MACHINING & MACHINERY CLEVER COMPOSITES
EXEL
Speed , accuracy and reduced downtime
Cheetahs are famed for their ability to reach high speeds , but it is in fact their agility that is truly impressive . Cheetahs can accelerate from zero to 60 miles per hour in just three seconds , and then quickly decelerate , turn , and sprint in another direction . But this exceptional combination of speed and precision doesn ’ t purely belong to the wild , and innovative composite materials are helping bring these qualities to the factory floor . Here , Robert Glass , head of marketing at global composite technology company , Exel Composites , explores how composite components can enhance the performance of automated machinery .
Improving manufacturing efficiency while maintaining high product quality is a common challenge in production facilities . Automation has undoubtably boosted productivity , but rising consumer demands drive a need to further optimize production equipment . By incorporating composite components into automated machinery , production speed and accuracy can be increased while reducing downtime .
AS FAST AS YOU CAN Composites , also known as fiber reinforced plastics , are fabricated by combining a resin matrix with reinforcement fibers . The blend of materials gives composites combined benefits , such as low weight with high strength and stiffness . In fact , composites have a specific gravity a quarter that of steel and two thirds of aluminum , and have a much higher strength-to-weight ratio .
This low weight gives composites the ability to move quickly , making them ideal for fast-moving machine parts . By using composite machine parts , which are lighter and stronger than their metal counterparts , the operation speed of a production machine can be increased , therefore increasing manufacturing efficiency .
This is especially true for textile machines . The textile industry must transform millions of miles of yarn into lengths of fabric to supply industries such as clothing and home furnishing . However , producing one
Robert Glass
length of fabric requires hundreds of weft yarns , making enhanced speed essential to keep up with demand .
In rapier weaving looms , finger-like carriers called rapiers repeatedly move the yarn back and forth across the width of the fabric . By using lightweight composite rapiers , as opposed to metal alternatives , the yarn placement process can be carried out faster and in greater volumes , therefore increasing fabric production efficiency . The high strength and durability of composites means the rapiers will be able to withstand working at the increased speed without breaking under greater force .
PROCESS PRECISION Composites not only allow production machines to move with increased speed , but also higher accuracy . Composite materials have low inertia , which means composite machine parts can start movements and change speeds more quickly , therefore performing with increased agility .
The low weight and high stiffness properties of composites means they can provide vibration dampening up to 20 times better than steel . This increases the stability of the machine , allowing the composite component to perform with superior accuracy .
Composites also have a low coefficient of thermal expansion , so machine components will not change their dimensions even if the temperature rises or falls in the environment . By maintaining the dimensions , the composite components can keep machine operation to tight tolerances .
An application where agility is essential is robotics . Robotics on the production line must accurately maneuver products without causing damage . This is especially important when handling small , delicate products like electrical components or even chocolates in boxes . Here , by using carbon fiber for robotic arms instead of aluminum or steel , the arms can perform movements with quick changes in direction and high placement accuracy .
REDUCED DOWNTIME Composite machine components don ’ t just perform well — they perform for a long time . Composite materials exhibit high durability , meaning they require less maintenance and less frequent replacement , therefore reducing factory downtime .
Vibration dampening properties mean composite components display reduced wear from processing , as they are unlikely to experience cracking in applications with high levels of oscillation , and their resistance to fatigue means they can withstand repeated load cycles . Composites are also resistant to many external factors , such as chemicals , temperature and moisture .
Exel provides strong and lightweight composite solutions to the machine industry , from carbon fiber robot delta arms to textile machine parts . With over 60 years ’ experience in engineering , we can work closely with customers to find a solution that is tailored to their unique project . This includes optimizing the properties of composites for a specific application by altering the fibers , matting and resin system .
The speed and agility of cheetahs demonstrates the incredible design of the natural world , a source of inspiration for manufacturing . Composite components help advance automated machinery , making them perform with increased speed and precision , while also exhibiting extended durability .
For further information , please visit www . exelcomposites . com
68 PECM Issue 49