408b 408mt - Amerex Machine Systems Inc.

Transcription

Turnkey solutions for
machining of high precision
complex parts
408b
Milling
5-7 Axis Machining Centre
Bar Stock up to ø 40 mm
medical
watch
industry
408mt
AVIATION
aerospace
MICROmechanical
Milling / Turning
Multi- Process 6-7 Axis Machining Centre
Bar Stock up to ø 36 mm
Bar Stock or individual Parts Machining
Automatic back-working Device
Complete Part Machining in a single Cycle
5-7 axis bar fed machining centres with back-working devices
408b | 408mt - Bar Stock Machining
The latest generation of 408B and 408MT machining centres
offers the perfect combination of the technology to machine
bar stock of up to Ø 32 mm (Ø 36 mm on 408MT and Ø 40 mm
on 408B as an optional extra) and the flexibility provided by
their automatic back-working devices. The high-performance
motor spindle is suited to the most demanding of machining
applications. The high-precision horizontal spindle / divider
works just like a divider at low-speed and a lathe spindle at
high-speed (408MT).
Machines adapted to the production from small to
large-sized batches of complex parts
Back-working devices with clamping by self-centring
vice or by collet (internal or external clamping)
Extensive operating autonomy through bar feeding and
automatic part unloading, as well as part conditioning
6-sided machining in
a single cycle
milling / turning from
bar stock up to Ø 32 mm
high-precision and highquality surface finish
High level of static and dynamic rigidity
Excellent degree of homogeneity in the
kinematics chain
High-speed machining, up to 42,000 rpm
Automatic 0-90° back-working device with
one working position: vice or collet (internal
or external clamping)
Tool magazine up to 48 positions,
tool change time: 0.8 sec.
Various bar feeders
Simple, precise, economic parts handling
systems
Optimum ratio between working volume
and required floor space

3
2
Bar Stock Machining Process with
automatic back-working Machining
Loading bar stock into the A axis
Bar stock is loaded from the bar feeder or bar magazine
(short or long bar stock)
Positioning is checked
Bar stock is then clamped in the divider
1st clamping
Front and sides are machined
Milling operation on 408B and milling / turning operations on 408MT commence
Cutting off
The back-working device rotates through 90° (into
the vertical position) and advances toward the A axis
divider in order to clamp the machined part of the bar
stock
The B axis motor-spindle moves into the 90° position to
allow cutting off to commence
The 408MT enables cutting off with a chisel
2nd clamping
The back-working device again rotates through 90°
(back to the horizontal position)
The rear side is then machined, thus allowing the part
to be completed in a single cycle
Evacuation of machined part
The jaws or collet holding the part are unclamped
The finished part is evacuated and stored outside the
machining area. Automated systems are available on
request
5
4
Design
Construction
Linear Axes
Machine Characteristics
Swivelling

Linear axes high-precision is ensured by guideways and
super-precision class preloaded linear roller bearings
Homogeneous rigidity within the structural guide system
is attained without energy dissipation or friction
High speeds of 30 m/min
The linear axis measurement resolution of 0.0001 mm (0.1
µm) is put to optimum use
Statics and Dynamics
The application of light construction principles improves the
machine’s dynamics and enables high accelerations, speeds
and precision positioning:
Construction minimizes structural cantilever effect
Excellent degree of homogeneity in the kinematics chain
Highly repeatable precision
High natural frequency structure
408b : A axis divider for
milling operations
408mt :A axis spindle / divider for
milling and turning operations

Advantages of the ball screw-nut reduction ratio:
Filters out disturbances (irreversible advance command)
Increased servo-control rigidity
Rotary Axes
High torsional rigidity and extensive loading capacity
High speed and appropriate acceleration according to
linear axis dynamics
Highly dynamic B axis, 0 to 90° in 0.5 sec.
Maintenance-free operations, i.e. no clearance adjustment
required
Table rigidity guaranteed by large axial / radial bearing

Kinematics
W= 360°
A= 360°
S2= 6’000 rpm (408MT)
B= -15° / +100°
Z= 300 mm
High-Performance Motor Spindle
Technical Data
The swivel motor spindles on the 408B / 408M machining
centres boast the qualities of compactness, rigidity and reliability.
HSK-E40 tool-holder taper
Broad operating range 500-30’000 rpm
42’000 rpm (option)
High power and torque 15 kW / 12 Nm (S6)
Wide angular movement from -15° to +100°,
-25° to +100° (option)
Hybrid bearings (ceramic)
Increased Precision through Thermostabilisation
The motor spindle is designed in such way that heat dissipation occurs by the stator. This enables direct cooling of the
system:
High-speed air / oil lubrication makes it possible to lower
the temperature and control spindle nose dilation
Spindle bearings undergo efficient thermostabilisation
Spindle Orientation Control (W Axis)
For operations such as turning, thread chasing and tapping,
planing, pinning, dressing, swaging preparation and boring
head orientation:
Effective and precise blocking with brake applying asymmetrical deformation to blocking ring
Y= 200 mm
0°-90°
X= 250 mm
Low-speed roughing operations with high
chip-removal rate
High-speed finishing operations compliant
with High-Speed Machining technology
Machining of materials that are difficult to
machine such as stainless and chrome-cobalt
steels, titanium and alloys, high ceramics
High-pressure cooling through centre (option)
Dynamic compensation of motor spindle dilatation
This function permits real-time compensation for geometrical
drifts in the mechanical components comprising the motorspindle caused by overheating and rotation speed.
Virtually all geometrical drifts between the machined part
and the tools are permanently compensated for.
Vmax
Dilatation in %
X= 250 mm
Y= 200 mm
Z = 300 mm
A= 360° / 408MT: S2 = 6’000 min-1
B= -15° / +100°
U= 80 mm
W= 360° (optional on 408B)
Linear Axis Drive
This design ensures
very high-precision
machining conditions
75
50
25
5
0
0,5
1
1,5
2
Time in h
Curve without dynamic motor spindle compensation
Curve with dynamic motor spindle compensation
15
10
5
0

