STC 1000 • STC 1250 • STC 1600 Dynamic 5

STC Series
STC 1000 • STC 1250 • STC 1600
Dynamic 5-axis machining centers
Technology
Crosses New Frontiers
5-axis machining of
V12 cylinder crankcases
With the modern STC range, StarragHeckert presents a machining
system fully exploiting the fine art of Swiss-Saxonian machine tool
building.
With these dynamic machining centers you have a production tool at your
­disposal capable of machining complex workpieces in aluminium, steel, tita­
nium or other difficult to machine materials; in a five axis simultaneous mode
and from five sides, at any angle, to the ultimate in precision.
The STC range is particularly suitable for challenging machining solutions in ­the
aviation and for the gas and steam turbine building industries, as well as in the
precision machine industry and general production technology.­Their high
modularity enables the machining centers to ­be optimally
adapted for various ­technological re­quirements.­
2
3
STC Series
New technologies call for ever more­
efficient production methods. At the­
same time, high quality and precision
are demanded. With the STC range,
StarragHeckert has de­veloped a ma­­
chining center offering unequalled fle­
xibility for achieving innovative pr­o­­­
duction concepts.­
Modularity for Flexibility
Flexible Machining Concept
Impellers and Blisks
With the STC range, StarragHeckert has
developed a machining system that can
convert your innovative production con­
cepts into reality with more flexibility and
consequently more production reliability.
New technologies, fast changing applica­
tions as well as ever increasing demands
on quality and precision require modular,
intelligent manufacturing methods and cor­
responding machining concepts.
Precision and high availability are essential­
when machining impellers and blisks of the
latest generation. This is particularly the
case when difficult to machine materials,­
such as titanium or Inconel, are being
machined. Thanks to decades of experi­
ence in the 5-axis machining of air stream
surfaces we are in a position to competently
support you in every way – not only with our
latest modern machines, but also with our
own specially developed CAM software, our
General Production Technology
The trend to wards ever more complex
work­­pieces in the automotive industry, the
precision machine industry and mould and
die manu­facturing, coupled with engineers’
aspirations for optimised machine modules,
call for new, innovative manufacturing con­
cepts. Solutions are called for that simplify
production processes, raise efficiency and
that can be flexibly implemented whilst
guaranteeing top quality. StarragHeckert’s
STC range fulfils these requirements in every
way thanks to their dynamic five axis con­
figurations. An intelligent tool management
system and modular extendable workpiece
handling ensure smooth and time saving tool
and pallet change systems.
specially adapted tools, and a wide range
of innovative­technological services.
Complex Structural Components
Parallel to the rapid development in metal
cutting technology, the innovative engineers’
demands on the production specialists also
continually rise – particularly in the modern
aviation sector where increasingly complex
titanium structural parts are manufactured.
Outstanding static and dynamic qualities
and high capacity machine spindles are cal­
led for from the machining centers; making
economic, high performance manufacturing
possible and thus saving time on the one
hand and simplifying the production process
on the other.
STC machining centers show their true
potential when it comes to machining
par­ticularly complex workpieces, where
machining has to take place non perpen­
dicular to the machine axis. Since the tool
can be positioned relative to the workpiece
at any angle, such components can be ma­­
chined in a single set-up, thus drastical­ly
reducing fixturing costs and shortening lead
times.
4
Complex aircraft component
Impeller – up to 2000 mm in diameter
STC Series
V12 Cylinder block
Titanium or Inconel blisks
Y
A
X
B
STC 1000 Axis
configuration
Z
5
Modular concepts offer the high­est
degree of flexibility and enable you
to adjust to the ever changing market situation.
Innovation and Cooperation
Machine Systems for the Demands
of Tomorrow
Shorter Machining Times and Minimal
Non-Productive Times
Global competition, short production cycles,
an ever increasing variation of components­
as well as the capability to anticipate prob­
lems are the characteristics of success­ful
production facilities. StarragHeckert’s STC
range is specially designed to accommo­
date the continuously changing demand of
manufacturing technology.
Thanks to its modular machine concept, the
STC Series can quickly adapt to new tech­
nological demands.
Our wide selection of high performance spin­
dles for different speed ranges, torques and
power, makes it possible to employ the very
latest tools. High feeds, shorter machining
times and reduced cutter wear result.
