5-Axis Precision Drill & Trim System

5-Axis
Precision Drill & Trim
System

MAG Composites Machining Platforms
(2) MAG Autodrillers Wet (Mist) Machining
Lockheed Martin Ft. Worth; F-35
(2) MAG Autodrillers Wet (Mist) Machining
MAG Selected at Lockheed Martin Marietta, GA; F-35
(1) MAG Twister Dry
Lockheed Martin Palmdale, CA; “Black” Programs
(2) MAG Emills Wet Machining
Boeing Frederickson, WA; 787 Stringers
(12) MAG Routers (6) 3-Axis; (6-Axis) Dry Machining
Boeing Everett, WA; All “7” Series Commercical
(2) MAG Routers Wet and Dry Machining
Boeing Development Center Tukwila, WA;
B-2/F-22 Programs
HyperMach PDT Confidential
July 2009

Modular Design
Universal Flexible
Workholding Systems
X-Axis Rails
Worksurface
Heads & Spindles
Chip/Coolant Systems
Tool Changer Options
HyperMach PDT Confidential
July 2009

Vertical Spindle Traveling Gantry
A family of Affordable, Reliable, & Durable High-Performance Aerospace
Profiling Products. The product family is a modular design based on proven
components allowing ease of configuration to customer specifications.
Rail-type traveling gantry or traveling table design
Large work envelope
Vertical configuration for lowest capital investment
Powerful 5-axis spindles
X & Y-axes driven by rack & pinion or permanent magnet linear motors
X & Y-axes platform modules designed to interface field proven head modules
– both A/B-Axes & A/C-Axes configurations
Scale/encoder feedback for extreme accuracy
Ideal configurations for aerospace applications
HyperMach PDT Confidential
July 2009

HyperMach Vertical Series
Single or Twin Spindle A/C Heads
HyperMach PDT Confidential
July 2009

2-Spindle 9-Axis HyperMach Vertical Profiler
HyperMach PDT Confidential
July 2009

HyperMach Vertical Series
Single or Twin Spindle A/B Heads
HyperMach PDT Confidential
July 2009

A/C-Axes Head Module
5-Sided Milling
A/C High Speed Head Module
Shop hardened - Durable
Field proven – reliable
MAG designed and built in USA
Over 100 A/C heads installed Worldwide
5-Sided/5-Axis Contour Milling
High volume dust/chip collection system
available
HyperMach PDT Confidential
July 2009

Precision Drill & Trim System
Features
Large rail-type gantry machine
5-axis / 5-sided contour part processing
Configurable design
Benefits
Range to process extremely long, wide
and tall parts
– Wind turbine blades, boat hulls, aerospace
composite structures
5-axis flexibility to process intricate detail
– Detail machining of part molds & fabrications
– Post-cure milling, trimming, drilling, cutouts
– Process wood, foam, composite, aluminum,
and titanium materials
Automate large part processing
– Reduce manual labor costs & part variability
– Improve efficiency, part quality & consistency
Modular building block design
– X-axis rails, Y-axis bridge, Z- axis ram, spindle
heads & MORE!
HyperMach PDT Confidential
July 2009

Precision Drill & Trim System
Rail-Type Configuration Alternatives
• High Rail (as shown)
• Concrete X-Axis rail supports
• Low Rail
• Below floor mounted rails with walk-on floor level roll-up covers
HyperMach PDT Confidential
July 2009

Precision Drill & Trim System
Work Holding Alternatives
• Floor Fixture Locators (as shown)
• Steel or Aluminum Floor Plates
• Universal Flexible Tooling
HyperMach PDT Confidential
July 2009

Flexible Tooling Systems
Supports many Aerospace
manufacturing applications:
– Trimming
– Milling
– Drilling
– Water-jet cutting
– Ultrasonic inspection
– Assembly processes
HyperMach PDT Confidential
July 2009

Flexible Tooling Systems
Intelligent solution for flexible fixtures
Low cost
Saves “hard” fixture cost and setup time
– Design
– Manufacture
– Storage
– Inspection
– Maintenance
HyperMach PDT Confidential
July 2009

Finite Element Analysis (FEA) Model
HyperMach PDT Confidential
July 2009

Finite Element Analysis (FEA) Model
HyperMach PDT Confidential
July 2009

Large Gantry & Router Machine
Installations Examples
HyperMach PDT Confidential
July 2009

Boeing Fredrickson
• For Aluminum Aircraft Wing
Skins, Spars and Stringers
• (2) 5-Axis Drill Routers for
precision drilling and detail
routing on stringers for 737,
747, 767, 777
• (5) Super Skin Mills 240 ft. (3
beds wide) for 747, 767, 777
wing skins
• (2) HyperMach Skin Mills 240
ft. bed-types for wide body
commercial aircraft
• (1) Skin Mill (2 bed wide) for
737 wing skins
HyperMach PDT Confidential
July 2009

Boeing Fredrickson
Super Skin Mills with vacuum chip collection
HyperMach PDT Confidential
July 2009

Triumph - Hawthorne
Flexible Skin Trim & Drill Cell
• Dual independent rail-type
5-Axis gantry routers
• Programmable universal holding fixture
systems
• Dry cutting with vacuum chip collection
systems
• Virtual clean-room environment
• Over 40,000 ATA Fuselage panels
produced for B747 & C-17 programs
• On-machine inspection with Renishaw
touch probes
HyperMach PDT Confidential
July 2009

Triumph - Hawthorne
HyperMach PDT Confidential
July 2009

Boeing Decatur – Delta IV Rocket
(10) single spindle skin mills
(6) single spindle 5-axis highspeed
Rail-Type Twister profilers
Used to produce the Delta IV
Rocket Rings
Complete turnkey provided
HyperMach PDT Confidential
July 2009

Boeing Development Center
(2) 5-Axis Gantry Routers for Composites Parts
HyperMach PDT Confidential
July 2009

Cutting Tools for cured composites machining
Solid Carbide fluted cutters & burr tools
HyperMach PDT Confidential
July 2009

Dry vs. Wet Cutting
Dry Cutting
+ Zero cost for coolant media or coolant maintenance
+ Secondary cleaning of finished part may not be required
- Some composite dust material types considered explosive
- must incorporate means to protect for this
Wet Cutting with Flood Coolant
+ Cutting process generates far less heat
+ Improved cutting tool life
+ Cutting fluid controls dust & explosion issues
+ Dust control reduces health risks
- Higher investment required for coolant system and requisite
coolant filtration systems
- Finished parts will require cleaning to remove residual coolant
HyperMach PDT Confidential
July 2009