JEC COMPOSITES MAGAZINE - Issue #63 - March 2011 - 103

The main problem consisted in finding blades that were sufficiently strong for cutting relatively rigid and hard honeycomb materials, up to a thickness of 75 mm and with an oscillation frequency of 20 kHz. Different sonotrode designs are required to cut honeycomb. The sonotrode must be precisely adapted to the blade type. Circular knives activated by ultrasound for the chamfering of honeycombs are available with a standard diameter of 50 mm and 25 mm. The sonotrodes may be exchanged automatically, and up to 12 sonotrodes may be stored in a tool change magazine. For cutting out pockets, staircase shapes or the like, the machines can be equipped with a second Z-axis and ultrasonic cutting can be combined with trimming (milling). Sophisticated milling knives have been designed for working on honeycomb cores. The availability of different types of blade makes these knives adaptable to most types of core. Thanks to its special shape, the knife evacuates and grinds up the pieces. One of the latest innovations is the oscillating knife, for materials of over 3 mm in thickness, driven by

ISO standard tolerances of GEISS CNC machines type FZ according to DIN 7151

Test results – Cutting of thermoplastic honeycomb material (PP)

a linear motor. The programmable path is a maximum of 10 mm, and it generates acceleration of 120 m/s’’. With path set at 5 mm, the blade oscillates at a frequency of approximately 25 Hz.

user, while continuing to qualify as a standard machine. The machine shown here is therefore just one example of the possibilities on offer from the company. The honeycomb cutting machines are equipped with a Siemens Sinumerik 840 D controller with NCU 730 and integrated safety system, and with linear motors for the X and Y axes (transverse velocity = 180 m/ min; acceleration = 15 m/s (X axis) and

Customized dimensions and options

The parametric design of all Geiss machines makes it possible to build each one to customized dimensions and with various options to suit each

Machine path nominal values, mm, tolerances in µm * Tolerance Row IT Factor 1 to 16 >16 to 25 >25 to 40 >40 to 63 >63 to 100 >100 to 160 >160 to 250 >250 to 400

Tolerance unit i IT 5 IT 6 IT 7 IT 8 7 10 16 25

0.783

1.241

1.455

1.71

2.013

2.385

2.832

5 8 13 20

9 12 20 31

10 15 23 36

12 17 27 43

14 20 32 50

17 24 38 60

20 28 45 71

IT 9
IT 10

40
64

31
50

50
79

58
93

68
109

81
129

95
153

113
181

No63 March 2011 / jec composites magazine
3.382 4.078 4.96 6.132 7.67 9.767 12.725 20 24 34 54 85 29 41 65 35 50 79 43 61 98 54 77 68 98 89 139 199 319 498 797 127 204 318 123 192 156 244 102 124 153

>400 >630 to >1000 >1600 >2500 >4000 >6300 to to 630 1000 to 1600 to 2500 to 4000 to 6300 10000

135

163

198

245

307

391

509

216

261

317

392

491

625

814

1274

103

Technology & Innovations
JEC COMPOSITES MAGAZINE - Issue #63 - March 2011

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #63 - March 2011
