GS 600 - Alzmetall

GS 600
www.alzmetall.com
Machining Center
ALZMETALL - COMPANY INTRODUCTION
Premises
is a company with an international reputation and global activities. For more than six decades we have been the
leader in technology for drilling, milling and casting.
ALZMETALL products have proven themselves in general machining applications, in the automotive industry, in mould and die business, at
the aircraft industry, as well as in many mid-size mechanical engineering enterprises. Our experience is based on over 198.000 machines
supplied.
We focus on precision, performance and Quality for all our products. With our own foundry we do not only produce gray cast iron and
spheroidal grey cast iron for our own machines, but also are supplier to the machine tool manufacturers and customers worldwide.
Our open company culture encourages innovation and performance by a continuous innovation towards High Tech and customer benefit
for added value. Developing the GS-series, we offer highly dynamic and extremely rigid machining centers according to our pretensions:
„we drive productivity“.
How to find us
Airport München
“Franz Josef Strauß”
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AT A GLANCE
Machining Center with options: chip conveyor, cooling unit and
coolant filter. These options are either to be installed along the
right - or left side of the Machining Center.
5-Axis Machining Center GS 600/5-T
Highlights
• ALZMETALL-Gantry-Concept (AGK)
• Grey Cast Iron and Spheroidal Graphite Cast Iron
• Monobloc Travel-System-Carriage with incorporated
Box-in-Box-System
• 4-fold Linear Guidance for Travel-System-Carriage and
Z-Axis with integrated Motor-Spindle
• 3-fold Torque-Drives for Swivel-Axis (A-Axis) and Rotary-Axis (C-Axis) at GS 600/5-T und GS 600/5-FDT
• Hybrid-Machining-Applications such as: Drilling/Milling/
Turning and Grinding at one Clamping-Set-Up
• Up to 750 kg workpiece weight including
Clamping-Set-Up-Device at GS 600E/3 (Static Table)
• Up to 500 kg workpiece weight including
Clamping-Set-Up-Device at 5-Axis Machines
Focus on operators needs
• Access to Machine-Table ergonomically configured at
working height
• Workpiece loading by front, side and from top access.
Crane loading possible
• Mist extraction directly at Machine-Table
• Steeply sloping chip tunnel straight below Machine-Table
• Working-Space flushing with coolant (option)
• Automatic Access-Door feature open/close (option)
• Access to all maintenance units at working height
User benefits
Streamlined Force-Circuit between workpiece and
Cutting-Tool in addition to geometrical and symmetrical
configuration of the Carriage-Travel-System.
➠➠Performing
• Thermal consistency at Tool Center Point (TCP)
at X-Y- level without additional Axis compensation
• Significant reduction of Cutting-Tool costs
➠➠Optimum
• Contour consistency at highest path velocity
• Lifetime of Motor-Spindle
➠➠Guaranteed
• High-grade Parallel-Path-Precision through two
Servo-Drives at each X- and Y-Axis
• Considerably reduced Total Cost of Ownership (TCO)
over lifetime period of Machining Center
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ALZMETALL - THE CONCEPT
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RESEARCH AND DEVELOPMENT
Development by using Finite-Elements-Method (FEM)
Z
Y
X
FEM generated Structural Model - Point of force-input at TCP and simultaneously at Machine-Table
Development
The „Finite-Elements-Method“ was applied to obtain the
desired static and dynamic characteristics of each individual
part of the machine and to investigate the collective rigidity
of the Machining Center.
Multi-Elements-Simulation
During the development process the Finite-Elements-Method
was already applied by building the structure of the machine,
patterned from the 3D-Volume–Model born from CAD to
simulate vibration characteristics. Thus enabling engineers to
determine the optimal dynamic rigidity of the machine under
terms and conditions of the daily use at the shop floor.
Modal-Analysis
Results gained by the Multi-Elements-Simulation of entire
machine structure and design had to be confirmed at the
prototype of the GS-Machining Center by using the Modal-Analysis. The experimental Modal-Analysis procedure is
being used to realize and demonstrate the quality of the
dynamic machine characteristics under production conditions.