In addition, thanks to the modularly extend­
able tool and workpiece handling systems
with their fast rapid traverses, idle times can
be kept to a minimum.
Excellent Process Stability
The unique process stability of the STC
range is due largely to its excellent static
and dynamic characteristics.
The STC Series has an extremely rigid
frame structure that has been calculated
and optimized by the FEA method. Even
under extreme cutting conditions and when
machining difficult materials, the drive power
can be exploited to the full. Long tool life
results from the stable, low vibration cutting –
a key factor in economical production.
High Availability
The economics of a machining center are
determined not solely by its performance
but also by its availability and total func­
tional reliability.
Economical Advantages of Complete
Machining
The STC range of machine centers makes it
possible to machine workpieces in a single­
set-up. The complete machining proc­ess
reduces preparation and the setting up of
workpieces to a minimum; resulting in short­
er lead times, lower logistic costs and there­
fore subsequ­ently increasing the efficiency
of the machine.
View of the STC 1000
6
STC Series
That is why StarragHeckert turns to depend­
able,­­proven sub-assemblies with high grade
components – and above all, highly skilled
and motivated people aware of their respon­
sibilities.
To minimize downtimes, the STC Series is­
equipped with a system that graphically dis­
plays diagnostic routines (SAM). The root
causes of errors can be localized in a very
short time and the diagnostic routines sup­
port their correction.
In addition, our re­mote diagnostic system
assures immediate online support from our
specialists.
Partnership for Problem Solving
StarragHeckert provides individually matched
solutions to your specific production chal­
lenges. Our experienced technologists­ will
help you set new production mile­stones.­
Needless to say, we are also ready to prove
and document the capabilities of the STC
Series by trial machining.
Productivity, precision, flexibility and re­­
liability are more than just catchwords for
StarragHeckert.
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Pooling of knowledge, unifying­ of
strengths and challenging­ current­­
tech­nological frontiers.­ These thou­
g­ht­ processes cha­racte­­ri­­­zed­­­ the de­­
velopment of the STC range.
Technology in Focus
Frame Structure
- Thermo-symmetrical build
- Elements of closed welded design
- Extremely stable and resistant to vibrations
- Optimized using the FEA method
Table Assembly
- CNC rotary table as fourth simultaneous axis
- Standard pallet designs as per DIN 55201
- Wormwheel drive with backlash compensation
- High torque
- Hydraulic B-axis clamping
Axis Drives
- Highly dynamic drives with digital control and monitoring
- High feed forces for heavy duty cutting
- Maintenance-free AC motors
- Belt drive to the auxiliary gearbox
- Pre-tensioned, ground and backlashfree ballscrews
Linear guideways
- Large-dimensioned, stiff and precise guide­ways
with re-circulating roller packs
- Automatic grease lubrication
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Motor Spindles
- Robust precision hybrid bearings
- Concentrically mounted high powered AC drive motors
- Oil mist lubrication direct through the outer ring
(Direct Lubrication System)
- Variable hydraulic bearing tensioning
- Vector controlled constant torque up to transition speed,
thereafter constant power
- Coolant through the tool as standard
- Spindle positioning and C-axis mode
- Standard HSK tool interface
- Sensors for bearing temperature, thermal spindle growth
with compensation and vibration monitoring during cutting
A-Axis Milling Spindle
Gear driven Spindles
- Simultaneously controlled fifth NC axis
- Stable roller bearings on both sides
- High positioning accuracy via a direct
optical measuring system
- Wear free worm and wormwheel drive
with coated steel-on-steel elements
- High drive torque
- Hydraulic axis clamping and dampening
- Also ideal for heavy duty cutting
- Drive via two step gearbox
- Torque 940 or 1'200 Nm
- Large dimensioned precision
hybrid bearings
- Oil mist lubrication
- Coolant through the tool as standard
- ISO or HSK tool interface
Tool Handling
- Chain magazine with 60 and 80 pockets
- Tower magazine with up to 320 tools
- Magazine loading during machining process
- Fast twin arm tool changer
- Tool breakage detection via laser within
the working area as an option
- Optional tool coding
- Tool management via CNC
Swarf Management
- Twin swarf conveyors in the longitudinal bed
- Generous swarf openings and angled areas
- Integrated washing system with workpiece shower
- Suited for either wet or dry machining
CNC
- Microcomputer CNC Sinumerik 840D
- Integrated digital solution for control and drives
- Superior performance with regard to dynamics, speed and precision
- Contour fidelity during high speed machining via look ahead feature,
dynamic pre-selection, programmable acceleration and jerk limitation
- Operator friendly
- SAM – Visualization system for efficient machine status monitoring
9
Thanks to the STC 1250/150’s in­no­­­
vat­­ive trunnion table concept, new
dimensions in high precision can be
reached for the economical machining of complex workpieces,­ which
often need to be worked at right
an­gles to the pallet.­
STC 1250/150
Technology in Movement
Outstanding Stability
Direct Measuring Systems
The STC 1250/150’s special axis concept
enables the milling spindle to work with ulti­
mate stability whilst remaining bidimension­
ally slim. This design allows high machin­
ing torque to be achieved, even with long
tools, thus procuring enormous advantages,
­particularly in the case of difficult to access
workpieces such as gear box cases.
