Stackmaster automated cell

Stackmaster Engineering Corporation

Stackmaster Engineering Corporation offers an automated cell for the production of sheet aluminum aircraft detail parts. The backbone of their cell is a high speed CNC Router Drilling machine powered by Siemens linear motors and controlled by the flagship version Siemens 840D CNC controller. Stackmaster CNC Router cell Sheet metal parts can be made from a single layer sheet held by vacuum and cut at 600 inches per minute. Up to half inch high stacks can be routed at 200" per minute. In the case of stack routing, the parts are held in place with tabs which are later automatically trimmed to free the parts from the sheet skeleton. Positioning speeds for drilling are 100 meters per minute with 1G acceleration.

The automatic sheet handling portion of the cell loads sheets from a station that holds a 24 hour supply. All aluminum alloys from O condition soft to T hard condition can be processed with 80 Ra or better edge finish. The cell recognizes the production order and composes the stack, and then prompts the CNC controller to process the nest as per the optimized nested part program created by NestOne software. The lifting devise has the unique capability to lift an entire stack with spoilboard at once, to purge the system or to offer more freedom in sheet handling as per factory floor space requirements.

The essence of Stackmaster's new technology is their pressure foot and high-speed spindle design with the following unique features:

35,000rpm precision balanced spindle, with hybrid ceramic bearings, cooled by a mist system which dispenses pressurized coolant directly into the bearing journals
Automatic pressure pad changer which changes from a gliding routing pad to a high friction tab trimming pad
A focused high pressure cutter coolant mist stream that penetrates the cutting tool vortex
A aerodynamic flow chip collect path connected to a high static pressure chip collector that picks up 99 percent of the chips
A check valve controlled air curtain to clean the top sheet surface in front of the pressure pad's path
A 40 tool automatic tool changer system with swing arm, with a 15 second chip to chip tool change, tool selection in the background and dedicated tool pockets
A broken tool sensor system

This automated sheet aluminum parts cell can produce parts in small quantities from single layer sheets and large quantities from stacks, all in optimized nested patterns for maximum material utilization. CNC controlled handling automation make set-ups costs an insignificant factor. Stacks are held on the machine table by Stackmaster's unique fast-acting Groundhog clamps that open and close around the spindle path. There is no wasted material due to clamp exclusion zones. Highly accurate ATA quality parts are made at the fastest possible pace and are cut from the most efficient nested patterns. One man is needed to attend the cell to keep the supply station stocked and to separate and label the parts before the de-burring step.

For more information please visit www.stackm.com