HSM today Issue 16

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HSM today Issue 16
Specialist journal from
Mikron Agie Charmilles AG
for the Milling Technology
Issue 16
The HSM 400U at
IWC in Schaffhausen/CH
Page 2-3:
Page 6-7:
Great enthusiasm for
the HPM 1000U/1100
Page 11:
The HSM 400 at
Hung Ming Ho in China
Page 12-13: Medical Technology,
the UCP 600 Vario und MEDARTIS
Large parts with
the HPM 1850U at Bühler/DE
Page 14-15:
Machining Centers for Medical Technology
HSM 400U ProdMed, HSM 400U ProdMed Dental and UCP 600 Vario ProdMed
In the medical technology market
segment, the manufacturing of
implants represents an area characterised by the expectations of
efficient production but which
nevertheless must satisfy the special constraints of a medical environment.
Ralf Löttgen
Autonomy and Process Capacity
The HSM 400U ProdMed in its
standard configuration and the
derived version for the production
of dental implants, as well as
the UCP 600 Vario ProdMed,
each have integrated and economic solutions for tooling and component automation. This not only
involves the physical change, but
also monitoring and evaluation of
tools and components by measurements and the inspection of breakage, including documentation of
the results.
In combination with the monitoring functions of the control system as well as the “smart machine”
modules included in the scope
of delivery for monitoring spindle
vibrations (Extended APS), the
automatic calibration of machine
geometry (ITC-5X) that can be
called in the NC program, plus the
option to transmit specific machine
and process statuses to GSM telephones (RNS), the ProdMed versions make a significant contribution towards reliable and traceable
results in production.
Reduction in Piece Times
Through a variety of completed
projects, it has been shown that for
frequently used tool diameters,
high-speed technology with spindle speeds of more than 15'000 to
30'000 rpm – even higher in exceptional cases – can be used even for
semifinishing and finishing work
on titanium alloys, and provides
considerable potential for the reduction of machining times. Edge
build-up and adhesion problems
with titanium alloys occur almost
exclusively during roughing operations, so that in general, low spindle speeds and higher axial and lateral infeeds are used accordingly.
In such applications, the wide performance range of modern motor
spindles can be used optimally,
with comparatively high torques at
low rotation speeds and, depending on the spindle type, at maximum speeds from 20'000 up to
54'000 rpm. With regard to machining aspects, the system’s high
flexibility makes a significant
contribution for shorter part
times whilst improving the level of
detail and surface quality at the
same time.
Required Characteristics of the
Materials to be machined
Contrary to titanium machining, it is hardly worth applying highspeed technology for alloys that are
difficult to machine, regardless of
the machining situation. Depending on the amount of material to be
removed and the part's geometry,
considerable emphasis should be
placed on the spindle output, i.e.
the UCP 600 Vario ProdMed – specialized for the operation of set,
clamped axes and with spindle
speeds of 20'000 rpm – is recommended for machining work that
is characterized by a high level
of material removal, whereas an
agile HSM 400U ProdMed, also
using simultaneous 5-axis machining with spindle speeds of
30’000 rpm, is preferable for more
complex machining operations
with low demands on material
removal.
Likewise, chip disposal and
cooling lubricant treatment are of
particular significance, especially
in the case of titanium machining.
Therefore, and depending on the
expected chip volumes, the three
ProdMed models feature adapted
designs based on bandpass filter
technology that permits smooth
production operation.
Integration into the Environment
and Processes
Of particular importance is the
smooth integration of new, demand-driven production resources
into the technical production environment, and also into the medical
environment in the case of medical
technology. In this case, various
company-specific aspects also play
a role. Apart from characteristics
that are taken for granted, such as
reduced space requirement, reliability, ergonomics, integration into
IT networks, etc., the traceability
of the machining results, the documentation of the NC program
used, and similar aspects assume
particular significance. For this
purpose, automatic logbook entries or those created on command,
status displays or measurement
results can be used and assessed
individually.
Frequently, the production
problem on the machine is only part
of a far more complex situation. For
example, an entire process can
begin with the capture of threedimensional geometry data on a
scanner, and must end with a part
that satisfies quality requirements.
This is where the development of
efficient and effective process
chains, in cooperation with the relevant partners from the area of production technology, is of paramount importance. If required, and
in addition to the ProdMed machines customized to satisfy the
needs of medical technology, services are also offered, which are intended to assist the development
and implementation of successful
overall processes in conjunction
with the client's expertise. This
includes advice on CAD/CAM
issues, questions regarding tool
selection or technological aspects,
as well as contact with partners in
the process chain who are already
able to offer solutions to relevant
problems.
Thus, the Mikron ProdMed
machines, including possible services in connection with the development of integral production
processes, reflect an offer that is
focussed on the needs of medical
technology.
Please take notice of the article
on the pages 12-13.
The company MEDARTIS/CH
manufactures medical products
with a UCP 600 Vario.
www.mikron-ac.com
High-speed machining
2
Editorial
Jens Thing
Brand Manager Mikron
HSMtoday Nr. 16
IWC Schaffhausen - Where
quality meets innovation
IWC prefers milling machines from within their own country.
For almost two years, watch cases have been manufactured for
the "Ingenieur" on a Mikron HSM 400U of Nidau/CH
Dear Readers,
In this edition of HSMtoday, we
once again introduce you to
companies who use our highspeed and high-frequency
machining centers, clearly
illustrating the fact that the
range of application for our
machining centers is highly
varied. Mikron offers each
user the machine best suited
to him from the broad spectrum of machining, from the
VCE Pro line vertical machining centers to the universal
high-performance machining
centers of the UCP line. With
its HPM line of products
(highly productive chip removal), Mikron launches machining centers on the market
with a working range of up
to 1850 mm for the first time.
The HSM line of 5-axis
high speed machining centers
has been continuously improved in recent years. Mikron
has put great effort into all its
machines in order to optimize
automation.
New arrivals include the
HSM 400U ProdMed,
HSM 400U ProdMed Dental
and the
UCP 600 Vario ProdMed,
machines specially developed
for medical technology. Each
machine features integrated
and economic solutions for
tooling and component automation. With every new innovation and further development, an important objective
is to increase the competitive
edge of your company – because your success is our
success.
Distinctive originals in chronometry are the undisputable
specialty of the North-eastern
Swiss watch manufacturer IWC
Schaffhausen: The famous "Da
Vinci" with permanent calendar is
a part just as the "Grande Complication", the super antimagnetic
"Ingenieur" or the "Aquatimer
Automatic 2000", which will withstand pressures to 2000 meters
water depth.
Jürgen Maurer
The fact that an American
Engineer from Boston, Florentine
Ariosto Jones set up the "International Watch Co." in Schaffhausen
in 1868 was no accident. The name
and the existence accounts the
manufacturing location on the
Rhein - far away from the watchcenters of Western Switzerland to this American. He found a newly constructed hydro-electric power plant as the drive for his
machines. - Ideal conditions for
his passion, building perfect mechanical clocks for the American
market. He also found watchmakers in Schaffhausen who's careers
were backed by long tradition.
