CUSTOM SYSTEMS ::: 5 AXIS Profiler

The challenge for this system was primarily in the size and complexity of the parts. Existing machines to make these parts are very large and slow. The part envelope needed to be at least 30’x15’x3’. An aluminum plate weighing 17,000 lbs. before machining will weigh less than 1,000 lbs. after machining. With this much material removal the time required to machine the part on the old style gantry machines was normally measured in weeks, not days.

Our machine is designed with direct drive on all axes, allowing traverse speeds of up to 3000-5000 inches/minute with 0.5G accelerations. Cutting speeds are only limited by the tooling. Direct drive allows the machine to have zero backlash and high rigidity for the life of the machine, and high resolution feedback systems ensure a perfect cut every time. The machine has a direct driven 2 axis rotary head with +/- 110° on A axis and unlimited C axis rotation. The tables have tool holders built into the edge with a retractible cover (not shown). This allows easy access to tools during loading and unloading, high capacity tool storage, and a simple and reliable Automatic Tool Changer(ATC). Coupled with a 100KW (>130 HP) 18,000 RPM spindle the machining time is reduced to a matter of hours.

To further add capacity, two tables are used. Operators unload and load parts on one table while the part on the other table is machined continously. The new part is ready to cut before the old part is finished, and the machine simply moves over and continues cutting on the new part. When a part needs to be cut that is larger than either table, the tables can be locked together to nearly double the usable length. The tables are surrounded by automatically retracting gates that lower when the table is down, allowing forklifts to drive directly onto the machine table, overhead cranes are not required. The center rails act as chip shields to keep coolant and chips away from the operators on the idle table.

A significant problem with older ganty profiler designs are that the parts are cut in a horizontal configuration with no place for the chips to go, as is illustrated in the photograph below. Not only do the operators have to stop the machine and remove the chips (scoop shovels are not uncommon) but the chips get recut constantly, resulting in poor finishes and decreased tool life. With our design the parts are machined with the spindle in primarily a horizontal orientation, allowing the chips to fall to the conveyor in the base of the machine.