Various factors contribute to the STC
1250/150’s class leading precision, but in
particular it is the high machining quality and
geometrical exactness in all precision based
assemblies that deserves a special mention.
On top of that we of course also use direct
measuring systems in all five axis.
Higher Precision
Wherever it is necessary to machine at
right angles to the pallet, the STC 1250/150
­displays its real strengths. Since the work­
piece can be machined from one side, elimi­
nating the necessity to index the ­component
180 degrees, machining precision is sig­
nificantly improved. An extremely stable
machine structure and high process stability­
are excellent requisites for the machining
of difficult materials such as titanium and
Inconel – deciding criteria, in particular for
the aviation industry, as well as in general
production technology.
Automatic Pallet Changer
Workpieces with a weight of up to 3'000 Kg
can be machined on the 1000 x 1250 mm
pallets. The STC 1250/150 is equipped with
two automatic pallet changers as standard.
NC Quill
Deep drilling and complex workpieces can
usually only be realised with great effort and
loss of stability. The STC 1250/150’s rigid,
horizontally arranged spindle is the perfect
requisite for the use of a wheel away quill.
Highly precise,
extendable NC quill
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STC 1250/150
Aero engine casing
Selectable Tool Handling
The STC 1250/150 is optionally available
with a modern chain or tower magazine with
space for 60 to 320 tools.
Integration into an FMS System
Depending on the requirements, the STC
1250/150 can be extended into a flexible
machining cell with linear pallet system or
can be integrated into an FMS solution with
main host computer.
Y
X
Z
B
A
STC 1250/150 Axis
configuration
Double sided driven
trunnion table
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4
Technical Data
Working range
Workpiece changer
Tool changer
Chip conveyor
Electrical cabinet
CNC with operator panel
Machine enclosure
Coolant tank
Safety fence at set-up station
Tool loading/unloading station
Electric power supply
Air supply
Main operating position
3
2
P
1
1
2
3
4
5
6
7
8
9
10
E
P
10
E
7
9
5
6
8
STC 1000/130
STC 1250/130
Pallets
Pallet clamping surface according to DIN 55201
mm/inch
Max. workpiece weight
kg/lbs
800x800 (800x1000) / 31,5x31,5 (31,5x39,4) 1000x1000 (1000x1250) / 39,4x39,4 (39,4x49,2)
3000/6615
5000/11025
Working area
Column linear travel X
mm/inch
1700/66,92
2200/86.61
Main spindle vertical travel Y
mm/inch
1600/63,00
1500 (1900)/59,05 (74,80)
Table traverse travel Z
mm/inch