Evidence of this was found in the
Schaffhausen public records office,
dated 29 January, 1583 in entries
of trades artificer, the gunsmith,
watch makers and winder makers
on the city council. These entries
prove that the watchmaker trades
existed in Schaffhausen at
that time. The beginnings of
Schaffhauser clock-making art go
back even further, back to 1409
when a Monk from the nearby
Rheinau Monastery built the striking clock in the St. Johann church.
Originals of chronometry were
created soon after the company
was formed, such as the Pallweber pocket watch with a digital
display, which is a much sought
after collector's piece. As one of
the first watch manufacturers, IWC
recognized the huge potential of
the ever more popular wristwatch
at the end of the 19th century,
which was the reason for developing a completely new factory. On
the other hand however, the original inner workings of the pocket
watch were also used in the wristwatches, as the market in the
30's demanded large precision
wristwatches. This led to the
Portugese line - still a trendsetter
for wristwatches today in "Kingsize" format.
The HSM 400U palette changer. 3 watch casings are mounted on the
fixture constructed for them at IWC
IWC was on the scene as the
watches were used as the pioneers
of flight were learning to fly - and
still has an extensive collection of
professional Pilot's watches, which
are equipped with a special protective magnetic field. In the nineteen
fifties, IWC wasn't only at the head
of the race for automatic self-winding watches but they developed an
unsurpassed self-winding system
with the Pellaton winding system,
which even today works exclusively in their automatic manufacturing plants.
During the major turbulences
of the Swiss watch-making industry at the end of the seventies,
Watches were engineered for
men in Schaffhausen under the
leadership of their revered Patron
Günter Blümlein - against the
push toward electronics - mechanical, innovative and of superior
technology.
This self-conception led to the
tongue in cheek advertising slogan:
"IWC – since 1868. And as long as
there are still men." Since the
men's watch has of course long
since become a woman's concern
as well.
The technical perfection, the
training of their engineers, the
prevention of manufacturing mass
products: All of this corresponds
with the old axiom of the IWC, to
make watches for few but of the
highest quality. This is the reason
that the watches with thorough
maintenance last for decades. This
is also why they are collector
pieces, which fetch collector's
prices around the world. Distinguished pulses for the mechanical
watch come from IWC. 450 employees manufacture the coveted
pieces in Schaffhausen. IWC has
belonged to Richemont SA since
the year 2000.
HSMtoday Nr. 16
High-speed machining
3
the definite start to the automatic
mechanisms in Schaffhausen. The
first time the “Ingenieur” appeared
on the market, carrying the
technical lightning symbol on
the number plate - for electricity was dated 1954/55. "Ingenieur”
also means: Protection from extreme magnetic fields with
an IWC-typical soft-iron casing
interior.
An entire family of athletic,
more attractive and especially
tough watches were derived
from the watch-makers solitaire
(www.iwc.ch).
Hubert Uebelhör,
over 20 years of CNC experience
Mikron and
the “Ingenieur”
An HSM 400U from Mikron has
been working in the IWC milling
shop in Schaffhausen for almost
2 years now. This milling center
is mainly for producing the
"Ingenieur" casings.
But first, more on this classic
watch from IWC. The name has
been the vision and the program
for 50 years. It stands for robustness, precision and technical
progress. Its development was
The HSM 400U, which has a
window location in the IWC milling
shop, is a processing center in a
class of its own, is very dynamic
and the precision of all 5 axes is
exceptional. When questioned as
to why a Mikron machine was purchased, Hubert Uebelhör, the responsible programmer and configuration technician, explained that
the name and the good machines
of the Swiss manufacturer are well
known. The large 5-axes mobility,
which is required for the parts
spectrum of IWC, the pivoting angle and the simultaneous operation abilities were important to him.
The solid construction of the machine and the acceleration were also very convincing. The iTNC 530
controller by Heidenhain with its
user-friendly interface is also significant for IWC.
As already mentioned, the
watch casing of the "Ingenieur" is
milled on the HSM 400U and it
is done using full material, either
of stainless steel or titanium.
The winding mechanism is also
produced with this machine to
achieve the best possible fitting
precision.
Since the HSM 400U is set up
with a palette and tool changer by
Mikron and the inexpensive palette
system by 3R for automatic operation, the assembled equipment
The Ingenieur Automatic AMG in Titanium casing. A statement for the common value, combining the IWC
and the Mercedes AMG as the mark of Engineers with their lean toward perfection
does not have to be unscrewed,
they can be "parked" on the
palettes. This reduces set-up times
to very nearly zero. IWC watch
casings can be produced overnight
and on the weekend without an
operator.
According to Hubert Uebelhör,
the HSM 400U is generally very
user-friendly and easy to operate.
It is also very reliable and dimensionally stable. The HSM 400U
meets all of the demands of a modern 5-axes processing center.
Particularly noteworthy is the
dependable cooperation with the
Competence Centre in Nidau. If
Hubert Uebelhör requires special
information or must have answers
to processing questions that are
out of the ordinary concerning the
There is enough space in the tool changer of the
HSM 400U for 68 tools
machine, he can rely on the extensive knowledge of the Nidau Application Engineers.
The experiences with the spindle are by all means positive and
the temperature compensation
(cycle 307) functions excellently,
added Hubert Uebelhör. Cycle 307
("smart machine" Module ITC-5X)
is a calibration cycle, which enables
the deviations in the pivoting rotational axis by determining the new
pivot point of the C axis. These
deviations occur on processing
centers because of the heating of
the pivoting rotational axes.
With HSK shrinking tools, such
as are used at IWC, the spindle
works like a charm. The exceptional rotational values produce a much
higher life-span of the tools compared with the ISO cone with collet grips and an improved surface
quality on the work piece.
2nd HSM 400U already on order!
Based on the great experience
and the excellent milling results
with the HSM 400U by Mikron, IWC
has ordered another machine.
In summarizing, the HSM machines by Mikron meet the highest
standards concerning speed,
precision and surface quality. Its
demand-oriented design, the
high quality components, the
digital drive technology and one
of the most modern controllers,
these machines are designed for
maximum efficiency, economic
value and functionality.
www.mikron-ac.com
Highly productive 5-axes machining
4
HPM 1150U and 1350U
now with direct
drives for all round
and swivel axes
Due to the impressive machining
capabilities of the HPM 1850U,
Mikron is now also using some of
the technology used in these
machines in the new HPM 1150U
and HPM 1350U. The HPM machines are based on the proven
models of the UCP Series.
Stefan Fahrni
The new HPM 1150U and
HPM 1350U 5-axis simultaneous
machining centers can be used for
heavy cutting work or highly precise machining processes. This
successful design with the design
of the fourth axis as a circular
milling attachment and the fifth axis as a swiveling head means that
very bulky work pieces can be
machined. The HPM 1150U / 1350U
universal machining centers make
an impact thanks to their outstanding performance as implemented in the aviation industry,
the manufacture of moulds and in
parts production as well as in many
other fields of application.