The final test of the Modal-Analysis accomplished at ALZMETALL verified the high degree of performance of the dynamic requirements in reality. Thus the ALZMETALL GS-Series
offers comparable Best-in-Class conditions for high dynamic
machining applications.
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BASIC DESIGN
Rigidity, Dynamic and Thermal Symmetry
„that‘s it what counts“
Extreme rigid, Integral-Basic-Body prepared for:
• Frame Side Walls as carrier for both Y-Axis (Y- and V-Axis)
• NC – Swivel- and Rotary-Table (A- and C- Axis) or Static-Table
• Disc-Tool-Magazine for 40 Tool Positions, alternative twin Disc-Tool-Magazine for [76] Tool-Positions.
Rack-Type Tool-Magazine for [224] Tool Positions [Option].
All statically stressed Basic-Machine-Parts made from EN-GJL 300 (GG 30) and all dynamically stressed
Basic-Machine-Parts and components made from EN-GJS 600 (GGG 60).
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TRAVEL - SYSTEM - CARRIAGE
Design Characteristics
Box-in-Box-System:
• Y- and V-Axis Frame Side Walls as static basic structure.
On top mounted Travel-System-Carriage with integrated
Z-Axis Monobloc
• Dynamically stressed Basic-Machine-Parts and components made from EN-GJS 600 (GGG60)
• Both Linear-Axis X and Y 4-fold guided, Z-Axis 8-fold
guided
• Linear-Axis Y driven by two Ballscrews and two Servo-Drives. X- and Z-Axis each driven by one Ballscrew
and one Servo-Drive.
➠➠Excellent Axis dynamics
➠➠Cutting edge Parallel-Path-Precision
➠➠Thermal stability due to geometrical symmetry with
Thermo-Symmetric Motor-Spindle
Z
Servo-Drive
Z-Axis
Z-Axis sliding tube
Ballscrew
Monobloc
4-fold Linear Guidance Systems
Travel-System-Carriage
Servodrive
X-Axis
X
2-fold Servodrives
Y-Axis
Ballscrew 2-fold,
Y-Axis
Y
Linear-Encoder
Linear Guidance Systems
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TRAVEL - SYSTEM - CARRIAGE
Krafteinleitung – Symmetrie
• Small lever arms through Z-Axis
Monobloc design
➠➠Increase of stiffness and thus gain of Stability
of overall framework
➠➠Maximized cutting capacity
• Thermo-Symmetric
• Narrow and direct Force-Circuit
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➠➠Thermal stability
➠➠High grade stability and stiffness with coexistent
weight-optimized Axes-Elements
NC - SWIVEL - AND ROTARY - TABLE (SDK)
Swivel- (A-Axis) and Rotary- (C-Axis) Unit
GS 600E/5
• A-Axes Servo-Drive with DC coupled preloaded gear.
