COMPOSITES
solutions for automated composites processing - WD Hearn
solutions for automated composites processing - WD Hearn
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SOLUTIONS FOR AUTOMATED <strong>COMPOSITES</strong> PROCESSING
Comprehensive Solutions for<br />
Automated Composites Processing<br />
MAG Cincinnati is the total solutions provider for automated composites<br />
processing. With nearly 100 installations around the world, we have more<br />
tape layers and fiber placement systems in operation than the combined<br />
total of all other suppliers of this equipment.<br />
Expanding Into Growing Composites Markets<br />
Today, MAG Cincinnati customers achieve superior production rates<br />
combined with the industry’s highest compaction forces to produce a wide<br />
variety of aerospace parts including:<br />
, Fuselages<br />
, Wings<br />
, Engine nacelle components<br />
, Horizontal and vertical stabilizers<br />
, Military aircraft inlet ducts<br />
, Satellite launch vehicle components<br />
The strength, durability and versatility of composites have been recognized<br />
in other key manufacturing sectors including energy, automotive and construction.<br />
MAG Cincinnati is leveraging our vast experience and processing<br />
expertise to serve these new composites markets.<br />
MAG Cincinnati has the world’s largest installed base. Here is a sample<br />
of the types of aircraft programs we have supplied equipment for.<br />
MAG CINCINNATI <strong>COMPOSITES</strong> SYSTEMS 20+ MAJOR AEROSPACE PROGRAMS<br />
02 | 03
MAG Cincinnati is the “Supplier-of-Choice” to leading aircraft producers<br />
around the world. Whether choosing automated composites processing<br />
equipment or related machine tools such as robust, titanium processing<br />
machines or specialized equipment, our equipment achieves superior<br />
results.<br />
Australia Hawker de Havilland<br />
Belgium SABCA<br />
Brazil Embraer Air, General Electric<br />
Canada Bombardier, NRC Institute,<br />
Magellan Aerospace, Heroux-Devtek<br />
China Chengdu Aircraft, Shanghai Aircraft,<br />
Xian Aero Engine, Xian Aircraft,<br />
Shenyang Aircraft, Liyang Aero Engine<br />
France Airbus<br />
Germany Airbus<br />
Hungary General Electric<br />
Indonesia IPTN<br />
Israel Israel Aerospace Industries<br />
Italy Alenia<br />
Japan Fuji Heavy Industries,<br />
Kawasaki Heavy Industries,<br />
Mitsubishi Heavy Industries<br />
Korea Korea Aerospace Industries, Korean Airlines<br />
Spain Airbus, EADS CASA<br />
UK Airbus, BAE Systems, Bombardier,<br />
Magellan, Rolls-Royce<br />
USA ATK, Bell Helicopter, Boeing, General Electric,<br />
GKN Aerospace, Giddens Industries,<br />
Goodrich, Hawker Beechcraft, HITCO,<br />
Lockheed Martin, NASA, Northrop Grumman,<br />
Raytheon, Spirit Aerospace, Vought Aircraft<br />
Improving Your Bottom Line With Automated Composites Processing<br />
Prominent aerospace manufacturers rely on our highly reliable equipment<br />
and unmatched process experience to achieve these benefits of automated<br />
lamination:<br />
, Component design optimization by utilizing simulations<br />
, Reduced weight and assembly cost<br />
, Reduced labor costs per component<br />
, Reduced in-process inspection costs<br />
, Reduced material scrap<br />
, Reduced re-work<br />
, Elimination of kitting<br />
SUPPORTING THE ENTIRE COMPOSITE MANUFACTURING PROCESS<br />
MAG Cincinnati not only supplies highly reliable and productive equipment but we also<br />
provide access to the industry’s most comprehensive solution to support the entire<br />
automated process
CHARGER Tape Layers<br />
MAG Cincinnati CHARGER Tape Layers achieve high-speed, precision lay-up<br />
that helps accelerate work flow to shorten build schedules and reduce<br />
work-in-process costs. This newest generation of MAG Cincinnati tape<br />
layers, the CHARGER Series, is engineered for world-class throughput with<br />
faster lay-up and easier, quicker setup. The CHARGER Series lay 75, 150<br />
or 300 mm (3, 6 or 12 in.) carbon/epoxy tape with any orientation and number<br />
of plies, assuring consistent quality part shape, thickness, and strength.<br />
Parts can be laid up over tool surfaces with contours, flats, and changing<br />
geometries, bringing flexibility and precision to the most complex jobs.<br />
CHARGER Tape Layers accommodate 300 mm (12 in.) wide tape<br />
lay-up on contoured surfaces with segmented compactor or<br />
conformable roller<br />
Tape can be “steered” along a path that is not the “natural” path that<br />