Direct drive
The HPM 1150U and HPM
1350U are now equipped with a
direct drive swiveling head, which
assures yet faster and more
dynamic machining. An advantage
of the direct drive is that the application window for five-axis machining opens further. Milling that
in the past could only be performed
by specialists is now much easier
to handle.
Since a torque motor now drives
the swiveling action, the gearbox
is no longer needed, as well as the
belts and possible factors that may
affect precision and service work
that goes along with that. The
simultaneous swiveling head is
also equipped with a hydraulic
clamping device that makes it possible to clamp the spindle in each
swiveling position. Optimal boring
and machining procedures can now
be carried from every position.
The advantages of the direct
drive are especially evident when
the possibility of simultaneous
milling can be fully utilized. The
best example of this is an airplane
part on which curved surfaces must
be produced in constantly changing angles by hobbing. The more
precise axis guides pay for themselves during simultaneous machining with direct drive in the
round and swivel axes. Better surfaces can be produced at even higher feed rates.
Strong motor spindles
Spindles of the latest generation are used on the HPM 1850U,
as well as on the HPM 1150U
and HPM 1350U.
At 15000 rpm and 193 Nm, they
are among the strongest motor
spindles on the market. In addition,
all spindles are equipped with
the necessary sensors to use the
"Advanced Process System" (APS
and APS extended) smart machine
module.
The APS module is a monitoring system that opens up new
opportunities for the user to
observe and control the milling
process on screen. This system was
especially designed for high performance and high speed machining. But it can also be used for
other milling work. With the help
of an acceleration sensor integrated in the spindle, vibrations during
the milling process are recorded
and displayed to the operator
on the console. If necessary, the
operator can adjust the cut values
to extend the service life of the
tools and to prevent damage to
the machine.
The emulsion treatment for the
cooling through the spindle is
equipped with the latest paper
band filter technology. A safety
HSMtoday Nr. 16
The HPM 1150U and
1350U product line
equipped with the latest
technology was developed
from the UCP 1150 and
UCP 1350
An airplane part of aluminum illustrates the difference: 5-axis
simultaneous machining centers with direct drive (photos above)
The direct drive and hydraulic clamping swiveling head make
machining of such quality possible today
filter is installed with this unit
to protect the rotary transmission
to the spindle.
In terms of optimal tool and
work piece measurement, the
machining centers are also
equipped with cutting-edge technology. An OMP 60 sensor and
the latest laser technology of the
NC 4 Laser from Renishaw ensures
that the HPM 1150 U and
HPM 1350U are ready for precision
work piece machining.
www.mikron-ac.com
HSMtoday Nr. 16
Universal machining
Complex components,
prototypes and a whole
pile of swarf and chips
Edi Hofstetter - Werkzeug- und
Maschinenbau AG in Benken,
Switzerland is a contemporary
family operation whose history
goes back to the year 1946. The
experience gathered in the years
since and their constant readiness
for continuous development has
made the company what it is today. A VCE 1600 Pro from Mikron
was put into operation in January
2005. It has been used ever since
to machine components for tool
and engineering applications, as
well as prototypes.
Jürgen Maurer
The company was founded by
Edi Hofstetter in 1946. After training as a machinist, Mr. Hofstetter
leapt into self-employment at
age 20. He was a noted handyman
with outstanding practical skills.
He ultimately felt most at home in
metal machining. With a "nothing
is impossible, everything is possible" attitude, he took on even the
most difficult projects.
Because of his great success,
the plant in Benken was expended
in 1966 to include a residential
building with a production hall. 20
years later, a new production hall
had to be built with a higher
ceiling to accommodate the new
machines. In 1993, the company
changed its corporate form to an
AG (public limited company) and in
1999, the siblings Ruth, Ulrich and
Josef Hofstetter took over the
company. In 2001, another production hall was erected directly next
to the existing buildings.
Edi Hofstetter - Werkzeug- und
Maschinenbau AG is today
equipped with state-of-the-art
machines. The proprietors are
competent and the employees very
well trained which is clear from
their exacting work and services.
They design complex three-dimensional components and then
manufacture the components on
the machines especially built
for that purpose. Work pieces of
up to 20 tons can be machined
in Benken.
Over 1000 m2 is utilized
with 12 machines in two workshops. Whether SMC compression
moulds, assemblies, components
or prototypes – thanks to the equipment, the personnel and the wellorganized workflows, all jobs are
performed in a timely manner and
with exacting precision. ISO 9001
certification is a given.
Ulrich Hofstetter, Head of
Engineering, answers questions
about his operation and the
VCE 1600 Pro from Mikron:
Mr. Hofstetter, how did you hear
about the machine from Mikron?
In recent years, we have invested in large, cumbersome machines, but were lacking a fast
machine. The original notion of a
small machine developed into the
idea covering a broader range with
a suitable machine. There was
initially no mention of a Mikron
because we thought it was too
expensive. Even so, we solicited a
comparison bid for a VCE 1200 Pro.
The price/performance ratio surprised us.
What were your reasons
for choosing the VCE 1600 Pro?
The knowledge of weight of our
work pieces caused us to seriously consider the VCE 1600 Pro. Important reasons were the table
load, the traverse paths, the Z traverse path in particular, the
dynamics and the rational and very
precise machining options of the
5
The VCE 1600 Pro from Mikron
is mainly used for machining
individual parts for tooling
and engineering applications,
as well as prototypes
machine. The control system was
also important to us. We absolutely wanted the Heidenhain iTNC 530,
which we were already using in
many areas. We also had a choice
of spindles and the 540 I water tank.
We decided on a 10,000 rpm spindle. The Konus BT 40 allows us to
use available tools.
A visit to Steinkamp in Germany
where we could view the machine
in person ultimately convinced us.
We already knew on our way back
that it would be the VCE 1600 Pro
from Mikron.
What parts or type of
components do you machine
on the VCE 1600 Pro?
We machine all kinds of proto-
types, e.g. suction nozzles, components with deep ribs with a diameter of approximately 2 mm, a
depth of 80 mm and a taper of 0.5°
where even small tools are also
needed.
What materials do you prefer to
machine on the VCE 1600 Pro?
Primarily construction steel,
tempered steels and tool steel.
Now and then also aluminum and
brass.
Another performance characteristic is its precision.
Milling in the 5 µm range is no
problem at all.
What industries are your
customers in?
Because individual components make up approximately
60% of production, our customers
naturally come from a variety of
industries, such as pressing plants,
rail car manufacturers (forms
for seat pans), as well as companies in aircraft and machine
construction.
How have your employees progressed with the machine since?
Trouble free. Employees were
briefed by me and off they went under the principle "learn by doing".
By the way, the manuals are good
and of course, you can glean something from them. A big advantage
was certainly the control system,
as already mentioned.
What experiences have you and
your employees had with the
VCE 1600 Pro, e.g. with stability,
precision or process safety?
We have been very satisfied
with the VCE 1600 Pro up to now.
