Defense-Grade FPGAs

Xilinx, Inc. (San Jose, CA) announced availability of its Defense-grade XQ UltraScale+ portfolio of products, providing the benefits of its UltraScale+ architecture plus extended temperature and ruggedized packages to address the needs of the aerospace and defense industry. The new products encompass the XQ Zynq® UltraScale+ MPSoCs and RFSoCs, as well as XQ Ultra-Scale+ Kintex® and Virtex ® FPGAs.

The XQ UltraScale+ product portfolio includes the industry's first defense-grade heterogeneous multiprocessor SoC devices, combining flexible and dynamically reconfigurable high-performance programmable logic and DSP, 16Gb/s and 28Gb/s transceivers, quad-core Arm ® Cortex™-A53 embedded processors, and dual-core Arm Cortex-R5 embedded processors. In addition, optionally available features include high-speed 4Gsps ADCs and 6.4Gsps DACs, Arm Mali™-400 GPU, 4k60 H.265/H/264 video codec, and ruggedized packages with support of -55°C to 125°C and 256-bit physical unclonable function (PUF).

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Additive Manufacturing (AM) Materials and Services

Goodfellow (Coraopolis, PA) offers a new line of additive manufacturing (AM) materials and services that can be expertly tailored to the design, function and product life of an application. Raw materials currently being offered include: metal, alloy and ceramic powders; metal and alloy wires; and polymer monofilaments.

In terms of manufacturing services, Goodfellow can provide comprehensive AM services, from initial drawing to post-production finishing. To be more specific, Goodfellow has the capability to: fine-tune your component design or create the design for you; assist in choosing the best AM process for achieving your desired results; produce finished parts using AM technology or, if more appropriate, traditional manufacturing methods; provide materials or finished parts in quantities from prototype to large-volume production.

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Tolerance Compensation Clamps

Destaco (Auburn Hills, MI) recently launched its TCC-2E Series Tolerance Compensation Clamps (TCC) that are designed to provide greater flexibility in welding and assembly applications requiring the clamping of components of differing thicknesses or tighter tolerances. The new TCC-2E model, which is directly interchangeable with Destaco's 82M-3E Series Power Clamps, is especially suitable for flexible manufacturing applications in the automotive and aircraft industries.

The TCC-2Es are available in a variety of sizes. They feature an enclosed body that protects the internal mechanism and have been tested to be maintenance-free for 3 million operating cycles. Various cylinder designs with unlockable non-return check valves, hold-open devices and rod-lock units are available to meet the needs of every unique application.

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Pico-ITX Single Board Computer

WinSystems (Arlington, TX) announced its Intel E-3800 processor-based computing platform in the Pico-ITX form factor. Measuring a mere 3.9 inches by 2.8 inches (100 mm by 72 mm), the ITX-P-3800 delivers low-power performance, endurance and versatility. The proven design of this rugged single board computer (SBC) accelerates time to market for new products while assuring that they will perform reliably in critical applications for many years – even under harsh operating conditions. Equally important, it gives embedded and industrial IoT designers the flexibility to create unique designs via easy-to-use expansion and configuration settings.

ITX-P-3800 single board computers include dual Ethernet and four USB channels, and accommodate a wide range of DC input power: + 9V to + 36V. They combine powerful Intel E3800 processors with a functional I/O set including four RS-232 serial ports plus a Mini-PCle connector for easy expansion. The smaller header-based connectors allow the SBC to be used within a small box or container.

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Composite Forming Facility

Rhodes Interform (Wakefield, UK), a specialist in bespoke composite and metal forming machinery, has recently completed the installation and testing of a ‘world class’ composite forming facility at the University of Sheffield's Advanced Manufacturing Research Centre (AMRC) in the UK. The state-of-the art facility, comprised of a 10,000 kN hydraulic press with six axis loading, high pressure RTM, twin die transfer tables, thermal fluid heating system and die splitter, is capable of a wide range of composite forming including Open and Closed Molding, Resin Transfer Molding (RTM), Prepreg, Compression Molding and Thermoplastics. The project attracted funding from the Government's Advanced Manufacturing Supply Chain Initiative (AMSCI). The machine will be available for use by companies looking to develop their composite capability through Research and Development.