the tape wants to follow on a complex contoured surface<br />
MAG Cincinnati has more than 25 years of experience in manufacturing<br />
automated tape laying equipment. The new CHARGER Tape Layers utilize<br />
proven machine components combined with patented features designed<br />
specifically to improve overall performance while maintaining superior<br />
reliability. CHARGER Tape Layers are offered with a choice of advanced<br />
technologies needed for high production tape laying including:<br />
An ultrasonic cutter integrated with the tape head eliminates the need<br />
to transfer and re-align laminates onto a separate cutting machine<br />
, Vacuum lay-up tables<br />
, Ultrasonic laminate cutting<br />
, Integral inkjet marking<br />
, Tape steering<br />
, CM100 computer control<br />
, ACES ® off-line software<br />
The tape head removes the optional inkjet marker from its docking<br />
station to mark white patterns directly onto the uncured laminate<br />
04 | 05
CHARGER Tape Layers<br />
MAG Cincinnati’s CHARGER Series includes both Contour and Flat<br />
Tape Layers available in High Rail, Low Rail and Bed Type configurations to<br />
meet production and facility requirements.<br />
New Contour Tape Head<br />
Recently re-engineered for easier set-up and operation, the new contour<br />
tape head contributes to the machines, higher total throughput. The head<br />
allows faster, simpler side-loading of tape rolls up to 300 mm (12 in.) wide<br />
and 650 mm (25.6 in.) diameter. Common hardware permits lay-up of<br />
75 mm (3 in.), 150 mm (6 in.) and 300 mm (12 in.) wide tape with minimal<br />
changeover time. The advanced head design also features integrated ultrasonic<br />
laminate cutting, cutter depth-setting assistance, and dockable inkjet<br />
marking for maximum system flexibility and performance.<br />
CHARGER Bed-Type Contour Tape Layers achieve up to 25 degree<br />
contours while delivering 50 m/min. (2000 ipm) lay-up rate. The machines<br />
feature MAG Cincinnati’s newest generation tape head which is the market’s<br />
most productive and consistent at compacting layers of carbon/epoxy<br />
tape.<br />
CHARGER Flat Tape Layers are excellent for high productivity lay-up<br />
of large laminates that are then cut into smaller pieces and drape formed.<br />
These machines feature programmable compaction force and optional<br />
vacuum lay-up/cutting tables and ultrasonic laminate cutting enabling<br />
superior quality and performance.<br />
New tape head accommodates fast loading via open sided supply reel<br />
and is capable of laying wrinkle-free 300 mm (12 in.) tape on contours<br />
.<br />
High mold clearance design provides superior conformance and compaction<br />
on ramps and joggles<br />
Segmented shoe allows tape laying with minimum use of roller for less<br />
risk of contamination
CHARGER Tape Layers<br />
NEW Small Flat Tape Layer<br />
MAG Cincinnati now offers a new, entry-level tape layer. This newest<br />
member of the CHARGER Series is designed and built to migrate proven<br />
modules and technologies from our larger composites products to an<br />
affordable, right-sized, yet extremely productive new platform. The Small<br />
Flat Tape Layer with its simplified, but versatile tape head and integral vacuum<br />
lay-up table is well-suited for new users that are making the transition<br />
from hand lay-up as well as for those users that are already experienced in<br />
automated lamination.<br />
Expanded Product Range<br />
To meet the demand for utilizing composite materials for long structural<br />
parts such as stringers, spars and beams MAG Cincinnati has expanded<br />
its tape layer product range to include a new platform, the Flat Charge<br />
Laminator. The Flat Charge Laminator is designed specifically to optimize<br />
processing of these long, narrow parts by accommodating ATL grade<br />
prepreg material up to 300 mm (12 in.) in width while utilizing high-capacity<br />
laminating heads in combination with a heavy-duty support structure for<br />
carriage and segmented vacuum table. The multi-headed design can lay<br />
prepreg unidirectional tape, prepreg woven fabric, and film/foil in the same<br />
variable thickness laminate.<br />
The unit is equipped with features designed for fast, error-free production<br />
Typical Tape Layer Applications<br />
, Wing skins<br />
, Control surfaces such as flaps, ailerons, elevators and rudders<br />
, Structural components such as stringers, spars, beams and shear ties<br />
, Horizontal and vertical stabilizers<br />
, Fuselage panels<br />
, Fairings<br />
