Manufacturer: Sunmill, production: Taiwan

General Information of JHV-710 CNC Vertical Machining Center

Options, descriptions

Every SUNMILL machine is tested:

BALL BAR TEST

Using the ball bar test, roundness, deviation from geometry and backstops (misalignment of the drives) are checked.

Laser check

Additional options:

4 and 5-axis machining (optional):

On a CNC milling machine, it is possible to install a 4th / 5th axis, and, accordingly, create a 4/5-coordinate machining center. Can be installed on the table of the machining center as a vertical Rotary table(4th axis) and tilt-and-turn axis (5th axis). When installing a 4th or 5th axle, it is recommended to use the FANUC 18iMB control system.

Coolant supply through the spindle:

The coolant supply through the spindle using a special tool allows better heat dissipation when machining blind holes and avoids overheating of the tool and workpiece. Supplied complete with filtration system.

High-speed spindle capable of maintaining parameters: 10000, 12000, 15000 rpm.

Tool magazine for 20 or 24 positions.

Complete set of this machine.

• Fanuc 0i-MD controller CNC system.
• Fourth axis interface.
• Spindle BT40 10,000 rpm
• Motor power 5.5 / 7.5 kW
• Spindle drive
• Spindle cone blowing system
• Automatic lubrication system
• Carousel tool magazine ATC 16-tools, BT40
• Complete enclosure of the cutting area
• Machine lighting
• Toolbox and Documentation Kit
• Spindle oil cooling
• Chip auger conveyor

Completion for an additional fee:

Metalworking production can only be considered efficient when the number of unpleasant surprises that appear in the process of manufacturing parts are minimized.

Efficient production cannot afford to increase the cycle time for the manufacture of a part, to obtain a correctable or irreparable marriage. Most often this occurs due to improper clamping of the workpiece, improper use of the tool, heating of the workpiece during processing, etc. In addition, you need to pay attention to the reasons associated with the failure of machine tool spindles.
In production, especially those involved in the manufacture of high-precision parts, when ordering equipment, care must be taken to install the most suitable spindles. During the operation of the machine, it is important that the spindle does not overheat, that there are no collisions with workpieces and machine tools, and the coolant and metal shavings did not seep through the seals and did not damage the spindle components.

WHEN HEATED, SOLIDS EXPAND
Not only the workpieces, but also the spindle itself can expand from the heat released during processing. This is usually the case for high speed machining and machining that requires high power over a long period of time. If the expansion of the spindle is large enough, it can move out relative to its normal position, and this, in turn, lead to the dimensions of the part outside the tolerance range.
With linear expansion, the time wheel can move relative to the machine sensors so much that the machine does not know the exact position of the spindle, and therefore the tool. As a result, it is quite likely that the machine will stop, this is especially unpleasant when it is working in an automatic cycle. Other possible problem- loss of binding of the tool position to the position of the manipulator arm for tool change. The arm of the manipulator works in unison with the pull of the spindle to secure the tool. If their movements are not coordinated, then the manipulator can cut into the tool, and the manipulator, the tool, and also the spindle can be damaged.
The linear expansion of the spindle can be controlled by several methods. The first method is to supply cooling to it. The working fluid is a mixture of water and glycol. It passes through a cooling jacket and is maintained at a temperature by means of a cooling station. The second method is to design the spindle in such a way that when heated, it expands not forward, but backward. Therefore, the dimensional accuracy of the part will not be affected.

Coolant MUST BE IN THE WORK AREA
The spindle can also be damaged by coolant penetrating the seals and reaching the bearings. Coolant penetration into the spindle is one of the main causes of spindle breakage. In this case, the spindle has two main enemies - high pressure coolant supply systems and coolant supply systems with big amount nozzles The nozzles should be fine-tuned to ensure that the minimum amount of coolant enters the machine spindle. In any case, coolant will enter the spindle, so additional shields, mechanical seals or labyrinth seals may be required. These seals should not interfere with automatic tool changes. Another way to help keep coolant out of the spindle is to use a spindle air purge system. It turns on when changing tools, increasing or decreasing the spindle speed. As the spindle speed changes, the air currents and the heat generated from the spindle cause the coolant mist to penetrate into the spindle. The air cleaning system removes the coolant and thus protects the spindle from damage. An air purge system is not necessary for all machining applications, but it is cheaper to install it as an option and save money on spindle repairs. During sanding, the air cleaning system also protects the spindle from fine metal dust.

