Major order for machining carbon fibre

CFRP frame components for a BMW model

Fräsen-CFK-Rahmenteile-PKW-CNC-BMW

Benchmark in performance and quality

HG GRIMME SysTech not only sets the benchmarks when it comes to machine performance and quality with its machines for milling CFRP frame components for a BMW model: The machine manufacturer from Germany’s Allgäu region also reduces dust emissions to a minimum.

Complete frame components made of CFRP

In recent years, the use and processing of carbon-fibre-reinforced plastic (CFRP) have become much more prevalent in the automotive industry: The use of high-quality lightweight materials, especially CFRP, also played a significant role in the development of a BMW model. The machine manufacturer HG GRIMME SysTech from Wiedergeltingen (Allgäu) won a tender from BMW AG to provide machines for milling CFRP frame components. After a year of intense development work, the first machine of the G-DT-F(33-18)SB-2Z type began operating at the BMW Group plant in Landshut.

The Landshut plant uses the machine to produce entire side sections of a vehicle: As they are visible, the requirements placed on the quality of milling are high. Short production cycles are guaranteed by two machining heads which can work simultaneously on one component. To prevent any unnecessary downtime caused by unproductive periods and to increase the level of flexibility, for each axis group a changer for 26 tools, an additional quadruple angular head magazine with customer-specific tool management and multiple spare tools are used.

Fräsen-CFK-Rahmenteile-PKW-CNC-Bernd-Settele Projektleiter-hg-grimme-systech

“When we were developing the machine, we together with the project team from the BMW Group were constantly thinking in particular about the fine dust that is produced during the milling process,”

Bernd Settele, project manager

Constant focus on fine CFRP dust

The solution focused specifically on the huge amount of dust that is produced when machining fibre-reinforced plastics such as CFRP.

“The objective was to guarantee very clean milling of CFRP.” This is ensured by a newly developed, powerful machine for extracting the fine dust from several sides. 15 slide valves operate with great efficiency here by concentrating on the area immediately surrounding the milling process for extraction. The additional medium-pressure machine also filters the suspended particulate matter in the machine room. After the milling process, the operator’s insertion area is also scrubbed and exhausted again. The company from the Allgäu thus ensures that the fine dust is also reliably filtered out of the air before any employee comes into contact with the component.

Industry 4.0 in focus

Special attention was paid to providing an extensive link to the BMW Group’s IT system and access to typical Industry 4.0 applications. “Our solution enables complete traceability and precise evaluation of data – by providing accurate information including about wear, the general condition of the tools and the machine, for breakage control and a preview of upcoming maintenance,” explains the project manager. “When we were designing the BMW-specific HMI interface, we were also particularly keen to make it very user-friendly.”

Ergonomics was also a key focus in the machine room: It is not only almost dust-free, but also soundproof. A vertical rotary table allows shuttle machining and therefore very efficient feeding of the machine which reduces the amount of unproductive time. The rotary table can even be swivelled in the space of three seconds for jigs weighing more than a ton. Vacuum clamping technology and additional clamps that move automatically ensure that components are fixed securely during the milling process.

“In supplying a milling system to the BMW Group, we have not only set high benchmarks for the performance and quality of the machine, but we have also managed to drastically reduce the impact on the surrounding environment from suspended particulate matter, for example.”

Wolfgang Grimme, Managing Director

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