The machine fits into our production workflow with its size and
a table load of up to 2.7 t. We
have several options and it is easy
to use for small or even large
components.
The VCE 1600 Pro is also
very dynamic in all axes.
At Edi Hofstetter - Werkzeugund Maschinenbau AG, every order
is seen as a challenge for the
entire company. Our employees
are used to facing challenging projects head on. Ulrich Hofstetter and
his team still take the time to
search for the optimal solution
even for individual component
manufacturing. This requires creativity and a mountain of experience in metal machining, something readily available at the family
company in Benken.
www.mikron-ac.com
Highly productive 5-axes machining
6
HSMtoday Nr. 16
HPM 1000U/HPM 1100
Machining in
another dimension!
Overwhelming enthusiasm – Feedback from
EMO 2005 in Hanover, Germany clearly
shows that the new Mikron HPM series is the
standard in high-speed machining
No other manufacture of stateof-the-art machining centers in
the HSM and HPM field has developed such extremely successful
concepts for cost-effective milling
so consistently in the first five
years of the 21st century. After
rolling out the HPM 1000U and
HPM 1100, experts agree: Mikron
has done it again!
Urs Hänni
Single minded, persistent, long
sighted and finally, thanks to a
focus on the important, successful; these are some of the main
characteristics you expect from
companies. Of course, these same
companies also expect similar
characteristics from the manufacturers of state-of-the-art machining centers and in a related sense
from the products, too.
Focusing on the important
Mikron introduces the new HPM
series developed and tested over a
period of two years and tested under production conditions, spot on.
The five-axis HPM 1000U and
three-axis HPM 1100 adeptly meet
the requirements of today’s companies thanks to imaginative conceptual considerations. The most
important characteristics of these
machining centers are unrestricted accessibility of the machine at
any time, the individual components perfectly coordinated to the
performance requirements in the
HPM area, the unique robot system through the center of the machine and the design of all components of the entire production
center on the three-shift operation.
HPM – High-performance milling
Following HSM (High-Speed
Milling), Mikon has also now
coined the term HPM (High-Performance Milling). HPM strategies,
i.e. milling with the goal of achieving the required performance over
the chip volume, not only place specific requirements on the machine
as a whole, but on each individual
element of the system.
The HPM 1000U and HPM 1100
can clearly show that these demands can be met. Two spindles
are available. On the one hand, the
20,000 rpm spindle and 198 Nm is
suited for powerful machining of
tough materials. On the other hand,
the 28,000 rpm and 40 kW spindle
has all the properties to also costeffectively machine parts with
smaller tools. The fully-simultaneous circular swiveling table is
available as a version for pallets or
with a T-slots table top. In regards
to power and dynamics, the linear
drive in the axes (two motors in the
A axis, one motor in the C axis)
offers complete security. The
A axis can be locked in the settings
operation. This improves the quality of the work piece on the one
hand and also prevents unnecessary heat build-up on the table
on the other. The temperature of
all power components mentioned
above including the switch cabinet
are controlled by a regulated
water cooling circuit.
3 shifts, 365 days a year
To achieve the high rate of metal removal the entire year, the new
machines must be equipped with
production-specific and reliable
options, e.g. the cooling of the
The HPM 1100 machining center can handle a table load of
up to 2000 kg
The steep incline of the side panels ensures perfect
chip discharge
Highly productive 5-axes machining
HSMtoday Nr. 16
HPM 1100 und HPM 1000U
Work area
Longitudinal
Cross
Vertical
HPM 1100
X mm 1100
Y mm 800
Z mm 600
Feed rate
Rapid traverse rate X, Y, Z
Feed rate. X, Y, Z
HPM 1000U
1000
800
600
m/min 60
mm/min 0 - 20'000
Working spindle
High-frequency spindle
Spindle power/Spindle torque
High-frequency spindle
Spindle power/Spindle torque
min
40% ED
min
40% ED
Work table
Clamping surface
Max. table load
-1
-1
20,000 - HSK 63
66 kW / 198 Nm
28,000 - HSK 63
40 kW / 107 Nm
mm 1200 x 900
kg 2000
Rotary tilting table
Tilt range
°
Rapid traverse rate
C min
Rapid traverse rate
A min
Clamping surface, autom. DIN-Pallet mm
Max. table load (central)
kg
Clamping surface, manual
Ø mm
-1
-1
Tool changer
Central tool changer
Tool changer (tower)
-
-
40
115/165/215
mm -
machining process: Internal and
external supply of coolant
(IKZ/AKZ) is possible with cooling
water, air or oil mist. The pressure
of the cooling water with IKZ (20
to 80 bar, 1200 I) can be variably
regulated from the operator console. If additional cooling is needed while machining, an optional
coolant system keeps the medium
at a constant temperature. In addition, steam extraction for coolant
steam and oil mist is available for
the series. It was designed for high
20,000 / HSK 63
66 kW / 198 Nm
28,000 / HSK 63
40 kW / 107 Nm
+30/-110
60
30
500x630
800
800
Tools 40
-
Pallet changer
Pallets
Dimension
60
0 - 20'000
5
500 x 630
efficiency and a long service life. A
fully-automatic bellows seals the
workspace. The barrier can be automatically unlocked when the
swiveling table is manually loaded
with a crane and relocked once the
loading is complete.
Of course, all smart machine
modules, e.g. ITC, APS or RNS can
be used to achieve a cost-effective
milling process.
Pioneering robot system
The real innovation with the
Mikron machining centers are well
known für their ergonomic design.
The new HPM 1100 und HPM 1000U
are unique when it comes to the
access of the machine, no matter
which machine configuration the customer needs to
produce its work pieces.
Basic machine
with central 40unit tool changer
Basic machine with
double pallet
changer and tool
changer
Basic machine with
pallet changer, 5unit pallet magazine
and tool changer
Flexible manufacturing system (FFS)
Combination of 3 basic machines, pallet changer and tool changer with a flexible manufacturing system
HPM 1,000U is the solution for automatic loading. Work pieces of
up to 800 kg are automatically
changed from the palette magazine to the circular swiveling table.
A hydraulic lift/rotation unit (pallet changer) sets the preselected
pallets on the clamping devices of
the circular swiveling table. The
pallet changer first executes a linear movement through a paddle
sealed from the working space. At
the same time, the pallet is placed
in the pallet magazine together
with the work piece to be machined,
a process that takes less than
30 seconds.
The optional swiveling setup
station on the pallet magazine
makes loading the magazine with
the work pieces secured on the DIN
pallets easier. The setup station
and circular swiveling table have
reliable fluid couplings. Of course,
the compact tool changer that can
keep up to 215 tools on barely
more than 1 m2 is part of
the extremely compact design
of the machine. This entirely new
solution for automating heavy components offers unparalleled ergonomic conditions at the workstation. Access to the working area
and pallet magazine is convenient
and safe.
