feed rate = 40 m/min (1575 in/min)• Acceleration rate = 0.20 g



Two-Axis Milling Head

• Dual rotary-axis, high-speed spindle head

• Field proven – Reliable

• Dual bearing, trunnion-style, A-axis support for maximized stiffness

• A & C axes powered by direct drive torque motors

• A & C axes equipped with rotary scales (standard)

• Multiple options for spindle speed, torque and power



Basic Head Specifications

• A-axis travel: +/- 110 degrees

• +90 / -100 with dust collection shroud

• C-axis travel: +/- 300 degrees (standard)

• C-axis travel: +/- 360 degrees (optional)

• Continuous C-axis travel (optional)

• A-axis feed rate: 300 deg/sec (50 rpm)

• C-axis feed rate: 300 deg/sec (50 rpm)



Basic Spindle (standard)• Motorized high-speed spindle

• 24,000 rpm maximum; constant power from 8900 rpm

• 20 kW / 22 Nm (26.8 hp / 16 ft-lbs)

• Grease lube

• Tool interface: HSK-63A



Five Alternative Spindle Options – additional details Optional spindle speed, power (S1), torque (S1) offerings

• Option: 18,000 rpm / grease - 20 kW / 30 Nm (26.8 hp / 22.2 ft-lbs)• Option: 24,000 rpm / grease - 42 kW / 23 Nm (56.3 hp / 17 ft-lbs)• Option: 24,000 rpm / grease - 34 kW / 39 Nm (45.6 hp / 28.8 ft-lbs)• Option: 30,000 rpm / oil air - 42 kW / 23 Nm (56.3 hp / 17 ft-lbs)• Option: 30,000 rpm / oil air - 34 kW / 39 Nm (45.6 hp / 28.8 ft-lbs)

Tooling interface HSK 63A



Fluid Services

• Fluid services are provided at one common panel • Fluid Service Panel is mounted on the cross-rail

• Visible from normal operator position • Devices grouped for maintenance accessibility

• Fluid service accommodations include • Fluid valves & pressure switches • Control nodes – profibus • Spindle fluid supply devices

• drawbar clamp/unclamp supply unit • glycol flow switches/monitors • pneumatic purge & tool blow-off control devices • external & internal cutting coolant control devices

• Rack & way lube pump • Permits additional optional content to be added later, with minimal effort



Operator Control Choices

CNC Control systems • Siemens 840D • Fanuc 30i

Operator station location • Standard location – see Location A in view below• Optional location – see Location B in view below

Choice of Siemensor Fanuc CNC

Operator Location B (option)

Operation Location A (standard)


PMT Optional Features

Optional Features: Automatic Exchangers

Automatic tool storage/exchanger options• Tool exchangers – HSK63A • Gantry mounted

• 18 pocket disk (upright mount) low-rail only• 24 pocket disk (cross-rail mount)• 2 x 24 pocket disks (cross-rail mount)

• Work-area foundation mounted • 5 pocket racks (wall mounted) • 24 pocket disk (floor mounted) • 48 pocket disks (floor mounted) • chain type – upon request (floor mounted)

Automatic “device” storage/exchanger options • Special tools & heads or dust vacuum spindle shrouds

• 3 pocket racks (wall mounted) • 8 pocket disk (floor mounted) Gantry Mount

Floor Mount 48-tool disk

shown

Gantry ‘Cross-rail’ Mount



Optional Features: Chip & Dust Removal Systems Efficient vacuum dust collection system for dry machining

• Vacuum collection & filtration unit • High-performance shroud & duct design

• High velocity, high volume design maximizes results • Patents applied for • Removable spindle face shrouds to suit tool length & diameters

Coolant & chip systems for wet machining • Chip conveyance & coolant filtration

• For aluminum • For composite materials

• External spindle coolant option available• Thru-spindle coolant option available

Both options can be included if processing requires wet or dry machining at different times, on the same machine.



Additional Optional Features

Probe options • Spindle probe • Laser tool probe (gage) • Artifact verification

CCTV video camera system – optional

Volumetric accuracy package - optional



Additional Optional Features

Machine enclosure options • Perimeter enclosure • Work area roof

Machine protection options• X & Z- axes way covers • Pressurized way cover upgrade package • Mist collection Perimeter Enclosure Work Area Roof

X & Z covers - options

Y cover - std



Head and Spindle – Additional OptionsPrecision depth control for high accuracy drilling and countersinking

• Precision drilling pressure foot • Third party depth-control tooling

Thru-spindle and external spindle coolant

Thru-spindle cryogenic cutting tool cooling

Dockable waterjet auxiliary head attachment and system for combination milling/waterjet operation

Dockable waterjet head provides multi-functional milling/waterjet capability



Work Holding Alternatives

• Floor Fixture Locators (below)• Steel or Aluminum Floor Plates• Universal Flexible Tooling (right) • Automated Pallet Shuttle Systems



Intelligent solution for flexible fixturing

Lower “Life-tooling” costs – reduces “hard” fixture cost and setup time• Design• Manufacture• Storage• Inspection• Maintenance

cincinnati pmt product presentation

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