Counter-Bearing with hydraulic clamping
• C-Axes Compact-Unit with Servo-Drive and
integrated gear
➠➠High grade torsion stiffness
➠➠Fast rotary motion of gear through capacious gear
transmission at short positional movements of the Axes
➠➠No single-edged wear
Counter-Bearing with
clamping
Servo-Drive with gear
Rotary-Table DIA. 320 mm
(Standard)
Highly self-locking
Gear-Motor
GS 600/5 -T and GS 600/5 - FDT
• Direct Rotary Drives (Torque-Motors) for high dynamic
and oscillating machining – maintenance free –
• Two internal Torque-Motors at each Frame side wall as
NC-Swivel-Axis (A-Axis) – patented• NC-Rotary-Table (C-Axis) equipped with Torque-Motor
➠➠Highest swivel and rotational speed
➠➠Higher accuracies – no mechanical backlash
➠➠Elimination of friction at Drive-Components
➠➠Wear – and maintenance free delivers reduced Total
Cost of Ownership (TCO) over lifetime period of
Machining Center
Torque-Motor
Torque-Motor sectional view
Rotary-Table 400 x 400 mm
[Option]
Torque-Motor
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WORKPIECE DIMENSIONS - MACHINING SPACE
10
ø
80
0m
m
100 mm
C-Axis
350 mm
500 mm
min. 150 /max. 550 mm
Machining Space
• Maximum utilization of Machining Space
• C-Axis DIA. 640 mm
• A-Axis DIA. 800 mm
• Swivel range ± 140°
• Table Load max. 500 kg
• Stainless steel Machining Space cover [Option]
ø 640 mm
A-Axis
SUPPLY - MAINTENANCE - SERVICING
➠➠All components at one cabinet
➠➠At ground level ergonomic access
➠➠Easy to maintain
➠➠Integrated cooling unit for Motor-Spindle at GS 600E
Switchboard cabinet
Pneumatic-System
Lubrication
Cooling unit for Motor-Spindle
Hydraulic-System
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OPTIONS
NC - Swivel - (A-Axis) and Rotary-Tables (C-Axis)
1) 2)
555 x 320
T-slots acc. DIN 650
5 x 14 H12
ø 320
Configuration
parallel in X-direction
Distance mm
63
Table Load max. kg
500
Notice
mm
m
Clamping surface mm
0m
32
Table-Set
Rotary-Table ø 320 mm
m
555 m
400 mm
1) 2)
400 x 400
T-slots acc. DIN 650
1 x 14 H 7 und 4 x 14 H12
Configuration
parallel
RPM max.
100
1200 2)
1)
Table Load max. kg
500
Distance T-slots mm
63
Rotary-Table C-Axis with NPS
m
without
Configuration NPS
4 x 90 °
100
3)
m
500
0m
Table Load max. kg
1200 2)
1)
20
RPM max.
GS 600/5-T
GS 600/5-FDT
0m
400 x 400
T-slots
2)
400 mm
1) 2) 3)
40
Clamping surface mm
1)
m
Clamping surface mm
0m
40
Rotary-Table C-Axis
NPS = Nullpunkt Spannsystem
200 mm
Further executions on demand
GS 600E/3
3-Axis-Machine with Static Table
T-slots acc. DIN 650
Configuration
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600 x 630
1 x 14 H7 und 8 x 14 H12
parallel in X-direction
Distance T-slots mm
63
Table Load max. kg
750
mm
Clamping surface mm
630
Static Table
600 mm
OPTIONS
CNC - C o n t r o l s
Heidenhain iTNC 530 HSCI (standard)
Heidenhain TNC 640
CNC - C o n t r o l s
Siemens SINUMERIK 840 D sl
KINEMATIK Gauging
Accuracy check and compensation
- KinematicsOpt., Heidenhain
- C 996, Siemens
Electrical Handwheels
- HR 410, Heidenhain
- HR 520, Heidenhain
- Mini-Handwheel, Siemens
3D-Touch Probes
Infrared transmission
- TS 640, Heidenhain
- TS 740, Heidenhain
- IRP 25.41, m&h Inprocess
- OMP 60, Renishaw
- TC 50, Blum
Multiple-Media-Coupling
for Rotary-Table
4-fold on selection air and/or fluids