Your access – "Your access to the
machine"
The robot system by the center
is part of the new "your access"
concept from Mikron. Regardless
of which machine configuration you
want, access to all relevant components of the machining center is
always optimal. The "your access"
concept shows its full effect with
the HPM 1000U. Whether as a version with a 40-unit tool changer or
as a version with a double pallet
changer in the center and a tool
changer, access to the machine is
always optimal.
Even connecting the pallet
magazine or a flexible manufacturing system does not affect access.
(see box) Past are the times when
a pallet changer or pallet magazine stood in the way of the user in
front of the working area.
The five-axes HPM 1000U and
the three-axes HPM 1000 meet the
requirements placed on stateof-the-art machines. The most important characteristics are unrestricted accessibility of the machine at any time, the individual
elements perfectly coordinated to
the performance requirements in
the HPM area, the unique robot system by the center of the machine
and the design of all components
of the entire production center for
extended shift operation.
www.mikron-ac.com
The large tool changer with up to 215 tools is near the
operator console
The pallet changer is handled through the portal directly, making
access to the machine effortless
The fully-simultaneous circular swiveling table is available as a
version for pallets (above) or with a T-slots table top
7
Universal machining
10
VCE 800 Pro-X and
VCE 1000 Pro-X
machining centers
Considerably shorter machining
times and larger volumes are possible with the new VCE Pro-X
machining centers. Even difficult
jobs, such as the production of thin
walled work pieces are now even
easier.
Stefan Fahrni
For each production order,
whether in parts production or tool
and mould making, carefully
calculated unit costs are becoming
increasingly more important. At
the same time, the day-to-day
business affects the demand for
flexibility and processing time. An
important element in this relationship is the selection of suitable
production resources.
With the VCE 800 Pro-X and
VCE 1000 Pro-X, Mikron offers universal machining centers that
guarantee maximum utility and
calculable investment costs.
Torque of nearly 100 Nm
The new inline motor spindle
from Step-Tec achieves 15 kW (S5)
and a torque of nearly 100 Nm.
These characteristics allow the use
of face milling up to 85 mm in diameter or boring tools up to 60 mm
in diameter. For machining with
smaller tool diameters, a maximum continuous speed of 16,000
rpm is available. The machine has
an internal coolant feed for costeffective use of suitable boring
tools. The cooling units are also
part of scope of delivery and are
used for cooling through the tool
achieving a pressure of 18 bar and
having all necessary filters. By integrating the bandpass filter in the
machine, no additional installation
space is needed.
Even plastics and filings are reliably filtered out. Equipped as
such, the VCE Pro-X series is ideally equipped for all machining.
Thanks to cooling through the
tool, the high spindle speeds
and the corresponding feeds, the
VCE Pro-X series is also ideal for
cost-effective chip removal of
aluminum.
HSMtoday Nr. 16
Universal machining
centers, capably and
completely equipped
process speeds of 36 m/min (X, Y)
and 24 m/min (Z) account for these
aspects. This characteristic makes
cost-effective machining of threedimensional cavities possible, e.g.
forging dies, injection and die-cast
moulds with little or medium complexity and the respective electrodes.
An optional divider further ex-
ufacture of moulds and in the
aviation industry but also those
arising in general mechanical machining. In this market segment,
the Mikron VCE Pro-X line offers
unbeatable advantages.
www.mikron-ac.com
Dynamic axes
An early realization when using high-speed spindles is the fact
that high surface quality of the work
piece and cost-effective service life
of the milling tools also require dynamic axes. The VCE Pro-X with
By integrating the bandpass filter in the machine, no additional
installation space is needed
pands the area of application of the
VCE Pro-X. The 4th axis is suited
for the additional applications in
the positioning and for simultaneous machining (S6).
The machine's workbenches are
designed to allow pneumatic
clamping devices or pallet clamping systems to be supplied with
compressed air.
The VCE Pro-X machines from
Mikron are also used for traditional machining. With high feed rates,
individual parts such as perforated plates, which include a large
number of traverse paths, can be
machined more economically. The
spindle torques also allow high
swarf volumes, such as in the man-
High-speed machining
HSMtoday Nr. 16
The Chinese company
Hung Ming Ho Co Ltd. relies
on European machines in the
production of zippers
11
The HSM 400 from
Mikron is also at home
in the world of fashion
The invention of the zipper cannot
be attributed to just one inventor.
Inventors in various countries had
worked on the idea of a quick
release fastener over decades.
Today, the zipper is indispensable
in the world of fashion. Numerous
manufacturers have brought their
goods to market in the mean time.
Yandi Ma
Because the demand for zippers has steadily grown in the past,
the entrepreneur Leung (photo
below) made the decision in 1987
to found a company to manufacture zippers. Hung Ming Ho Co Ltd.
has since become one of the most
progressive companies in China in
this industry, developing into a
market leader in just a few short
years.
As an official zipper supplier to
several internationally recognized
clothing brands, Hung Ming Ho Co
Ltd. represents a brand that guarantees the quality of their products.
Production of the zipper manufacture takes place in Southern
China near the city of Nanhei, about
a 1-hour's drive from Guangzhou.
Machines from the Agie
Charmilles GF have certainly also
contributed to the big success of
Hung Ming Ho Co Ltd. The machine
park includes 5 Mikron machines,
4 machines from Agie and 5 machines from Charmilles. Mr. Leung
appreciates the AgieCharmilles GF
as a solid and reliable partner.
First HSM 400 purchase
In 2004, Mr. Leung purchased
his first Mikron HSM 400 with a
42,000 rpm spindle. There were two
primary reasons why he chose machines from Mikron: the option of
high-speed machining and the fact
that he was already very confident
in the customer service from Agie
Charmilles China (HK) Ltd.
His decision to choose Mikron
machines has been profitable to
date. The components milled
using the HSM 400 are extremely
precise as is required in the zipper
industry. In addition, the machining times with the HSM 400 have
been cut by 50%. Just six months
after installing the first HSM 400,
Hung Ming Ho Co Ltd. purchased
two more HSM 400s configured
identically.
"The wages for a well-trained
and experienced machine operator are fairly high in our area.
Thankfully, the training and
demonstration center from Mikron
offers training and other development opportunities. As a result, we
have also been able to hire lessexperienced operators and have
them trained on Mikron machines.
Zippers – they are needed everywhere. Boxer Laila Ali, daughter of Muhamad Ali, poses for
HSMtoday in a fashion shop
Mikron technicians also visit us
often, not only to see whether the
machines are running well, but also to test milled components to see
whether they meet the required
standard. They give our employees
advice, e.g. what concerns the
CAD/CAM programming, explain
milling strategies or provide instruction for selecting the right
tools," explains Leung, Business
Manager.
Expansion planned
The company plans to build
their own machines for the manufacture of zippers in the future.
The first step in this direction
was the purchase of two Mikron
VCE 600 Pro machining centers at
the end of last year. Both machines
are equipped with a pallet system.
The next step is then to purchase
a 5-axis high-speed milling machine HSM 600U equipped with
a high-performance 36,000 rpm
spindle with high torque.
