At the Paris Air Show earlier this month, machine tool manufacturer Schwäbische Werkzeugmaschinen (SW) presented its technology portfolio for the high-precision machining of aerospace components. Using aluminium and titanium wing ribs and blisk parts as examples, SW experts demonstrated how the combination of multi-spindle machining centres and integrated automation solutions can enable fully integrated and efficient production.

“Our customers are under pressure to maintain or even increase productivity in the face of skills shortages and tight delivery schedules,” said Markus Löhe, key account aerospace at SW. “At the Paris Air Show, we showed how our integrated machining and automation solutions help achieve exactly that.”

The exhibits were produced on the BA space 3, currently the largest machine in the SW portfolio. It was developed to meet the demands of modern aircraft manufacturing. The machine’s dual-spindle configuration allows either parallel machining of two workpieces or simultaneous operation of both spindles on a single component – suitable for high production volumes or large workpiece dimensions. Thanks to its two-axis swivel head, it is possible to machine complex components in five axes in a single set-up.

“In the aerospace industry, where structural components such as wing ribs are milled from up to 95% solid material, this machine really stands out for its high dynamics, precision machining and stable processes,” said Löhe. “This also applies to challenging parts such as blisks.”

As complexity increases – especially in large-scale aerospace projects – suppliers are seeking fully integrated solutions that cover every step from machining to process control. SW says its technology offers not only increased output through dual-spindle machining, but also seamless automation throughout the process chain.

More information https://sw-machines.com/

Heller presented its expertise in the productive and flexible manufacture of complex components at the Paris Air Show earlier this month. The accent was on the company’s F and HF series of five-axis horizontal machining centres (HMCs), which see regular use in the aerospace industry for producing various sizes of engine component, doors, landing gear and structural parts.

Especially with regard to the machining of difficult-to-machine materials, Heller says its robust yet compact machining centre solutions are configurable with a choice of automation options, all models being equally suitable for single-part manufacturing or high-volume production, 24/7.

Since the end of 2023, Heller has rolled out five-axis production centres of various sizes in the new F series. In addition to a small footprint, the machines offer acceleration up to 7 m/s² in the linear axes and positional tolerances in X/Y/Z up to 6 µm. A further advantage is the large working volume relative to the external dimensions.

With one-hit machining playing an increasingly important role in many aerospace manufacturing applications, Heller has embraced this all-in-one concept and offers an optional turning function for combined turn-milling on the F series for machines up to 1.6 m in the X axis. The facilitating high-torque rotary table delivers speeds up to 700 rpm, allowing external or internal contouring in the longitudinal or transverse direction in a single set-up, as well as the production of undercuts and recesses. Even the cutting of external and internal threads is possible.

Error prevention features include a digital twin integrated into the Siemens Sinumerik One control system, which supports virtual mapping of a production process before removal of the first chips.

More information www.heller.biz

Mills CNC has introduced a range of simultaneous five-axis machining centres into the UK market. The second-generation DVF 5000 series, successor to the original series introduced in 2018, builds on the success of its predecessor through improved accuracy, faster processing speed and greater machining flexibility.

Faster X-, Y-and X-axis rapids (42 m/min) and 0.4 g acceleration/deceleration rates combine with increased B- and C-axis rotation speeds (25 rpm) and impressive tool-to-tool changeover times of 1.3 seconds to reduce part cycle times and increase throughput.

Standard second-generation machines are equipped with a directly-coupled 18.5 kW/15,000 rpm spindle capable of processing a diverse range of materials in double-quick time. To increase machining capabilities, built-in high-torque 30 kW/15,000 rpm/230 Nm or high-speed 37 kW/20,000 rpm options are available.

Irrespective of the spindle type selected, all options feature advanced oil-cooling which, working in conjunction with strategically located sensors on/in the spindle head, column and bed, monitor thermal displacement throughout the machining process. Automatic parameter adjustment minimises the effects of thermal expansion and drift.

The incorporation of precision roller-type LM guideways and high-accuracy 0.0001° B- and C-axis rotational mechanisms, with the optional IKC (Intelligent Kinematic Compensation) system to monitor and adjust rotary axis errors, guarantees precision even over extended use and lengthy machining runs.

DVF 5000 second-generation machines can handle larger workpieces than their predecessors and feature 630 mm diameter rotary-tilting tables that accommodate workpieces up to 600 mm in diameter and 500 mm in height. There is also a 26% increase in table size, a 32% increase in the machining envelope available, and a 20% increase in X-, Y- and Z-axis travels.

More information www.millscnc.co.uk