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OPTIONS
14
Tool Setting System
Laser System for Tool Setting and Breakage Detection on
selection including mechanical Touch Trigger Probes
LTS 35.65, m&h, (without mech. Touch Trigger Probes)
LC NT, Blum, (without mech. Touch Trigger Probes)
TC 76, Blum, (with mech. Touch Trigger Probes)
Camera and Screen
Camera mounted at Machining Space with transmission
to external flat screen or Video-Server for process-set-ups
and process-controls
Tool-Magazines
Twin-Disc-Tool Magazine for 76 Tool Positions
Tool-Magazines
Rack-Type Magazines with 224 Tool positions
Production Package
On selection A, B, C with Scratch-Type-Conveyor,
Hinge-Type-Conveyor, Magnetic-Conveyor
Production Package
Coolant Cleaning Unit with Metal-Edge-Filter
or Compact-Paper-Filter
OPTIONS
Mist Extraction Unit
Attached to Machine-Basic-Body
Remote Diagnosis,
Remote Maintenance
and for NC-Programming-Support
Machining Center Acceptance
Workpiece according to ALZMETALL-Standard, on selection
Customer-Workpiece (option)
Services
NC-Program-Training, Operator-Training for Heidenhain
and Siemens
Services
Machining Center Installation, Set-Up, Production Assistance
and Maintenance
[ ] Options
• Rotary-Table (C-Axis) various configurations
• Mutiple-Media-Coupling for Rotary-Table (C-Axis)
• Motor-Spindles RPM-Range 18.000 RPM/24.000 RPM
• Disc-Tool Magazine up to 76 Tool Positions
• Tool Magazine Rack-Type up to 224 Tool Positions
• Chip Conveyor: Scratch-Type-, Hinge-Type-,
Magnetic-Conveyar 1)
• High pressure Coolant Units up to 150 bar 1)
• Electrical Handwheels
• 3D-Touch Probes
• Automatic Workpiece-Changing-System
• Tool Setting and Detection Systems
• Workpiece-Pallet-Changing-System
• Robot-Systems
• Custom-Made Solutions
• Services
1) Optional placement along the right- or left side of
the Machining Center
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TECHNICAL DATA
Type
Working Range
Traverse Path
Static Table
Distance Spindle - Static-Table min./max.
Clamping Surface (w x d)
8 T-Slots acc. DIN 650 at X-Direction
1 T-Slot at Table Center Line at X-Direction
Machine-Table Load
NC-Swivel-and Rotary-Table
Distance Spindle - Table min/max.
GS 600E/3
CNC-Controls
GS 600/5-T
GS 600/5-FDT
460 / 600 / 400 mm
100/500 mm
600/630 mm
14H12 x 63 mm
14H7
750 kg
150/550 mm
conventional
indirect
± 140 °
30 min-1
Drives at Swivel- and Rotary-Axis
Swivel Range of A-Axis
Swivel Speed at A-Axis
C-Axis Rotation
C-Axis RPM max.
Diameter Machine-Table C-Axis
8 T-Slots acc. DIN 650
Star-Shaped Configuration
Machine-Table Center Bore
Table Load max.
C-Axis Rotary-Diameter at A-Axis Center
A-Axis Swivel Diameter (Swing) at X-Axis Center
Distance A-Axis-Center to Rotary-Table
Feed-Drive-System X-, Y-, Z-Axis
Digital AC-Servo-Motors, maintenance free
Max. Rapid Travel X-, Y-, Z-Axis at TCP
Feeding Force X-, Y-, Z-Axis at CDF 40%
Motor-Spindle-Drive
High Frequency Motor-Spindle
Cutting-Tool Interface
Motor-Spindle-Power at CDF 20%
Variable Speed Range max.
Motor-Spindle Torque at CDF 20%
Tool-Magazines
Tool positions, Type
Max. Tool Diameter, Chain fully loaded
Max. Tool Diameter, Chain neighbour positions
unloaded
Max. Tool Length
Max. Tool Weight
Tool-Change-Cycle (approx.)
Chip-to-Chip Cycle
Linear Encoders X-, Y-, Z-Axis
Positional Tolerance TP acc.