The business manager of Hung
Ming Ho Co Ltd. plans to acquire
still more machines from Mikron
in the next five years for the planned
expansion of his company.
www.mikron-ac.com
Photo: adidas
Universal High Performance Cutting
12
HSMtoday Nr. 16
The UCP 600 Vario
by Mikron in
medical technology
MEDARTIS® - Impressive technology
and the Medic's art
What do Mikron machines have to
do with medical technology?
Operative supply for bone breaks
and other bone injuries with
metal implants (osteosynthesis)
is found more and more often now.
The company MEDARTIS, with its
main office in Basel Switzerland
produces exactly those plates
made of titanium on machines by
Mikron.
Jürgen Maurer
In 1997, Dr. h.c. Thomas Straumann founded the MEDARTIS
Group. It was a re-entry into
Osteosynthesis for mouth, jaw and
face surgery. His father already
works in this branch at the Straumann AG Institute. In 1954, Prof.
Dr. Reinhard Staumann, who is the
Grandfather of Thomas Staumann,
had already founded the Straumann AG Institute, which was
then specialized in Metallurgy and
Physics for the watch industry. His
son, Dr. h.c. Fritz Straumann implemented the synthesis of metallurgy, physics and medicine by utilizing the special metallurgical and
physical knowledge for developing
metallic implants for handling
bone breaks. MEDARTIS led the
further development of metallurgy and now has extensive knowhow in the production of high quality titanium implants. Philosophy
and operation have been embossed
through the pioneering work of the
Staumann Group in metallurgy,
osteosynthesis and implantology.
In 2004, the MEDARTIS Group expanded their product portfolio with
orthopedics and hand surgery.
Meanwhile, MEDARTIS has close
to 100 employees in its service.
The goal and the responsibility
of MEDARTIS is to provide the surgeons and the OP personnel in the
mouth, jaw and facial surgery, the
plastic hand surgery and the orthopedic surgery with all innovative implants, instruments and
services that mean advancement
in the osteosynthesis and the
refore quality of life for the patients.
In order to satisfy this high-set
goal, the intensive cooperation
with surgeons, scientists, universities and clinics are of the utmost
importance to MEDARTIS.
Osteosynthesis
Osteosynthesis is the operative
provision for bone breaks and other bone injuries with metal implants. The goal is to fix the fragments with one another in the most
normal position possible. Unlike a
cast, osteosynthesis normally enables early movement or even loading on the fracture. The choice
of whether a fracture should be
handled with a cast, osteosynthesis or no treatment is made
depending on localization, stress,
misalignment of the fragments,
results of movement loss and the
operation risks.
Titanium plate as it is milled on both Mikron UCP 600 Vario's in the
MEDARTIS plant in Bretzwil (Baselland/Switzerland)
The production of plates with the
machine by Mikron
In 2005 MEDARTIS had to expand production. Mikron machines
were also utilized in the new
facility in Bretzwil (Basel-Land,
Switzerland), two UCP 600 Vario's
and an HSM 600U. Special plates
are being produced for the
so-called radius (underarm and
hand) here. The prototypes for this
are also milled in Basel and on a
UCP 600 Vario.
All product development starts
with MEDARTIS keeping in close
contact with customers. Product
concepts for which the optimum
application is planned together
with the surgeons are developed
this way. Detailed three-dimensional CAD construction drawings
and computer simulations make up
the basis of the first prototypes,
which are then evaluated in clinical testing. The products are manufactured in-house and with the
cooperation with external partners
on the most modern CNC systems.
The highest level of quality
testing according to internationally recognized standards and guidelines secure a constantly high product quality. During a visit, Peter
Weisskopf, member of MEDARTIS
management and responsible for
production, showed us the new
plant in Bretzwil. Upon entering,
we had already determined unmistakably that special things are
made here. Everything is very
clean, light, organized and almost
clinical already. The work stations
with microscopes and other measurement and testing equipment
stood out. Medical products must
often be tested thoroughly before
they arrive on the market.
The Mikron machines stand at
one end of the hall - two UCP 600
Vario's and one HSM 600U. We are
glad that MEDARTIS decided on
Mikron and again for the 5-axes
processing centers. We wanted to
find out some of the background
that the decision was based on.
Peter Weisskopf gladly provided
us with the information.
„We manufacture medical
Bone models with various plates for fixing finger bones
made by MEDARTIS
The x-ray shows the exact position of the plate screwed in place
after the operation
For continued processing on titanium plates fastened on an
apparatus
Universal High Performance Cutting
HSMtoday Nr. 16
Machine model UCP 600 Vario
Working range
Longitudinal
X mm
Cross
Y mm
Vertical
Z mm
Swivelling
B°
Turning
C°
High speed motor spindle
Maximum speed
min
Spindle performence at 40% ED/S6
Toolholder
Feed drive
Feed - rapid speed X/Y/Z m/min
Tool changer
Magazine positions
quantity
-1
Rotary swivel table
Table dimension
Max. workpiece weight
(5-axis operation)
Table versions
mm
kg
Pallet versions
Control
CNC
Construction
kg
Pallet changer (Optional)
Number of pallets
Units
Pallet surface
mm x mm
products here in Bretzwil. You can
imagine that quality and the technology used have the highest priority, especially after realizing that
the various implants are used for
people. Naturally, we decided upon a manufacturer that we know
builds high-quality machines. The
decision for Mikron was of course
preceded by comparisons with other companies. The price/performance ratio of the Mikron machines
convinced us. The 5th axis is
an investment in the future. The
Heidenhain controller is also important to us and is proven in
operation. It is also no problem
to transfer programs from the
HSM 600U to the UCP 600 Vario;
this type of compatibility is a strong
advantage as well. One of our employees, who had already had
600
450
450
-115 / +30
n x 360
12,000 / 20,000 / 42,000
kW 15 / 16 / 14
ISO 40 / HSK A63 / HSK E40
max. 22
30-220, (configuration
upon request)
450
200
table Ø 450 mm,
with starshaped or parallel .
arrangement of the T-slots
3R (Dynafix), Erowa (UPC),
Mecatool (GPS)
(others upon request)
Heidenhain iTNC 530
7700
7 (Dynafix, UPC), 10 (GPS)
3R (Dynafix) 280x280,
Erowa (UPC) 320x320.
Mecatool (GPS) 240x240,
(others upon request)
some good experience with machines by Mikron, also provided
some positive influence."
Automation is indispensable
Both the UCP 600 Vario and the
HSM 600U are set up with palette
and tool changers for automatic
operation, to guarantee 24 hour
operation. „The automation was
also an important aspect for
procuring the Mikron machines“,
stressed Peter Weisskopf. „The
machines have to run for 24 hours
and this is possible because of
palletizing. “ The Mikron-offered
"smart machine" module RNS
works better and cheaper than if
we would have run the operation
in shifts. “RNS makes it possible
to obtain information about the
operation status of the Mikron
13
machining center as well as
the milling process regardless of
the location.” The operator can
receive information about the
operating status or program
status of the machine via SMS to
a mobile phone.