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Dual Tank/Dual Action Ultrasonic Agitation Flow Cleaner

Omegasonics (Simi Valley, CA) recently introduced the new 815BTX, an innovative dual tank bench top ultrasonic cleaning machine. The model's left tank utilizes Bio-Solv, a biodegradable, non-hazmat cleaning detergent developed by Plural that is far superior to sodium-hydroxide (NaOh). Alternatively, the unit's right tank simply uses hot water. Its programmable dual action cleans 3D parts safely and efficiently. Ultrasonic technology is used to optimize the cleaning of precision areas and is combined with agitation to thoroughly remove support material. The 815BTX also features programmable alternating cycles to provide hands-off cleaning from start to finish.

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Shop Management Software

Adion Systems (Vancouver BC), developers of ProShop software, recently debuted a new generation of shop management software ideal for Industry 4.0 practitioners. ProShop offers an integrated, comprehensive set of modules for managing the shop's typical ERP operations. In addition to “front office” activities such as estimating, quoting and purchasing, ProShop includes MES (Manufacturing Execution System) and QMS (Quality Management System) control, monitoring and collection capabilities. Among the MES functions are: tracking machine utilization, cutting tool management, media-rich work instructions, part inspection data, and more, including integration with coordinate measuring machine data.

ProShop also offers an integrated, comprehensive set of modules for managing the shop's QMS such as ISO-9000, AS9100, API and ISO 13485. These include standards, equipment, users, training, audit reports, non-conformance reports, corrective actions and the like, basically all of the tasks required to be in compliance with the various quality systems in place at the worksite. The program may be hosted in the cloud or on site, depending on the customer's preference.

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CAD/CAM Software

OPEN MIND Technologies AG (Needham, MA) recently released hyperMILL® 2019.1 with a range of new features and enhancements including greater blending capabilities, 3D-optimized roughing & finishing, global fitting, rotational abilities for CAD electrode applications - and virtual machining simulation. Developed with Industry 4.0 in mind, hyperMILL® VIRTUAL Machining enables constant real time bi-directional communication between the machine tool controller and a remote hyperMILL® VIRTUAL Machining simulation, significantly improving manufacturing workflow.

Two new functions in hyperMILL® for 3D Z-level Shape Finishing will result in reduced programming time and improved milling. These include an “Automatic Face Extension” capability that can be used during programming to extend the selected milling surfaces, eliminating the need to modify the milling faces in the CAD system beforehand. Barrel cutters (in addition to general, tangential and conical barrel cutters) can also now be used for 3D Z-level Shape Finishing. 3D Optimized Roughing has also been enhanced, to ensure that multiple allowances are taken into account when free tool geometries are used.

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5-Axis Vertical Machining Center

Mitsui Seiki's new Vertex 100 5-axis vertical machining center has been engineered to fulfill manufacturers’ demands for a compact, high-speed machine capable of high-precision milling of larger parts such as blisks for aircraft engines. The Vertex 100 can machine workpieces 1,250 mm in diameter and 850 mm tall while occupying only 3 m × 4.2 m of shop floor space. X-Y-Z axis strokes are 1000 mm, 900 mm, and 750 mm respectively. Maximum swing diameter is 1480 mm.

From CAT 40 to HSK-A100 taper sizes the Vertex 100 is supplied with multiple spindle options (15,000 rpm, 25,000 rpm and 30,000 rpm). A large 60-tool standard automatic tool changer handles maximum tool lengths of 300 mm and maximum tool diameters of 125 mm (CAT40/HSK A 63) or 160 mm (CAT 50/ HSK A 100), offering maximum flexibility for job shop applications. Larger capacity tool changers are an additional option. The machine's tilt/rotary table, designed and built by Mitsui Seiki and supported by the rigid and robust cast iron base, provides high precision and rotation speed up to 100 rpm. The table's C-axis motors are direct drive while the A-axis has tandem direct drive motors. The machine is capable of workpieces up to 1250 mm (49.25") diameter.

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Scan System

SCANLAB GmbH (Puchheim, Germany) has announced series production of its high-end excelli-SCAN scan system. This premium scan head has proved its suitability for reliable industrial deployment in series micro-machining and has now itself gone into series production. Last but not least, the scan head's built-in intelligence predestines it for integration in automated fabrication environments that leverage Industry 4.0 and IoT (internet of things).