DIN/ISO 230-2 (VDI/DGQ 3441)
Angle Encoder System A-, and C-Axis
Machine Weight excl. Options
GS 600E/5
50 min-1
Ø 320 mm
4 x 90 °
30 m/min
Torque direct
± 140 °
90 min-1
360 ° endless
100 min-1
1200 min-1
Ø 320, [400 x 400] mm
14H12
4 x 90 ° [ 5 x parallel|, Distance 63 mm]
Ø 50 H7 mm
500 kg
Ø 640 mm
Ø 800 mm
100 mm
30 m/min
60 m/min
4 - 4 - 5 kN
HSK-A63
16 kW [26] [17] kW
10.000 min-1 [18.000][42.000] min-1
102 Nm [82] [11] Nm
HSK-T63
13 kW
10.000 min-1
80 Nm
40 Disc, [76 Twin-Disc] [224 Rack-Type]
80 mm
130 mm
indirekt
300 mm [150 at upper Disc]
4 kg [10 kg at Rack Type]
2s
4,5 s
absolut, direct
≤ 0,007 mm
direkt
6800 kg
Heidenhain iTNC 530HSCI,
[Heidenhain TNC 640], [Siemens 840 D sl]
Siemens 840 D sl
[Heidenhain TNC 640]
[Option]
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MOTOR - SPINDLES
RPM - Power - Table
P S1
Md S6/25%
102
90 Md S6/40%
16
14
P S6/25%
P S6/40%
11
P S1
Md S6/25%
83
73 Md S6/40%
Md S1
7
1.500
1.500
10.000 n (min -1)
GS 600/5-FDT
[RPMmax. = 18.000 min -1] Option
Md (Nm)
Md (Nm)
P (kW)
[RPM max. = 42.000 min -1] Option
Md S6/25%
82
73 Md S6/40%
55
P S6/25%
P S6/40%
Md S1
P S6/25%
P S6/40%
P S1
3.000
GS 600E/3, GS 600E/5, GS 600/5-T
9
Md S1
10.000 n (min -1)
GS 600E/3, GS 600E/5, GS 600/5-T
13
11,5
P (kW)
70
Md (Nm)
Md (Nm)
P S6/25%
P S6/40%
P (kW)
RPM max. = 10.000 min -1
Hirth-Gear-Indexing for turning Operation
P (kW)
RPM max. = 10.000 min -1
18.000 n (min -1)
26
23
17
P S1
Md S6/25%
11
8,3 Md S6/40%
6,4
17
13
10
Md S1
15.000
42.000 n (min -1)
GS 600E/3, GS 600E/5, GS 600/5-T
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approx. 2.300 mm
GS 600
max. 2.800 mm
MACHINING CENTER DIMENSIONS
incl. Options A) und B) approx. 3.250 mm
approx. 1.350 mm
approx. 1.900 mm
Machining Center (Single Unit) Transport Dimensions)
GS 600
F)
E)
• Width approx. 1.900 mm
• Depth approx. 3.750 [4210] mm
B)
R1
approx. 600 mm
0
.15
A)
18
incl. Options E), approx. 4.010 mm
• Height approx. 2.370 mm
Coolant Unit
approx. 3.150 mm
C)
D)
Options
A)Chip Conveyor
B)Chip Trolley
C)High pressure Coolant Unit
D)Coolant cleaning system
E)Rack-Type Tool-Magazine
F)Mist Extraction Unit
Please observe: Options A, B, C and D are either to be
installed along the right- or left side of the Machining
Center!
AUTOMATION SOLUTIONS
PowerCell Robot-Loading-System and Zero Point Tooling System with 24 workpiece-pallets
Robot-Loading-System for workpiece-pallets with external Rack-Type-System
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PRODUCT RANGE - PLEASE CONTACT US
Machining Centers
Machining Centers
• GS 800/3
• GS 800/5-T
• GS 800/5-FDT
• GS 1000/3
• GS 1000/5
• GS 1000/5-T
Machining Centers
Machining Centers
•
•
•
•
• CS 600
• CS 1200
• CS 1200 P
GS 1400/3
GS 1400/5-T
GS 1400/5-FDT
GX 1400/5-AF
• GS 1000/5-FDT
• GX 1000/5-AF
• GX 1000/5-LOB
Also contact us for further Machining Centers of the CS-Series, Drilling Machines-Series and Custom made Cast-Iron-Products.
ALZMETALL Werkzeugmaschinenfabrik
und Gießerei Friedrich GmbH & Co. KG
Postfach/P.O. Box 1169
D-83350 Altenmarkt/Alz · Germany
Harald-Friedrich-Straße 2-8
D-83352 Altenmarkt/Alz · Germany
Tel./Phone +49 (0) 86 21/88-0
Fax +49 (0) 86 21/88-213
E-Mail: [email protected]
Internet: www.alzmetall.com
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