, Satellite antenna panels<br />
, Bulkhead<br />
06 | 07
VIPER ® Fiber Placement Systems<br />
MAG Cincinnati VIPER ® Fiber Placement Systems are the most<br />
versatile and advanced composites manufacturing equipment in production<br />
today. The VIPER ® platform of machines combines the advantages of tape<br />
laying and filament winding with advanced computer control and software to<br />
achieve unmatched production capabilities for a wide variety of complex<br />
composites parts. Offered in a variety of sizes, 1200, 4000 and 6000,<br />
VIPER ® Fiber Placement Systems are designed for dexterity and flexibility<br />
for production of wrinkle-free lay-up of convex and concave parts. These<br />
highly productive machines are equipped with patented features to produce<br />
superior quality while dramatically reducing scrap.<br />
These patented features include:<br />
, Segmented Compaction Roller offers superior compaction on core<br />
and tight radii contour surface features<br />
, Bi-directional Tensioners located in the creel enclosure maintain<br />
precise tension control of each tow as well as monitor the individual<br />
pay-out of each<br />
, Re-direct Roller Systems reduces the likelihood of twisted tows by<br />
maintaining a flat fiber band<br />
, Individual Tow Cut-Clamp-Restart adds versatility by adjusting the<br />
width of the fiber band by adding or cutting individual tows on-the-fly<br />
Get the VIPER ® Advantage<br />
With 7 axes of motion, VIPER ® Fiber Placement Systems are particularly<br />
suited to highly contoured structures. High contour, variable wall thickness,<br />
and cut-out sections are all produced to near net configuration which<br />
significantly reduces material waste (as low as 2%) in the initial lay-up and<br />
post-process machining operations.<br />
VIPER ® Fiber Placement Systems automatically and independently control<br />
up to 32 individual tows or slit tape producing a variable bandwidth<br />
“on-the-fly”. Each tow can be independently dispensed, clamped, cut and<br />
restarted during fiber placement. Gaps and overlaps are minimized as the<br />
machine precisely lays interior or exterior contoured boundaries.<br />
The VIPER ® ’s advanced design delivers other key advantages to automated<br />
production including maintaining constant angle on a complex surface,<br />
in-process compaction of material and no limits to ply orientations.<br />
Individual Tows (x32) 3.2 mm (0.125 in.) 6.4 mm (0.25 in.) 12.7 mm (0.5 in.)<br />
Collimated Fiber Band 102 mm (4 in.) 205 mm (8 in.) 406 mm (16 in.)
VIPER ® Fiber Placement Systems<br />
VIPER ® 1200<br />
, Part diameters up to 2 m (80 in.)<br />
, 12 tows; 3.2 or 4.0 mm (0.125 or 0.157 in.)<br />
NEW VIPER ® 4000<br />
, Part diameters up to 6 m (236 in.)<br />
, 24 or 32 tows; 3.2 or 6.4 mm (0.125 or 0.25 in.)<br />
VIPER ® 6000<br />
, Part diameters up to 8 m (315 in.)<br />
, 32 tows; 3.2, 6.4 or 12.7 mm (0.125, 0.25 or 0.5 in.)<br />
NEW Expanded Product Range<br />
The VIPER ® 4000 is the newest machine in our VIPER ® Series of fiber<br />
placement systems. This machine offers high dexterity and clearance for<br />
lay-up on female molds. The new VIPER ® 4000 utilizes standard components<br />
from MAG Cincinnati’s VIPER ® 6000 platform combined with special<br />
features to deliver unmatched dexterity and flexibility in processing medium<br />
to large contoured parts. The machine offers unprecedented ease-of-use<br />
and is capable of processing a wide range of composites parts up to 6 m<br />
(236 in.) diameter utilized in today’s new aircraft designs. In particular the<br />
VIPER ® 4000 is well-suited for producing fuselages for both regional and<br />
business jets as well as engine nacelles.<br />
VIPER ® Applications<br />
VIPER ® Fiber Placement Systems deliver proven fuselage production<br />
capabilities from the smallest business jet to the world’s largest commercial<br />
aircraft. Hawker Beechcraft‘s Premier 1 Business Jet is made of two 360°<br />
fuselage sections produced on a VIPER ® Fiber Placement System. The<br />
composite fuselage design is 20% lighter than aluminum and reduces the<br />
number of parts from the original 3000 to two.<br />
All skin panels for Sections 19 & 19.1<br />
of the Airbus A380 are made on<br />
VIPER ® Fiber Placement Systems.<br />
Other VIPER ® Applications<br />
, Wing skins<br />
, Nacelles<br />
, Inlet ducts<br />
, Launch vehicle components<br />
08 | 09
Powerful Control and Software<br />
MAG Cincinnati leads the industry with control and off-line programming<br />