The scan system features novel SCANahead servo control as well as galvanometer scanners with highly precise digital angle sensors. And its built-in intelligence can be compared to autonomous driving – the scan head autonomously calculates its own control parameters and anticipates in real time for optimal navigation of curves. This servo innovation breaks through the irreconcilability between higher dynamics and maximum precision, thus providing an appreciable productivity boost to users. Additionally, contour fidelity is substantially improved at high marking speeds, e.g. when traversing sharp corners and circles. Control is furnished as standard by the powerful RTC 6 control board, now available as an Ethernet variant.

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Hybrid Press Brake

Cincinnati Incorporated (CI) (Harrison, OH), a U.S.-based, build-to-order machine tool manufacturer, will introduce a 150-ton version of a new hybrid model. New features found on this press brake are an ergonomic sliding overhead control arm, unique built in storage cabinets, LED lighting, protective cylinder covers and side and rear guards. Cl's CIberlink generates daily log files of machine production with the ability to monitor machine status in real time on a desktop dashboard.

This hybrid press brake brings the advantages of servomotor pump technology to CI's existing lineup of hydraulic and electric drive press brakes. Unlike fixed-speed induction motors that drive the pump in conventional hydraulic systems, the servo-motor driven pump only runs during the working portion of the stroke, conserving energy while the ram is stationary. Ram speed of 550 ipm and precision ram repeatability of +/-.0002" assure fast and consistent production. The generous 14" stroke and 21" open height tackle challenging part shapes and tool heights.

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AGD Group 1 Digital Indicators

The L.S. Starrett Company (Athol, MA) has introduced a range of Digital Electronic Indicators conforming to true AGD (American Gage Design) Group 1 dimensions, providing the ability to replace traditional mechanical indicating applications in the smallest AGD size specification class. Starrett 2700 Electronic Indicators are the first digital gages to match true AGD Group 1 dimensions (1.70"/ 43mm diameter).

Gages feature a .400" (10mm) travel, accuracy of ± .0001" (0.002mm) on the F2715 models and accuracy of ± .0002" (0.004mm) on the F2714 models. The gages can store and view 200 readings internally. Stored readings can be downloaded with included software and a USB style cable. Starrett 2700 Digital Indicators have a CR2032 cell long-life battery that can last up to 3,000 hours under typical use. Gages are output-compatible for SPC documentation via cable or wirelessly using a Starrett DataSure® Data Collection device. Switchable resolutions are .001/ .0005/ .0001/ .00005 or .001/ .0005/ .0001 in inch. In metric readouts, switchable resolutions are 0.02/ 0.01/ 0.002/ 0.001 or 0.02/ 0.01/ 0.002 mm.

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Gear Grinding Platform

Norton I Saint-Gobain Abrasives, one of the world's largest abrasives manufacturers, announced the introduction of its new Norton Xtrimium™ range of gear solutions designed for high performance gear grinding in extreme, tight tolerance environments. Highlighting the new range is an innovative dual-worm wheel design that enables two operations in one grinding wheel. Norton Xtrimium Dual-Worm Grinding Wheels feature a unique design with a high-performance vitrified bond section for grinding and a fine-grit resin section for polishing the gear teeth, enabling one wheel to perform what traditionally required two wheels. In addition, improved surface finishes of Rz = 1.0 mm and Rpk = 0.05 mm, and reduced harmonics (noise) are realized.

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5-Axis Machining Centers

Doosan Machine Tools (Pine Brook, NJ) recently introduced its new DVF Series of compact 5-axis machining centers. The DVF 5000 comes standard with an 18,000 RPM integral 40 taper spindle. A FANUC 31iB5 CNC controller makes full 5-axis simultaneous control possible, giving complete contouring capabilities. It also features a 500 mm diameter (630 mm option) built-in rotary table. Available table supports allow a maximum weight of 880 lbs and minimize any table deflection. The rotary table is designed for user-friendliness and consummate work efficiency, minimizing interference as the part is machined. Doosan also offers a DVF 5000 5-Face version with a FANUC 0iMF CNC controller and a 12,000 RPM directly-coupled spindle.

The DVF 8000 is a larger full 5-axis machining center that incorporates many of the features of the DVF 5000, but has a larger (800 mm diameter) rotary table which can support a maximum weight of 3,086 lbs. Each machine comes with a 60-tool servo-driven automatic tool changer that can be expanded up to 120 tools, giving the customer more tooling to tackle complex parts that have varying profiles. An oil cooled spindle controls heat to minimize thermal issues.

