This new hybrid machine will be the first hybrid machine that can be equipped with an ultrasonic-capable spindle and can be used for five-axis machining applications.
The DMU 340G linear five-axis machining platform manufactured by Demagison Precision Machinery. This platform has a working area of 12 million, which is especially suitable for large-scale parts processing such as aerospace industry, tools, mold manufacturing and general mechanical engineering. Image source: Demagison Precision Machinery
The world's largest ultrasonic-assisted machine tool is set to enter the University of Sheffield Advanced Manufacturing Research Centre (AMRC, Sheffield, UK). At the end of this year, the ￡ 1.8 million DMU 340 G linear machine will be installed in AMRC, the first composite machine that can be equipped with an ultrasonic-capable spindle and can be used for 5-axis machining.
The 59-square-meter machine was designed and developed by Demagison Precision Machinery (Bielefeld, Germany) with the help of Dr. Kevin Kerrigan, head of the AMRC Composites Processing Center.
Whether it is a high-end luxury automotive microcontroller or a new type of aero engine light fan blade, the DMU 340 G composite machine tool can significantly improve its composite processing performance. In addition, it can perform titanium drilling and finishing operations, and can be combined with new materials such as glass fiber reinforced aluminum, a glass fiber with aluminum sheets and a series of high temperature composite materials interspersed in a resin layer.
It is said that the functions of this machine mainly include high-precision linear motors, fast motion, dust removal technology, high-pressure cutting fluid delivery system, machine detection technology, and industry 4.0 functions including wireless process monitoring and control technology, enhanced connection and plug-in technology.
According to AMRC, the biggest advantage of this machine's ultrasonic capability is high-frequency motion-which can achieve 40,000 tiny motions per second-to help the system better control chip formation and heat. AMRC claims that this machine can bring less harm, less waste and achieve better finishes. These advantages make this technology very suitable for processing hard, rough or fragile carbon fiber composites, alloys and CMCs. s material.
Kerrigan said: "The basic operating process of the ultrasonic-assisted machining process is the same as the standard rotary tool operation process, except that it uses a highly tuned, micro-scale and axial movement of the cutting tool to provide a secondary process for the cutting process. motion.
"This additional movement can control the total energy provided to the cutting interface and further affect the thermal and fracture energy associated with this process.
"This new machine also has a linear drive that brings better acceleration and acceleration changing performance. This drive can quickly propel the machine in a 5-axis tool path, which will help produce complex shapes at high rates while maintaining a certain geometry. Precision. With this linear drive system, the machine can reach a running speed of 90 m / min. At present, the feed rate of the machine is maintained between 1 and 4 m, which is mainly driven by the force generated during the cutting process, even if the rpm exceeds With 20,000 revolutions per minute, there is still room to accelerate tool production with a sufficiently high feed rate. This epoch-making difference is enough to make a leap in productivity. "
The new machine is also intelligent and equipped with an intelligent customizable controller, which enables the machine to have integrated process monitoring technology, which can not only measure performance data, but also increase the service life of the tool.
Kerrigan also said: "The role of this machine is also reflected in process monitoring. The 840D controller is recognized as the most advanced controller, which can extract process information, perform machine health monitoring, workshop connection and closed-loop adaptive control. It also It can be additionally connected to real-time updated process measurements related to measuring tool wear and damage defects. This information can effectively help us gain a deeper understanding of processing operations on complex materials. "
The work of a subordinate department of the Composites Center is to study cutting forces and cutting temperatures. They can provide a wealth of information to determine whether the running process is good, such as whether the dynamic process is stable, whether chattering or forced vibration has occurred, and whether the tool and machine wear Exceeding drive capacity and whether mechanical or bearing wear has occurred.
Kerrigan added: "Because this is a highly abrasive process, and even diamonds are often used as cutting tools, for carbon fiber-based composites, you must often change the tool when the process reaches 50% or 60%. This has also led to higher costs. "
According to reports, this machine can perform both dry and wet processing without harming the machine's moving parts, electronics or operators. It can also work on a range of materials such as titanium or polymer composites. Its high-speed traversal rate makes it very productive. In addition, it also has a particle-controlled door opening function, an infrared measuring probe and a tool changer designed with the introduction of DMG's new modular carousel design.
It is speculated that the DMU 340 G machine will enter AMRC in late December.