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working on a new development in
partnership with Boeing in the US.
With over 600 orders confirmed for its
787 Dreamliner, Boeing needed to
increase its efficiency when machining
the large number of composite
components present in the new aircraft.
Prior to developing the new Series 20-
CCR solid carbide cutter with SGS
Carbide, Boeing had been using helical
Tomorrow’s materials today
Delcam recently staged a seminar on composite product development at its Birmingham HQ
where a number of experts presented their latest innovations. Steed Webzell listened in
Left – machining composites at Delcam,
Birmingham: Above – fixtured composite parts
39
COMPOSITES
www.machinery.co.uk • January 2008
milling cutters normally used for metal
parts, but these often caused problems
such as fibre breakout, delamination and
excessive tool wear.
The new Series 20-CCR is a 12-flute
range of routers for machining composite
materials that overcomes these issues and
provides a better cut edge. It is essentially
an end cutter and profiling tool that will
also plunge to produce holes and pockets.
The secret behind its success lies in the
very shallow helix which reduces the
cutting forces that lead to delamination.
The 20-CCR is patented and SGS is
licensed to produce the cutter. David
Cawkwell, the company’s UK sales
manager revealed that the Vodafone
McLaren Mercedes Formula One team is
currently testing the cutter, while Airbus
and BAE Systems are also interested.
Delcam has itself been actively
involved in the composites market for a
number of years. Delcam’s software for
pattern makers has a number of
synergies with composites and many of
its latest developments are based on
these routines.
For example, Delcam pattern making
functionality such as wire cutting of foam
can get rid of huge quantities of bulk
material. The result is massive time
savings for roughing operations. Delcam’s
PowerMill can also be used for paste
deposition on foam patterns, where the
spindle of a milling machine is loaded
with a paste gun and used to add
material before it is machined away again
for a smooth finish.
ON MACHINE VERIFICATION
Peter Dickin, Delcam’s marketing
manager, also pointed to the company’s
on-machine verification (OMV) routines
in PowerInspect as helpful when
machining composites. This is largely
because these materials can distort or
shrink under cutting force; OMV can
identify out-of-tolerance features on a
first-off and generate another toolpath to
compensate. This can be done over a
number of passes, with the resulting
toolpaths ‘merging’ each time
to create an
optimum final toolpath.
Mr Dickin said that Delcam customers
in the composites area include the Team
Roberts Moto GP team, which is using
PowerMill to drill and trim composite
parts, and Coventry-based Visioneering,
which used PowerMill to produce the
carbon-fibre-reinforced body and underfloor
for the record-breaking JCB
Dieselmax car (picture, below).
Delcam has also successfully
transferred technology from its Crispin
CADCAM product for shoemakers to the
composites sector where it can be used to
‘unwrap’ 3D CAD models into 2D shapes
for tape laying.
Tape laying and fibre placement are
central to the production of composite
parts and it is in these two areas that
MAG Cincinnati is already successful.
Offering what MAG Cincinnati’s
European sales manager Julian Frankland
calls “machine tools of the future”,
material lay-up rates can be increased to
more than 60 kg/hour using automated
methods compared to lay-up rates of
around 1.5 kg/hour for manual methods.
Automation also offers the ability to
condense several parts into a single, more
cost-effective component. The front end
of a fuselage produced by Raytheon was
recently reduced from a staggering 3,400
different parts into just one, using a
MAG-Cincinnati automated solution.
The company has sold 51 flat/contour
tape layers worldwide, including 21 to
Boeing. Bombardier in Belfast is one of
the few UK customers to date: the
company’s Global Express machine
runs around the clock producing
horizontal and vertical stabilisers.■
Material world
Other speakers at the Delcam event included Andy Smith, composite research
engineer at the Composites and Advanced Materials and Technology Centre.
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