U= 80 mm
100
0
Power Rating in kW
Travel and Axis Definition
Thermic Behaviour
Any thermic drifts are controlled by thermostabilisation
within the mechanical components. Thermostabilisation is
improved by the cutting fluid cooling.
0
12'000
30'000
42'000
Speed in rpm
0
12'000
30'000
42'000
Speed in rpm
12
Torque in Nm
spindle
high level of static and dynamic rigidity is achieved
thanks to ribbed, compartmentalized cast iron structures
Minimized heat variations occur in the structures thanks
to a separation between machine area and machining
environment
Main structures are located isostatically on a frame, which
also supports the peripherals
A
8
0
S1 Power in 100% service
S6 Power in 40% service
6
Machine Equipment
Automatic back-working Device
1 working-Position 0°-90° swivel Device
Automatic back-working device on U axis, 80 mm travel,
equipment:
Self-centring vice
Internal and external clamping collet
HSK-E40 Tool Magazine and Changer
24 positions (48 positions optional)
Several positions in magazine for indexed tools
Fast tool change time: 0.8 sec.
Tool management
- Sister-tool management
- Tool lifetime management (time and
number of used tools)
- Tool data saving

HSK 40 ETS 9
ETS 16
Shrink fit toolholder
Economic Handling Systems
Simple evacuation
Cut-off part recovery system with collet, for machine
without back-working device
Handling device with collet for part removal, for machine
with back-working device
Handling Arm
To increase the machine’s machining autonomy, WilleminMacodel recommends a handling arm for loading and unloading parts or pallets. The handler has longitudinal and vertical
digital axes to permit part handling between the storage and
machining areas. Adaptation options for specific startups:
0° to 90° rotating device enabling horizontal / vertical grip
movement
2nd grip adaptation
Transverse digital table for storing parts in specific compartments, pre-positioning for pallets
Grips adapted to applications
Parts orientation station
The handler can be fitted with a palletizing system for large
series of parts. This then makes it possible to handle pallet
transfer during idle time without ceasing production.
Cylindrical
chisel-holder
48-position tool magazine
Milling cutterholder
Boring headholder
HSK 40 head-holder
A Axis Divider
Milling mode (rpm)
Torque (Nm)
Turning mode (rpm)
Power (kW)
Taper interface
Locking (N)

408b
100
250
A4
16’000
at 80 bar
408mt
100
9 / 29 (S1 / S6)
6’000
1.5 / 3.7 (S1 / S6)
A4
27’500 at 40
bar (hydraulic)
F-type chuck
Chuck for Ottet
collet
Mecatool Pallet
Clamping GPS70
Precise positioning
Simple to operate
Quick return on investment
Small dimensions
Diameter tolerance
Circularity
Cylindricity
Roughness
Concentricity
ØD
Ra
: IT5
: 0,0015 mm
: 0,003 mm
: 0,6 µm
: 0,004 mm
ØD
Ra
Turning Precision (408mt)
A
Back-working device with vice
Cut-off part recovery system for machine without back-working device
Handling arm fitted on the machine side with accessible door

A vast range of chucks permitting clamping of many different
bar types (round, square, polyhedron) and blanks is available
as standard. Other clamping systems are being developed and
adapted according to the application.

7
Bar Stock Machining
A wide range of bar feed systems can be fitted according to
bar stock types (different shapes and lengths) to help meet
requirements such as bar guidance, bar swarf evacuation, or
production autonomy.
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9
dental industry
Dental Abutment Machining
408b / 408mt Application
The 408B and 408MT machining centres are perfectly suited
to abutment machining and are capable of ensuring automated production.
Medical / Dental
Cervical plate
Specific Applications
Bone screw
Abutment
Full Control of Machining Process
Complete machining from bar stock or individual parts assured in a single cycle by means of back-working device
Back-working with special collets for internal or external
clamping of parts
Ultra-precise clamping of all existing interfaces
Machining strategy guaranteeing rapidity and highquality surface finish of parts made of titanium,
zircon (ceramic), etc.
Specific equipment for ceramic machining:
- improved isolation of machining area
- oil-free
- dust removal