software platforms compatible with both our CHARGER Tape Layers and<br />
VIPER ® Fiber Placement Systems.<br />
Powerful CM100 Control<br />
MAG Cincinnati’s CM100 computer control is the only control designed<br />
specifically for automated composites production. This powerful, yet<br />
extremely easy-to-use control features an open-architecture design<br />
powered by industrial grade processors and digital servo drives to deliver<br />
fast, smooth and accurate machine motion.<br />
The CM100 provides coordinated motion of all machine and head axes<br />
and controls all dispensing functions to accurately place the composite<br />
material onto the lay-up surface with programmable compaction control.<br />
The highly rated, operator-friendly CM100 executes part programs without<br />
requiring a separate PC to serve as a front end processor, and it complies<br />
with all applicable industry standards, including CE Mark requirements.<br />
The CM100 utilizes 100% standard commercial hardware which includes<br />
a large 19 inch color touch screen monitor, industrial keyboard, and<br />
pointing device. MAG Cincinnati’s proprietary control software enables<br />
multi-level password access, multiple display pages and menus, real-time<br />
combined diagnostic displays, and exclusive push button history. The<br />
Observer Part History software included with the CM100 gathers and<br />
reports manufacturing data that can be used to optimize the lamination<br />
process for maximum system productivity. Data access is provided<br />
through standard Windows ® network utilities and optional OPC Server.<br />
ACES ® – Advanced Composites Environment Suite<br />
ACES ® is MAG Cincinnati’s proprietary programming and simulation<br />
software tool for tape laying and fiber placement. This powerful suite is<br />
PC-based, compatible with CATIA V4 and V5, CATIA CWB/CD3, and<br />
FiberSIM, and provides a variety of path generation types. ACES ® supports:<br />
part programming, part simulations, productivity analysis and production<br />
animations.<br />
With the largest number of users worldwide, our ACES ® off-line programming software<br />
consistently receives superior customer satisfaction ratings
Optimized Cutting Performance<br />
MAG Cincinnati designs and builds a wide range of highly reliable<br />
machine tools utilizing features that optimize cutting performance. Whether<br />
you’re machining composite, titanium, steel, nickel alloys, or aluminum,<br />
we have the equipment that delivers long-term, high productivity operation.<br />
MAG Cincinnati offers processing expertise and machining techniques wing<br />
drilling and forward fuselage system performs automated drilling to drill and<br />
countersink fastener holes on the outer skin and substructure of the upper<br />
and lower surfaces of the wing and forward fuselage cockpit side panel for<br />
F-35 (Joint Strike Fighter) aircraft.<br />
High-Speed Aluminum Cutting<br />
MAG Cincinnati offers the broadest range of products for high-speed<br />
processing of aluminum. Our equipment can be found in production across<br />
the globe processing thin wall aluminum components of all shapes and<br />
sizes. The HyperMach TM linear motor profiler is achieving the highest metal<br />
removal rates in production – 7538 cm 3 /min. (460 in 3 /min.).<br />
Waterjet Cutting<br />
Waterjet cutting is one of the best methods for cutting composite material,<br />
hard metals and high temperature resistant material. MAG Cincinnati offers<br />
a highly reliable system that is in production manufacturing composite skins<br />
and structural parts at leading manufacturers around the world.<br />
Titanium and Hard Metal Cutting<br />
Titanium brings tremendous advantages to aircraft construction –<br />
compatibility with composite materials, light weight, great stiffness,<br />
strength, as well as being heat- and fatigue-resistant. MAG Cincinnati<br />
provides robust machine tools combined with expertise in helping<br />
customers select tools, fixtures and machining techniques – all critical<br />
elements in machining titanium.<br />
Specialized Tooling Solutions<br />
Through our award-winning service and support organization, MAG Maintenance<br />
Technologies, MAG Cincinnati exclusively offers specialized Technicut<br />
cutting tool solutions for machining aerospace alloys and composite materials.<br />
Together, we are setting new benchmarks for composite and metal removal<br />
rates throughout the aerostructure and aeroengine markets.<br />
Composite tooling solutions<br />
