Introduction
Uchida has been molding and processing composite materials (FRP) since its establishment in 1968. Our business centers on paving new pathways in next-generation mobility and weight reduction through the advancement of CFRP and its distinctive “lightweight, strong, and non-corrosive” characteristics.
This issue explores machining centers for composite materials from our perspective, as a specialist manufacturer.
What is a Machining Center?
A machining center is an automated system and numerical control (NC) machine that automatically switches machining tools and blade while leveraging numerical data for automated control of processing operations.
The equipped Automatic Tool Changer integrates multiple machining processes by automatically switching between machining tools in single process, thereby eliminating manual tool changes and labor-intensive operations.
Machining Centers for FRP, GFRP, CFRP and Other Composites
For CFRP and composites, machining centers are used as follows:
(1) Cutting and grinding the molds
(2) Cutting and grinding jigs and inspection tools
(3) Secondary processing products/parts after molding
Two Key Points to Note for CFRP Cutting, Grinding and Machining
There are some important points to note when machining CFRP.
(1) Knowledge of its Anisotropic Structure (Fiber Orientation)
As a review, CFRP is an anisotropic material whose strength depends on the direction of the fibers. Thus, machining requires a specific understanding of the fiber orientation, lamination structure, and properties of the resin used as the matrix. Proper machining paths cannot be created without unique know-how on CFRP (composite material) handling and property variances, such as differences in machining resistance depending on the amount and orientation of the fibers, laminate configuration, or differing thermal properties contingent on the resin.
(2) Dry Processing Prerequisites
Cutting oils are incompatible with CFRP machining due microscopic liquid-absorbing properties of the carbon fibers which soak up and retains the oils if immersed. Although moisture absorption is not visible on the exterior, as any soaked surfaces may delaminate after long-term use of the product, we must exercise caution when handling the material. If using the products in humid environments, we will specially treat the surface with paint or sealant after machining to prevent moisture absorption.
Uchida’s Commitment to CFRP Machining
Tool and Jig Room: The First Step in Manufacturing
The Jig and Tool Room is the center (department) for CFRP processing. Here we design and manufacture molding dies, inspection or adhesive jigs, and other tools used for CFRP molding in our machining center, alongside secondary processing of CFRP products after molding. At Uchida, we offer one-stop services ranging from design and analysis to mold fabrication, laminate molding, secondary processing, coating, inspection, and testing. And our Jig and Tool Room oversees getting the entire manufacturing process rolling.
Commitment to CFRP Machining
While we say CFRP machining, the item often employs a different internal material. Many of the CFRP products we manufacture are complex structural items with foam or metal inserts at the time of molding. In machining, we conduct prior investigations for (1) understanding CFRP anisotropy and resin, and (2) CFRP parts composited with metal, to determine the optimal machining method. Even the most complex composite product, such as the above, machine processing is generally performed dry. At Uchida, we possess vast experience in drilling, thread tapping, trimming, and 3D-shape machining, and employ a wide range of tools based on specific knowledge of CFRP’s characteristics.
Exhibit: “Car Bonsai,” a CFRP bonsai tree reproduction. The entire circumference was de-skinned in our machining center.
UCHIDA Machining Center
Large, high-precision 5-axis machining center for meeting diverse needs and requests.
Uchida was featured on DMG Mori TVCM (television commercial) “DMG Mori × Front Runner” Vol.46 as a front runner company in cutting-edge innovations.
DMG MORI TVCM 「Front Runner Vol.46 UCHIDA Co.,Ltd.」
Machining Materials: “CFRP/GFRP Composites, Aluminum, Titanium, and Chemical Woods”
- DMG MORI, 5-Axis, M/C DMU 200 Gantry： X2000xY2000xZ1200
- DMG MORI, 5-Axis, M/C DMU 125P： X1250xY1000xZ1000
- DMG MORI, 5-Axis, M/C DMU 100P： X1000xY1000xZ1000
- NEO, 5-Axis, M/C MM4223： X4000xY2000xZ1200
- DMG MORI, 3-Axis, M/C VS10000： X2050xY1000xZ600
Summary
This issue explores the role of machining centers used in CFRP machining. As explained, CFRP machining is nearly impossible, and has high risk of problem of failure, without specialist knowledge and know-how of the material’s structural properties. CFRP is generally dry processed and, consequently, cannot be processed with metalworking machines or other machines that use cutting oils. Consulting a specialized manufacturer to get a comprehensive understanding of CFRP, and the above mentioned processes, is the safest and best way to ensure results when employing CFRP.