1950/76,77
2100/82,68
Swing diameter
mm/inch
1700/66,92
2200/86,61
A-axis
degrees
-100/+60
-100/+60
B-axis
degrees
endless
endless
Feed rate/Rapid traverse rate
X/Y/Z
m/min inch/min
A-axis
rpm
40/40/40
1574,8/1574,8/1574,8
6 (12)
40/40/40
1574,8/1574,8/1574,8
6 (12)
B-axis
rpm
5,5 (10)
5,5 (10)
Main spindle
Gear driven spindle, max. speed
rpm
Max. power at 100% duty cycle
kW/Nm hp/lbf-ft
4000 (8000)
37/940
Tool taper
4000 (8000)
49,61/693,30
37/940
ISO 50 (HSK-A100)
Motor spindle 1, max. speed
rpm
Max. power at 100% duty cycle
kW/Nm hp/lbf-ft
15000
70/230
Tool taper
15000
93,87/169,64
70/230
HSK-A100
Motor spindle 2, max. speed
rpm
Max. power at 100% duty cycle
kW/Nm hp/lbf-ft
Tool taper
24000
93,78/44,25
70/60
HSK-A63
Tool handling
Chain
93,87/169,64
HSK-A100
24000
70/60
49,61/693,30
ISO 50 (HSK-A100)
93,78/44,25
HSK-A63
Tower
Chain
Tower
HSK-A100 HSK-A63 HSK-A100 HSK-A63 HSK-A100 HSK-A63 HSK-A100 HSK-A63
ISO 50
ISO 50
ISO 50
ISO 50
Tool taper
60 (80)
60 (80)
Max. tool ø (full occupancy)
Number of tool locations
mm/inch
125/4,92
80/3,15
110/4,33
110/4,33
Max. tool ø (free adjacent pockets)
mm/inch
325/12,80 160/6,30
250/9,84
Max. tool ø, oversized tools, 4 tools per tower (only 3/4) mm/inch
(120/180/240/320)
60 (80)
60 (80)
125/4,92
80/3,15
110/4,33
(120/180/240/320)
110/4,33
160/6,30 325/12,80 160/6,30
250/9,84
160/6,30
-
-
325/12,80
-
-
-
325/12,80
-
-
500/19,68
-
500/19,68
-
500/19,68
-
Max ø Bridging tools
mm/inch
500/19,68
Max. tool length, standard
mm/inch
600/23,62 400/15,75 450/17,72 400/15,75 600/23,62 400/15,75 450/17,72 400/15,75
Max. tool length, over length for 15 tools (only possible in tower 1, reduces capacity by 15 locations)
mm/inch
-
-
600/23,62
-
-
-
600/23,62
10/22,04
Max. tool weight
kg/lbs
35/77,16
10/22,04
35/77,16
10/22,04
35/77,16
10/22,04
35/77,16
Max. tilting moment
Nm/lbf-ft
50/36,87
10/7,37
50/36,87
10/7,37
50/36,87
10/7,37
50/36,87
Positioning accuracy according to VDI / DGQ 3441
Axes X/Y/Z mm/inch
Axes A/B
Axes X/Y/Z mm/inch
10/7,37
Axes A/B
Positioning uncertainty (P)
0,008/(0.007) 0,00031/(0,00028) 9/(7) sec 0,008/(0,007) 0,00031/(0,00028)
9/(7) sec
Positioning scatter (Ps)
0,005/(0.004) 0,0002/(0,00016)
6/(4) sec
Reversal error (U)
0,004/(0.003) 0,00016/(0,00012) 4/(3) sec 0,004/(0,003) 0,00016/(0,00012) 4/(3) sec
6/(4) sec 0,005/(0,004) 0,0002/(0,00016)
Dimensions and weight
12
Weight
t/lbs
Space requirement for basic machine L x W x H
mm/inch
42/92594
58/127867
9500x7800x4550 / 374x307x180
11400x8300x5450 / 449x327x215
Values in brackets = (option)
* Enhanced accuracy package (option)
STC Series
Option: also available with NC quill.