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Automation Solutions

Fastems LLC (West Chester, OH) has a broad array of automation solutions aimed to handle high mix, low volume production available. Among its more popular modules are its recently renewed FMS ONE, a fully configurable machine tool pallet automation system. Further, the latest generation of Manufacturing Management Software (MMS) is being highlighted showing its new features for manually operated work cells, and its extended capability for controlling robotic automation. This new software was only recently launched at IMTS. Additionally, a compact loading robot cell called Halter Load Assistant was recently demonstrated in partnership with Halter CNC.

Fastems’ automation equipment includes a variety of extendable and flexible manufacturing systems, robot applications, and control software; stacker cranes; conveyors; loading/unloading stations; pallet magazines and assembly organizers; and raw material stations to name a few. These automation systems have open interfaces and can be incorporated with virtually any modern CNC machine tool and auxiliary equipment brands. Typical applications range from joining two machine tools together with Flexible Palletized Container (FPC) to highly sophisticated, factory-wide flexible manufacturing systems.

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Circle-Segment End Mills

Emuge Corp. (West Boylston, MA) has introduced “circle-segment” cutters, an innovative class of end mills designed to enable substantially more material removal with fewer passes in 5-Axis machining, over 80% cycle time reductions and up to 50% smoother surface finishes. Circle-segment tools are a totally new end mill design, exclusive to Emuge

Emuge circle-segment solid-carbide end mills are offered in four geometries: barrel-shaped, oval form, taper form and lens shape. Oval and taper form mills are ideal for curved shapes such as blades or straight-walled pockets, freely engaging more of the cutting edge. Barrel design mills provide highly effective flank milling to the sides of spiral grooves and similar applications, while lens shape mills excel in narrow channels or in lands on molds.

Specific CAM system software, such as hyperMill (Open Mind) or Mastercam® recent versions are required to support and compute the geometries of Emuge circle-segment end mills to achieve the performance levels the tools were designed for.

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Measurement Software

Hexagon's Manufacturing Intelligence (North Kingstown, RI) has launched PC-DMIS 2018 R2, the latest edition of its measurement software. This is the second of two major releases that were scheduled for PC-DMIS in 2018, with continued service pack updates to ensure maximum reliability of the platform.

PC-DMIS 2018 R2 introduces a new reporting workflow, making it easier to create customized reports with simple drag and drop and an intuitive slideshow-style interface. A new QuickPath tool expands on existing QuickFeature functionality to simplify feature creation with a safe path. PC-DMIS 2018 R2 also introduces the ability to add run charts from qs-STAT into the PC-DMIS report. Improved Probe Utility allows users to mark favorite tip configurations, create required tip angles by simply clicking on CAD, and buy replacements with Shopping Cart tools; a new e-Store is coming soon to here .

Other notable improvements within PC-DMIS include a new 2D Radius Gauge for quick checks on the go, added MoveInspect XR8 support, improved QuickFixture workflow with snap-to-grid capability, NX 12 DCI and Catia v5 R27 DCI & DCT support, added support for the HP-L-5.8 sensor, improved Q-DAS support, added Measurement Strategy Editor parameter sets, and Vero SMIRT integration.

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Additive Manufacturing Software

The additive manufacturing Software 4D_Additive from CT Core Technologie GmbH (Moembris, Germany) has interfaces for an independent and precise data exchange with all common CAD systems and 3D Printers. It supports CAD formats such as Catia, Nx, Solidworks, Jt, Step and many others. The tool comprises various additive manufacturing specific functions like automatic nesting and support generation.

The mature geometry kernel of 4D_Additive is equipped with sophisticated 3D data analysis and repair tools as well as direct modeling capabilities based on the exact BRep.

This technology ensures watertight models that do not deviate from the original CAD model like “tesselated” i.e. approximated models in STL format. The system offers functions e.g. for direct modeling, generation of offset surfaces and defeaturing to enable a precise modification of critical areas as well as the reduction of complexity and an efficient error compensation. Freely selectable scaling parameters allow the models to be scaled differently along the three major axes to compensate for shrinkage or distortion.

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Aerospace & Defense Technology Magazine

This article first appeared in the February, 2019 issue of Aerospace & Defense Technology Magazine.

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