Moore Tool Machining Line Provides An Advanced Aerospace-Specific Software Feature
When Moore Tool set out to build a true five-axis, high-speed machining center for use in the production of critical components, the challenges were many. The machine was targeted to serve critical needs in the turbo machinery market, mold and die, scroll compressor and medical. Therefore the machine had to have capability to provide superior high speed machining capability when milling materials ranging from aluminum to hardened steel and titanium.
The machine needed high-speed (30-40,000 rpm) cutting capability, dynamic response, superior stability and vibration damping, automation adaptability, user-friendly Windows working environment, onboard cooling, substantial onboard memory in a CNC without external devices for downloading complex programs and, above all, high-precision. However, when your company was founded by a man, Richard Moore, who's credited with "adding a decimal place to the industry," that last requirement is practically a given.
Moore thus took a "from the ground up" approach in developing its Five-Sided Precision (FSP) line of machining centers. They reviewed all the cutting parameters of their prime markets. Speed and accuracy were considered carefully when evaluating the needs of working in different materials along with the differing requirements of production and part accuracy. After all, the requirements of machining aluminum and titanium with high production rates can differ when compared to the intricate contours and features of mold components produced directly in hardened steel. When you add in requirements for efficient graphite machining, the challenges are significant.
The need for a combination of high-precision and high material removal rates was obvious. Plus, the complex contour surface profiling on leading and trailing edges of blades and especially blisks and IBR's, where pocket profiling is most challenging, made a high-speed processor essential to maintain acceptable feed rates. The machine configuration, especially as it relates to the position and configuration of the rotary tables and spindle, would be a key to both the high production and precision needs of Moore's customers.
On the showcase member of this machining center line, the FSP300X five-axis, Moore brought together the fulfillment of its agenda items. With up to 1.7G acceleration in a five-axis mode, 24- and 44-position tool changers with laser toolsetter, precision spindle with HSK40E taper and a Siemens SINUMERIK 840D CNC, the machine can accommodate all the particular needs of its key markets for precision component manufacture in a high-production environment. Plus, the FSP300X offers the flexibility to perform highly complex operations on one-off runs at a cost competitive level.
In order to achieve the maximum machine performance, Siemens performed a detailed dynamic analysis of the complete machine, control and servo drive system. This service is called Mechatronics. Data gathered during the Mechatronics process is used to optimize the complete machine concept, thus allowing the machine builder to push their machine designs to the absolute performance limits with predictable accuracy and part finish results.
In highly complex blade contour and finishing operations, the Siemens SINUMERIK 840D CNC provides an advanced aerospace-specific software feature, COMPCAD, by which the control's compressor function smoothes point-to-point programming. The real benefit of the control is realized when processing the part using NURBS (Non-Rational Uniform B-Splines) which takes the machine to the most advanced level of smooth contouring and chatter elimination. This is achieved by using splines in an axis-specific tolerance window. Contour violations are thus avoided, plus the efficiency of acceleration/deceleration curves is increased, while slowdowns/speed-ups at block transitions are eliminated. These are absolutely critical factors in the machining of aerospace surfaces.
In programming, according to Moore engineers, the open architecture of the CNC, along with its high-speed, user-defined macros and flexible block search capabilities, made it an ideal choice for the FSP300X. The ability of the 840D to handle very large programs typical for intricate mold and die applications without "drip feed" was also of utmost importance.
Options for heightened aerospace, mold and die, medical and other high-precision uses of this machine include high-frequency spindle options up to 80,000 rpm; a variety of robotic part loaders all designed and built by Moore Tool with all control parameters incorporated onto the host CNC; a graphite machining package; laser toolsetter with measurement and compensation standards, plus other custom configurations.
Moore Tool further enhances the machine dynamics on its FSP300X by use of Siemens SIMODRIVE 611D drive packages.
SOURCE: Siemens Machine