Surgical instruments
Watch Industry
Exterior
Handling and conditioning
Blanks and finished parts are loaded / unloaded by
handling arm enabling high production autonomy
Parts are stored in numbered compartments outside
the machining area
Automatic collet change with handling arm
Back-working collet magazine management
Casing ring
Watch case
Machining of specific Materials
Ceramics: high spindle speed, perfect clamping control,
dust extraction
PEEK: specific chip processing, part clamping suited to
material, improved isolation of machining
area
Titanium: high spindle torque, cutting tool control
Marking of medical parts
Automatic setting of markers on PEEK parts
Part Management
Parts are identified either by batches, or by part, by means
of a bar code to fulfil the traceability requirements in
some industries
Jewellery

Jewels with
specific shapes
Wedding rings
Abutment machining on A axis
Micro-mechanical
Turnkey Machining Solutions
Machine perfectly suited to the
machining of small complex parts
Controlled clamping of small parts
Possibility of clamping all existing part
interfaces
Automated back-working collet on
pallet change management

Willemin-Macodel offers a comprehensive range of services, from examination of part drawings through to machine installation and commissioning on the customer’s premises.
Development of turnkey projects including machining programme, tooling, part clamping concept
Programming recommendations and support
Machining tests conducted on the basis of job specifications
Design and development of automation devices adapted to the machines and to job specifications
Customer training provided in machine programming and operation
Machines commissioned by highly skilled staff
Customised after-sales service with hot-line
Proposal of preventive maintenance contracts for machines according to their
equipment
Study of finance schemes

Rear side machining on back-working device
10
Technical Specifications
Layout in mm
250 / 200 / 300 / 80 mm
360° / 115° / 360°
1692
(48 tools)
1490
(24 tools)
6360 (bar stock 3 m)
R
R
2040
1385
1840
90
0
75
0
85
0m
General Data
Voltage:
Installed power 408B:
Installed power 408MT:
Air pressure:
Air consumption: Net weight:
m
Layout with handling arm
3 x 400 V / 50Hz
9 KVA / 25 A
16 KVA / 25 A
6 bar
~ 150 l/min
1’700 kg
pomzed.ch
SwissMade
Route de la Communance 59
CH-2800 Delémont
Tel. +41 (0)32 427 03 03
Fax +41 (0)32 426 55 30
[email protected]
www.willemin-macodel.com
Subject to modifications 09.2009
Feed and forces
Rapid feed
30 m/min
Thrust
2’600 N
Axes drivesAC motors
Resolution
0.0001 mm (0.1mm)
Spindle with built-in
Tool taperHSK-E40
motorPower S1 / S6
10 / 15 kW
Torque S1 / S6
8 / 12 Nm
Speed
500 – 30’000 rpm
B axis
Movement
-15° to +100°
Resolution
0,0001°
Nominal torque
180 Nm
Holding brake (hydraulic)
500 Nm
Max. rotation speed (G0)
20 rpm
A axis - milling mode
Movement
360°
Resolution
0,001°
Torque S1 / S6 (408MT)
9 / 29 Nm
Max. torque (408B)
250 Nm
Holding brake (hydraulic)
130 Nm
Speed
100 rpm
Spindle taper interfaceA4
408MT: A axis - turning Max. speed
6’000 rpm
mode
Power S1 / S6
1.5 / 3.7 kW
Ø through bore
Max. Ø
32 mm
Clamping systemF27, F35, F48, W31.75, Ottet collets, Mecatool GPS70
(A axis)
pallet, various collets for internal and external clamping
Tool magazineNumber of tools
24
Indexed positions in magazine 5 (408B); 10 (408MT)
Max. tool Ø
50 mm
Max. tool Ø
63 mm
(with 2 free positions)
Max. tool length
95 mm
Tool change time
0.8 s
Chip-to-chip
~3 s
Coolant
Chips tray
0.03 m3
Tank capacity 80 l
Pump flow
40 l/min
Pressure 2.5 bar
Lubrication
Central lubricationPressure 25 bar
Lubricant 2,7 l
Hydraulic groupNominal pressure
100 bar
Numerical controlFANUC 31i-A5
Options:
Motor spindle speed: 42,000 rpm
Motor spindle orientation control (option 408B, standard 408MT)
Back-working device on rail with 0-90° unit with 2 positions
Vice or collet for back-working machining
Hydraulic divider locking by differential pressure (408MT)
Through bore Ø up to 36 mm (408MT), 40 mm (408B)
48 position tool magazine
Tool breaking detection / tool measurement
Dimensional parts measurement
B axis angular movement-25° at +100°
High-pressure cooling through spindle
Thermostabilisation of cutting liquid and mechanical cabinet
(option 408B, standard 408MT)
Filtration systems
Chip conveyor
Micro-pulverisation
Various bar feed systems and bar magazines
Various automatic part loading and unloading systems
2450
X – Y – Z - U
A – B - W
R3
10
Travels and
movements
1200
Capacities