Precision parts are absolutely
necessary
Where precision and surface
quality is concerned, there are no
compromises at MEDARTIS. Since
these parts are for use in medical
products, aesthetics are also
important. Since the Mikron
machines are known for their
good milling results and for the
exceptional surface quality of the
parts they process, they meet
the requirements of MEDARTIS
perfectly.
Peter Weisskopf confesses that
a good machine also needs a
capable operator however. That is
why two employees spent some
time in the Nidau Mikron facility.
They were trained on the Heidenhain controller in the HSM Competence Centre.
Peter Weisskopf continues:
„We've made a good decision with
the Mikron machines. The two
UCP 600 Vario's and the HSM 600U
are very versatile. They are dependable and are designed very
well for the automation. The parts
that are milled with them have a
quality surface and are very precise, exactly what we need."
The palette changer of the UCP 600 Vario offers room for 7 to
10 palettes depending on the manufacturer
Loading the palette changer is comfortable because of the optimal
working height of the UCP 600 Vario
Solution - the Vario System
With its UCP 600 Vario, Mikron
has a convincing 5-axis solution for
automated production. As well as
the compact basic machine itself,
the Vario system has: a multitude
of high-performance milling spindles; a scaleable, modular tool
changer system, the best known
pallet changer from other Mikron
machines; and the right disposal
or cleaning solution for every chip
and coolant situation. It is up to the
customer to decide just how vari-
The Heidenhain iTNC 530 makes the UCP 600 Vario safe and
easy to operate
able their UCP 600 is to be. However, one thing is guaranteed to
stay the same: access to the
machine and peripheral devices is
wonderful.
The basis of the UCP 600 Vario
has everything required to be used
successfully in tool and mould
making, medical technology and
the entire machining process for
frame components, etc.
www.mikron-ac.com
Highly productive 5-axes machining
14
High accuracy
with up to 4 ton work
piece weight
Today's tools enable ever better
machining performance. They
have smaller diameters but
require greater feeds in return. To
use these advantages of modern
machining in parts production
with up to 2 meter swings, Mikron
built the HPM 1850U.
Stefan Fahrni
The HPM 1850U is the machining center for consistent implementation of current machining
technology. It has been developed
to ensure high performance combined with extremely high precision in the manufacture of moulds,
cast parts and in batch production.
Due to its rigid structure it is suitable for heavy roughing as well as
accurate finishing operations.
The HPM 1850U allows high
accuracy 5-axis simultaneous
machining. The machine bed is
cast from a single piece. This eliminates geometric deviations on
the basis caused by year-long
stresses in machining. The portal
of the machine supports the Z-carriages of new, weight saving
materials. This is in accordance
with the high dynamics of the
machine, approximately 300 kg
lighter than a comparable Z-carriage of cast but has the same
strength and better vibration
damping. The advantages are
especially evident in fast Z-axis
movements such as are required
for mould manufacturing.
The versatility of the HPM 1850U
• High dynamics with directly
driven round and pivot axes
• Selection between palette and
circular milling attachment
• Stability in processing thanks to
hydraulic clamping on the
round and pivoting axes
• 5-axes simultaneous machining
• Spindles with 15,000 or 24,000
rpm, or 8,000 rpm with up to
324 Nm with the HSK100
• Tool magazine with over 200
tools
• Tools having swing diameters
of up to 2 meters and 4 tons in
weight
The HPM 1850U is especially
liked by the operators because of
the ideal accessibility. The machining can be observed easily at any
time. Part loading is also very userfriendly. When using the machine
with a palette changer on both
loading stations, even a platform
is not required. The palettes can be
lowered to a work-level that is comfortable for the operator.
Flexible milling head
The HPM 1850U enables undercutting a work piece without any
trouble when using 5-axes simultaneous machining. The milling
head allows the tool spindle to pivot by 140° simultaneously. The pivot axis can also be clamped to efficiently utilize the highest motor
spindle speed. The clamp is made
so powerful that it needs no index-
HSMtoday Nr. 16
The HPM 1850U offers the
most modern high-power
machining of work pieces
with up to 2 meter swings
and 4 ton weight
ing. The spindle can therefore be
fastened at any angle position. The
switching time from vertical to
horizontal machining is less than
1 second. This makes machining
possible that could not have even
been imagined before. From rough
machining, 5-side complete machining to 5-axes simultaneous
machining on turbine blades, the
application of the new Mikron
HPM 1850U are almost limitless.
Direct drive circular milling
attachment
New challenges concerning
machining power require new
paths and new technology to implement them effectively. This is
why a linear motor has been used
as the circular milling attachment
drive on the HPM 1850U by Mikron.
Swift acceleration and high speeds
are only possible with this technology. The large clamping table with
up to 1600 mm diameter and loads
of up to 4,000 kg can be moved at
a rate of up to 30 rpm. Its enormous torque and achievable positioning precision is impressive. Two
characteristic values that are important to Mikron in this machine.
2 meter swing diameter and up to 4 ton weight
High-performance motor spindle
Either motor spindles with
15,000 rpm and 193 Nm torque
or 24,000 rpm are used with the
HPM 1850U. The tool interface is
the modern and widely used HSK63
interface. For machining with long
and large tools, the high-torque
The HPM 1850U is perfectly suited for large work piece machining
The HPM 1850U for 5-axis simultaneous machining
HSMtoday Nr. 16
motor spindle with 324 Nm and
8,000 rpm is recommended. Naturally, this motor spindle has an
HSK 100 tool receptacle to transfer maximum rigidity to the tool.
This provides the machine with
enough power and reserves to handle even the most demanding tasks
with no problems.
Pallet changer offers direct
access
Large machines are normally
encircled by a platform in order to
enable the machine operator access to the machine for loading.
Mikron is of the opinion that this is
very cumbersome to the operator.
They have therefore done away with
the platform. The machine is
equipped with a lifting apparatus
that brings the palette up to the
height of the work-table. The
HPM 1850U is the only machine of
this size with ground-level access
to both loading stations. Both loading stations are also equipped with
a manual rotating mechanism. This
is especially useful for clamping
large work pieces at the rear
as well. This makes loading and
unloading clamping towers much
easier.
Adaptive control
The HPM 1850U is equipped
with the Heidenhain iTNC 530 controller. This controller can be easily integrated into the most different of operational procedures. No
matter whether producing individual parts or in a series, simple or
complicated parts or whether the
production is to be done "on demand" or has been organized centrally, the iTNC 530 is the ideal controller for any field of application.
Software controls feed totally
automatically
To fully utilize the high powered
modern tools, the machine must
have ideal interaction between uncompromising mechanics and dependable software. This makes the
HPM 1850U able, for example, with
Highly productive 5-axes machining
the optional software "Adaptive
Control System" (ACS) to record
the loads of the work pieces and to
automatically adapt feeds for rough
cutting accordingly. This is always
based on the programmed feed set
to 100%. The controller uses the
measured load values on the tool
to calculate the optimum feed for
the current cutting conditions and
automatically regulates upward or
downward accordingly. Since blank
contour deviations occur and
therefore can create varying tool
holding capabilities (enlacement,
clamping depth), tool wear, air cutting, measurement deviations and
hardening, these contour differences must be compensated for
during machining so that the optimum feed is guaranteed in every
situation. As high as possible, as
low as required. If the "Adaptive
Control System" (ACS) is used, the
result is shortened production
times with simultaneously improved machining security. Other
"smart machine" modules such as
"APS" and "APS extended" also
help to optimizing the machining
and in keeping the wear to the tool
and the machine to a minimum by
recognizing vibrations.