Metalcutting tooling solutions<br />
Wing drilling systems<br />
Waterjet cutting<br />
With over 20 years experience of composite machining methodologies,<br />
Technicut has the capability to manufacture optimized tooling solutions<br />
which profile, surface machine, rout, contour, and produce holes in all<br />
composite materials. Technicut designs and manufactures solid carbide,<br />
brazed carbide, high speed steel, and polycrystalline diamond roughing and<br />
finishing tools for a diverse array of materials and machining applications<br />
ranging from titanium blisks, blades and impellers to titanium and aluminum<br />
monolithic solid aerostructures.<br />
Titanium cutting<br />
High-speed cutting<br />
10 | 11
Automated Assembly, Systems<br />
Integration and Testing<br />
Automated Assembly, Systems Integration and Testing<br />
World-class producers of aircraft and aircraft components are now seeing<br />
the cost savings and accuracy improvements that can be achieved utilizing<br />
manufacturing practices that were once only used in automotive manufacturing.<br />
MAG Cincinnati Automation business is leveraging its automotive<br />
expertise to tailor solutions for the aerospace industry. We have successfully<br />
designed, built and installed systems for some of the most respected aerospace<br />
manufacturers. MAG Cincinnati Automation offerings include material<br />
handling, composite forming, robots and fixturing solutions employing<br />
standard, flexible or customized solutions to satisfy specific manufacturing<br />
challenges and ergonomic needs.<br />
Proven Aerospace Solutions<br />
1 Material Handling: conveyor & transfer mechanisms, including<br />
gantry, pick and place and conveyance<br />
2 Detail Part Manufacture: manufacture and fabrication of raw<br />
Material: components include rib, skin, stringer, spar, bladder, floor<br />
beams and panels<br />
3 Robotics: drill, riveting, sealant application for wing and fuselage<br />
assembly End of Arm Tooling (EOAT)<br />
MAG Cincinnati Automation has more than 30 years of experience with over<br />
2500 installations worldwide. We offer a complete range of products from<br />
machining to assembly to automation.<br />
More Process Experience from MAG Cincinnati Automation<br />
1<br />
, Leak testing , Marking<br />
, Vision , Servo control<br />
, Laser applications , Signature analysis<br />
, Ultrasonic welding , Heavy duty pressing<br />
, Splicing/cut-off , Resistance welding<br />
, Web handling/converting , Torqueing<br />
, Riveting , Gauging<br />
, Dispensing<br />
Conveyance<br />
2<br />
End of arm tooling (EOAT)<br />
3<br />
Forming press
MAG Cincinnati<br />
Cincinnati Machine, LLC<br />
2200 Litton Lane<br />
Hebron, KY 41048<br />
USA<br />
tel +1 859 534 4600<br />
fax +1 859 534 4995<br />
www.cinmach.com<br />
MAG Cincinnati, a leading supplier of innovative production machinery for<br />
nearly 125 years, designs and builds a broad range of machine tools and<br />
related equipment including Vertical Machining Centers, Horizontal Machining<br />
Centers and Cells, Universal Machining Centers, Profilers, Automated Composites<br />
Processing Equipment and Special Machines. Our well-equipped products<br />
combined with extensive process knowledge deliver superior industry results<br />
for the aerospace, heavy equipment, energy and general machining markets.<br />
For information regarding local<br />
addresses and partners visit<br />
www.mag-ias.com<br />
Since 2005 MAG Cincinnati has been a part of MAG Industrial Automation<br />
Systems, a dynamically expanding group that has achieved a leading position<br />
in the global machine tool manufacturing industry. With its innovative, highly<br />
productive machine solutions MAG is a strong partner for the metalworking<br />
industries in the aerospace, machining, automotive, heavy equipment and<br />
energy sectors. A growing number of leading international companies are<br />
relying on the impressive innovative power of the MAG group to assure their<br />
technological leadership and prepare for future challenges.<br />
Going straight to the top with MAG<br />
– that’s the opportunity offered by<br />
the technology leading companies<br />
in our group.<br />
Through our commitment and innovative<br />
power, we steer a broad<br />
range of industrial manufacturing<br />
companies to success. Our reach<br />
extends across the globe as we<br />
help the wheels of progress to<br />
turn faster.<br />
The machines shown are examples. Actual machines may vary based on selected options.