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ABOUT UCHIDA - 55 years since our founding
We leverage a wealth of technical expertise as a CFRP molding and processing manufacturer using FRP, GFRP, and CFRP materials. We offer a one-stop solution, encompassing design, analysis, manufacturing, secondary processing, assembly, painting, quality assurance, and testing.
UCHIDA's equipment
We have cutting-edge equipment to ensure that we can address even the most advanced challenges of our customers.
DMG森精機 - VS1000/40/2050
X軸：2,050mm（ストローク） ／ Y軸：1,000mm ／ Z軸：600mm ／ テーブル作業面：2,250×1,000mm
ASHIDA MFG Co., Ltd.
Autoclave Oven 2
Size : Ø1,150x1,000mm / Operating temperature : at normal temperature - 400℃ / Design pressure : 2.0Mpa (maximum working pressure) / Vacuum system : back suction system / Vacuum units : 5
ASHIDA MFG Co., Ltd.
Autoclave Oven 3
Size : Ø3,000x6,000mm / Operating temperature : at normal temperature - 200℃ / Distribution accuracy : ±2.5℃less / Heating rate : 4.0℃/min. (empty furnace) / Cooling rate : 4.0℃/min. (empty furnace) / Design pressure : 0.99Mpa (maximum working pressure) / Working pressure : 0.7Mpa less (if no specification from the manufacuturer 0.3Mpa around) / Pressure accuracy : ±0.02Mpa（for pressure setting of ０ - 0.99Mpa/cm²） / Boost pressure accuracy : 0 - 0.03Mpa/min / Pressure source : compressed air (regular use) / Vacuum system : back suction system / Vacuum units : 10
Oven
Size : W1,000xH1,000xD1,000mm / Temperature range : Environmental Temperature +20 - 300℃ / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 45min less / Vacuum system : back suction system / Vacuum units : 10
ESPEC CORP.
Temperature & Humidity Chamber
INSTRON
Static Universal Testing Machine 5985
Oven
Size : W7,000xH3,000xD2,000mm / Temperature range : Environmental Temperature +20 - 300℃ (Max) / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 60min less / Vacuum system : back suction system / Vacuum units : 10
NEO
X axis : 4,000mm (stroke) / Y axis : 2,000mm / Z axis : 1,200mm / C axis : 0° - ±270° / B axis : 0° - ±110° / Table working place : 4,000x2,000mm
【開発】
3Dプリンター | Markforged
Painting booth
Various painting, and clear finish is done in dedicated painting booth
Adhesion, Finishing, Coating Room
Finishing process, such as trimming, drilling, and bonding, surface treatment of the molded product type and is done in a private booth
Toshiba Matrixeye EX (Ultrasonic flaw detector)
Matrix-Arrey : 32
AMETEK CREAFORM Metra
SCAN750 Elite (3D scan)
Olympus Corp.
Inverted Microscopes
Oven
Size : W450xH450xD450mm / Temperature range : Environmental Temperature +20 - 650℃ / Temperature elevation capability : Environmental Temperature+50 - 650℃/120min less
Cutting Plotter Table working place : W1,500xL3,500mm
SHIMA SEIKI MFG., LTD
Cutting Plotter
KUKA
Robot
Krauss Maffei
Epoxy resin injection machine Resin 60L ／ Hardener 25L
Krauss Maffei
630t Press machine Height total 5,200mm ／ Length max 1,500mm ／ Width max 1,200mm ／ Whole cycle time per component part 240sec
DMG森精機 - NV5000B/40
X軸：1,020mm（ストローク） ／ Y軸：510mm ／ Z軸：510mm ／ テーブル作業面：1,320×600mm
Big sized clean room
JIS B 9920 cleanliness class maximum concentration (Pcs/m³） / Class 5 : 100,000m³ / Capacity : m² (16,000x16,000mm) 760m² (16,000x16,000x3,000mm) / Temperature and humidity condition : Temperature : 23℃±3℃, Humidity 65% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Temperature -5℃ during winter, Humidity 40% less
CAD / CAM
CATIA V5 : 2 / THINK DESIGN : 1 / MASTER CAM : 4 / Other 3D/CAD : 3 / Other 2D/CAD : 5
Markforged - 3D Printer
Video Library
In the following video, we provide a detailed overview of our manufacturing process. Please feel free to watch and learn more.
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