Horizontal Machining of Aerospace Aluminum Structural Components

Makino, Inc. (Mason, OH) offers their next-generation MAG3.EX 5-axis horizontal machining center, a proven machine platform updated with expanded capabilities for the processing of complex aluminum structural parts for the aerospace industry. With its speed, power and motion control enhancements, this new machine provides aerospace manufacturers with the productivity necessary to exceed customer demands for costs, quality and lead-times. It is fully equipped to take on aluminum structural parts up to 4 m long (approximately 13 ft), including wing ribs, bulk heads and beam-type components. Its X, Y and Z-axis travels of 4,000 mm, 1,500 mm, and 1,000 mm (157.5 in, 59.1 in, 39.4 in, respectively) accommodate part sizes up to 4,000 mm by 1,500 mm by 750 mm (157.5 in by 59.1 in by 29.5 in, respectively). The machine’s A and C-axes are located within the spindle housing and provide ±110 deg tilting and 360 deg rotation.

Many key components, including the spindle, coolant system and automatic tool changer, have been updated with enhanced technologies to achieve next-generation productivity. By increasing the spindle power from 120 kW to 130 kW in the updated model, maximum power can be achieved at 26,000 rpm, rather than 33,000 rpm with the previous spindle. Cutting feed rates and acceleration rates have also been improved, with cutting feed rates increasing from 25.4 m/min to 50 m/min and acceleration rates reaching 1G. Together, these enhanced features dramatically improve processing speeds for all aluminum structural type components. Besides added power and feed rates, rapid traverse rates have been improved across all axes: 25 rpm on the A/C, 62.7 m/min (2,440 ipm) on the X-axis, and 58 m/min (2,283 ipm) on the Y and Z-axis. These faster axial movements, combined with an improved automatic tool changer and automatic pallet changer, reduce non-cutting times in operation for the highest degree of machine utilization. In some test parts, cycle times have been reduced by up to 23 percent compared to the previous model.

To keep up with the larger volume of chips removed by these improved spindle capabilities, coolant and chip management systems have also been updated for improved maintainability. The MAG3.EX is built with a large capacity automatic tool changer, capable of holding up to 120 tools and reducing the time it takes to change tools by 30 percent, and an automatic pallet changer, eliminating the need to stop machining for work setup. Furthermore, the platform features a horizontally oriented work-setting station that lets operators quickly and easily set workpieces on the pallet, similar to how they would a vertical machining center. Three key features of the next-generation MAG3.EX include the Pro6 control, MPmax real-time process monitoring and Collision Safe Guard technologies. A dedicated monitor screen for MPmax is located next to the Pro6 control. Here, the operator can watch uptime rates, view images captured by the monitoring camera and monitor the condition of the spindle in real time. Moreover, operators can access the recorded data and check details afterward.

Proprietary Collision Safe Guard technology is a function that runs real-time interference checks to avoid spindle crashes. By combining on-board machine geometry models with workpiece, fixture and tooling data input by the user, it can predict and stop the machine prior to collision, protecting investments in the machine, fixture, tooling and workpiece. This state-of-the-art sensing technology protects the spindle from damage caused by overload. The updated MAG3.EX can be used with existing pallets, work-setting stations and even pallet changers, making it fully compatible with highly flexible MMC2 systems. This design enables manufacturers to expand existing MAG3.EX cells or replace older machines from their MMC2 with no changes to the foundation.

Makino, Inc., 7680 Innovation Way, Mason, OH 45040-8003, 513-573-7200, Fax: 513-573-7360, www.makino.com.