The new 5-axes machining centre HPM 1850U by Mikron opens
new paths to the modern and economical production of large parts
up to 1.6 m3 parts volumes.
No matter whether the
HPM 1850U is used in mould manufacture, in cast machining or in
series production, the high power
and precision is very impressive.
Many users are positively surprised
that such precise machining is
possible considering the size of
the HPM 1850U.
The HPM 1850U allows high accuracy 5-axis simultaneous machining
The exceptionally large sliding doors ensure optimal accessibility to the loading area
The pallets can be manually turned and locked in 8 positions
www.mikron-ac.com
The HPM 1850U is ideal for series production with
an optional palette changer. Automation allows
extending productivity in the nightly and weekend hours
with no operator
15
“smart machine”
16
“smart machine”
Modules
for optimizing the
milling process
Mikron offers various modules under
the term "smart machines" (software
and hardware) to make the milling
process simpler and easier to control
for the operator
makes spindle condition prognosis
possible. SPS enables real-time inspection and contributes to effective servicing and efficient corrective maintenance.
The operating principle of SPS
Wear, age-related damage and
overloading are the main reasons
for spindle failure. Insufficient
bearing lubrication or extrusion
cooling accelerates these symptoms of fatigue. A real-time condition monitor compares the current
state with knowledge-based target
behavior. Depending upon the
event, either an SPS warning or an
SPS error message with a stop in
production is triggered.
Just as a Formula 1 driver would
never be able to get the most out
of his race car without electronic
support, an operator of a machining center needs support to maximize the total available potential
of his milling machine for the machining process; smart machine
gives him this support.
In addition, he is also able to significantly improve the service life
of various machine components.
Alexandre Condrau
The ITC upgrade to 5-axis
machines
ITC-5X is an additional module
of the "intelligent thermal control"
for machines with circular swiveling tables.
With steadily increasing machine performance, it is no longer
possible to prevent thermal effects
through design measures alone.
Despite exact compensation
between tool and work piece, the
position of the rotation axes saved
in the control system can change
due to thermal drift, something
particularly evident when working
in tilted plains. This is where
ITC-5X comes into play.
ITC-5X functionality:
Using a caliper (option), a simple, automatic calibration cycle
measures the spatial position of
the rotation. The measurement can
be taken on a reference pallet
(option) or reference surfaces of
the work table or the work piece.
The position measured is automatically saved.
Benefits of ITC-5X:
• Greater work piece precision
with pivoting and/or rotating
machining (cycle 19, plane
functions, M128)
• Compensation for external influences through recalibration
• Increased process safety for
5-axis machining
• Minimized downtimes (no manual measurements)
• Automatic recalibration during
unmanned operation
Spindle Protection System - SPS
Condition-oriented monitoring
for daily production
Conventional corrective maintenance is only performed when
damage has already occurred. This
leads to unexpected machine
capacity reduction and high maintenance costs.
A prerequisite for preventive
maintenance is, therefore, perfect
knowledge of the condition of the
machine and its components. Monitoring of the main spindle is the
key. Condition-oriented monitoring
HSMtoday Nr. 16
The benefits of SPS
• Automated, self-monitoring of
spindle condition
• Continuous maintenance of
spindle condition, thereby resulting in earlier identification
of spindle faults
• Optimal time planning of corrective maintenance measures
and, therefore, the avoidance
of long downtimes after a spindle failure
SIGMA - The management system
for your process chain
SIGMA generates and manages
order, drawing and parts data in an
integrated way for milling and electric discharge machining (EDM),
custom-made to workshop specifications.
Furthermore, the management
system acquires and manages
work pieces and data at the predetermined location. Data such as NC
programs and work piece corrections are processed for machining
by SIGMA and made available to
various systems via a network.
Starting and monitoring of machining is fully automatic. At the
same time, process data is recorded and displayed.
The functionality – SIGMA grows
as the need grows:
The SIGMA Cell Management
System is responsible for the management of a MIKRON milling cell.
With the SIGMA Workshop Management System, it is possible to
add one or more measuring devices and as many machining centers as desired. The entire process
chain can be controlled via this
Multi Machine Management.
Normally, SIGMA is installed on
the Mikron machine controller or
on the measuring device computer. However, the use of an additional terminal is recommended if
the workload of the measuring
device is heavy or the distance
between machining station and
measuring device is large.
Thanks to SIGMA's open architecture, all Agie Charmilles machines can be managed.
part of the standard configuration
of machines. Others are available
as an option. Each “smart machine” module fulfils a specific
function. Like a modular system,
the user can choose the modules
that he finds most suitable for improving the milling process.
A list of available modules can
be viewed on the Mikron website
under Products, smart machine.
The SIGMA identification system
SIGMA can work with pallet
identification. Pallets can be supplied with ID chips which provide
each with a distinctive, permanently stored identity. As soon as a pallet is identified, all data stored in
the database for this pallet is made
available.
An electronic ID system ensures
high process safety:
• Always the right machining
program
• Always the right correction
values
• Always the right magazine
position
• Always the right machining
sequence
www.mikron-ac.com
Support for the retrofitting of
existing pallet changers with ID
systems.
Regarding multi-machine systems, System 3R can provide further assistance with the project
planning and installation of the
SIGMA Workshop Management
System.
Impressum
HSMtoday
TM
Specialist journal from Mikron
The benefits of SIGMA
• Unmanned, automatic job machining and further treatment
of process data
• Increased productivity
• Job priority: Simple scheduling
and rescheduling
• Scalability: Sigma adapts itself
to your needs
• Concise operation and
process data display for various
machines
• Single measurement of work
pieces and pallets
• Automatic electrode manufacture control for cavity sinking
by EDM via the respective
superior order
• Increased process safety
The "smart machine" modules
can be used on all Mikron machines
with current Heidenhain controls.
Some of the modules already form
Publisher:
Mikron Agie Charmilles AG
Ipsachstrasse 16, CH-2560 Nidau
Tel. +41 32 366 11 11,
Fax +41 32 366 11 66,
E-Mail: [email protected]
Brand Manager: Jens Thing
Managing and Design Editor:
Jürgen Maurer
Photo adaptation: Vik Furer
Circulation: 60,000
Published in German, French,
English, Italian, Spanish and Chinese
Photos: adidas, IWC, MEDARTIS and
Mikron
Print: Stämpfli AG, CH-3001 Bern
Issue 16, 2006
© Mikron Agie Charmilles AG 2006
www.mikron-ac.com
Agie Charmilles Group

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