STC 1250/150
STC 1600/130
1000x1000 (1000x1250) / 39,4x39,4 (39,4x49,2) 1250x1250 (1250x1600) / 49,2x49,2 (49.2x62,9)
3000/6615
8000/17640
1950/76,77
2800/110,23
2000/78,74
1900/74,80
2100/82,68
2450/96,46
1950/76,77
2800/110,23
-50/+95
-100/+60
endless
endless
40/40/40
1574,8/1574,8/1574,8
40/40/40
1574,8/1574,8/1574,8
5
6 (12)
5,5
5,5 (10)
6000
37/1235
4000 (8000)
49,61/910,89
37/940
ISO 50 (HSK-A100)
10000
28/700
49,61/693,30
ISO 50 (HSK-A100)
15000
37,55/516,30
70/230
ISO 50 (HSK-A100)
93,87/169,64
HSK-A100
24000
70/60
93,78/44,25
HSK-A63
Chain
Tower
Chain
Tower
HSK-A100 HSK-A63 HSK-A100 HSK-A63 HSK-A100 HSK-A63 HSK-A100 HSK-A63
ISO 50
ISO 50
ISO 50
ISO 50
60 (80)
60 (80)
60 (80)
60 (80)
125/4,92
80/3,15
110/4,33
(120/180/240/320)
110/4,33
125/4,92
80/3,15
110/4,33
(120/180/240/320)
110/4,33
325/12,80 160/6,30
250/9,84
160/6,30
325/12,80
160/6,30
250/9,84
160/6,30
-
-
325/12,80
-
-
-
325/12,80
-
500/19,68
-
500/19,68
-
500/19,68
-
500/19,68
-
600/23,62 400/15,75 450/17,72 400/15,75 600/23,62 400/15,75 450/17,72 400/15,75
-
-
600/23,62
-
35/77,16
50/36,87
10/22,04
35/77,16
10/7,37
50/36,87
Axes X/Y/Z mm/inch
-
-
10/22,04
35/77,16
10/7,37
50/36,87
Axes A/B
600/23,62
-
10/22,04
35/77,16
10/22,04
10/7,37
50/36,87
Axes X/Y/Z mm/inch
10/7,37
Axes A/B
0.008/(0.007) 0.00031/(0.00028)
9/(7) sec 0.008/(0.007) 0.00031/(0.00028) 9/(7) sec
0.005/(0.004) 0.0002/(0.00016)
6/(4) sec 0.005/(0.004) 0.0002/(0.00016)
0.004/(0.003) 0.00016/(0.00012)
4/(3) sec 0.004/(0.003) 0.00016/(0.00012) 4/(3) sec
6/(4) sec
75/165345
63/138890
14300x10200x5450 / 563x402x215
14500x9800x5450 / 571x386x215
All machines can be used as a stand-alone machine, as a manu­
facturing cell or be integrated into a flexible manufacturing system.
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More Value Thanks
to Process Services
Our high tech, latest generation machining centers open up, until
now undreamt possibilities in the world of 5-axis milling of extremely
complex workpieces. But what use is technology to you if you can’t
completely realise the full potential from the outset? It is exactly here
that our process services begin.
CPE – Center of Production Excellence
In order that your investment in our technology pays off immediately, a
comprehensive service package is on offer at our Center of Production
Excellence. For example you can run pilot series, test fixturing or even
train your employees on our machines whilst your machining center is
being made.
SAM – Service Assistant Module
Throughout the world StarragHeckert machines are operating 24 hours a
day. We aim to guarantee the greatest machine availability possible. It is
with this in mind that we developed SAM – a software solution that controls
and monitors your machine right down to the last switch and valve. SAM
enables the machine operator to achieve a quick problem analysis and
provides support in finding immediate solutions on location.
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STC Series
Highest Precision and
Productivity Guarantee
StarragHeckert is a leading company in the area of production
technology. We offer our customers a wide range of technologi­cally
ad­vanced precision milling systems, comprehensive engineering
and­software solutions for process optimization, as well as perfectly
designed special tools and services.
Our discerning customers originate from diverse high-tech sectors such
as aerospace, energy production, automotive parts, and machine tool
­manufacturers. We support our customers in achieving higher product­
ivity, efficiency, precision and up-to-date manufacturing, both today and
in the future, with the latest technology and our complete know-how.
The StarragHeckert group has production locations in Germany, Switzer­
land and Great Britain, as well as distribution and service companies in
China, USA, France, Spain, Great Britain and Russia.
15
www.level-east.ch
7. 2008 © Copyright 2008 by StarragHeckert. All data is nevertheless, nonbinding.
StarragHeckert AG
Seebleichestrasse 61
9404 Rorschacherberg
Switzerland
Phone +41 71 858 81 11
Fax
+41 71 858 89 88
[email protected]
www.starragheckert.com
StarragHeckert GmbH
Otto-Schmerbach-Strasse 15/17
09117 Chemnitz
Germany
Phone +49 371 836 22 88
Fax
+49 371 836 23 98
[email protected]
www.starragheckert.com
SIP
Société d’Instruments de Précision
Rue du Pré-de-la-Fontaine 19
1217 Meyrin / Geneva
Switzerland
Phone +41 22 719 02 00
Fax
+41 22 719 02 02
[email protected]
www.sip-geneva.ch
TTL
Units 1a & 1b
Haddenham Business Park
Thame Road
Haddenham, Bucks HP17 8LJ
United Kingdom
Phone +44 1844 296650
Fax +44 1844 296651
[email protected]
www.ttl-solutions.com