HOW TO AVOID COLLISIONS
Collision damage to the spindle is common. Collisions occur for various reasons. For example, an operator may accidentally enter an incorrect value, forgetting to put a separator, and press the button. Even if he immediately realizes the mistake, there may not be enough time to stop the machine. One way to solve this kind of problem is to use software to simulate processing. The graphical interface allows you to follow the entire process step by step and see the points of possible collision with the workpiece, fixture or the machine itself.
Often it is necessary to carry out processing close enough to the machine tooling. For example, when milling or drilling, close to the vice. The result is increased rigidity and, consequently, manufacturing precision. They fight vibrations in the same way. The proximity of the tool to the machine tool during simulation can turn into a collision in reality. In this case, after modeling, programmers must warn operators about possible locations collisions, and then the latter will be ready to pass dangerous sections while debugging the program at minimum speed.
Per spindle negative impact vibrations arising from insufficient rigidity of the machine - device - tool - part system can produce. Certain applications may require vibration damping tools and accessories to provide high rigidity to the tool.

02.11.2012
New directions in coolant technology for metalworking

1. Oil instead of emulsion

In the early 90s. proposals for replacing coolant emulsions with pure oils were considered from the point of view of analyzing the total cost of the process. The main objection was the high cost of anhydrous working fluids (5–17% of the total process cost) compared to water-based coolants.
Currently, replacing coolant emulsions with pure oils is a possible solution to many problems. When using pure oils, the advantage lies not only in the price, but also in the improvement of the quality of metalworking, as well as in ensuring safety in the workplace. In terms of safety, clean oils are less harmful when exposed to open areas human skin rather than emulsions. They contain no biocides and fungicides. Anhydrous cutting fluids have a longer service life (from 6 weeks for individual machines to 2-3 years in centralized circulation systems). The use of pure oils has less Negative influence on the environment. Pure oils provide a higher quality of metalworking at almost all stages of the process (over 90%).
Replacing the emulsion with oils provides better lubricating ability of the coolant, improves the surface quality during grinding (finishing) and significantly increases the service life of the equipment. The price analysis showed that during the production of the gearbox, the cost of almost all stages is halved.
When using anhydrous coolants, the service life of CBN (cubic boron nitride) stripping and pulling equipment is increased by 10-20 times. In addition, no additional corrosion protection is required when machining cast iron and mild steels. The same applies to equipment, even if the protective paint layer is damaged.
The only drawback of anhydrous cutting fluids is the generation of a large amount of heat during metalworking. Heat dissipation can be reduced by up to four times, which is especially important in operations such as drilling in hard, high carbon materials. In this case, the viscosity of the oils used should be as low as possible. However, this leads to a decrease in operational safety (oil mist, etc.), and the volatility depends exponentially on the decrease in viscosity. In addition, the flash point is reduced. This problem can be solved by using unconventional (synthetic) base oils that combine a high flash point with low volatility and viscosity.
The first oils to meet these requirements were blends of hydrocracked oils and esters, which appeared in the late 1980s. XX century, and pure essential oils that entered the market in the early 90s.
Ester oils are the most interesting. They have very low volatility. These oils are products of various chemical structures, obtained from both animal and vegetable fats. In addition to low volatility, essential oils are characterized by good tribological properties. Even without additives, they provide reduced friction and wear due to their polarity. In addition, they are characterized by a high viscosity-temperature index, explosion-fire safety, high biostability and can be used not only as coolant, but also as lubricating oils. In practice, it is better to use a mixture of essential oils and hydrocracking oils, since the tribological characteristics remain high, and their price is much lower.

1.1. A family of multifunctional coolants

A decisive step in optimizing the cost of lubricants in metalworking processes has been the use of pure oils. When calculating the total cost of cutting fluid, the influence of the cost of lubricants used in metalworking was underestimated. Studies in Europe and the USA have shown that the mixing of hydraulic fluids with coolant occurs three to ten times per year.
In fig. 1 shows these data graphically over a 10-year period in the European automotive industry.

In the case of using a water-based cutting fluid, the ingress of significant amounts of oils into the cutting fluid leads to a serious change in the quality of the emulsion, which deteriorates the quality of metalworking, causes corrosion and leads to an increase in cost. When using pure oils, contamination of the coolant with lubricants is imperceptible and becomes a problem only when processing accuracy begins to decrease and equipment wear increases.
Trends in the use of pure oils as cutting fluids in metalworking open up a number of cost savings opportunities. An analysis carried out by German machine builders showed that, on average, seven different types of lubricants are used in each type of machine tool. This, in turn, raises issues of leakage, compatibility and cost of all lubricants used. Improper selection and use of lubricants can result in equipment failure, which is likely to result in production interruptions. One possible solution to this problem is the use of multifunctional products that satisfy a wide range requirements and can replace lubricants for various purposes. An obstacle to the use of universal fluids is the requirements of the standard ISO to hydraulic fluids VG 32 and 46, as modern hydraulic equipment is designed with the viscosity values ​​given in these standards in mind. On the other hand, metalworking requires a low viscosity coolant to reduce losses and improve heat dissipation during high speed metal cutting. These contradictions in the requirements for viscosity at various uses lubricants are allowed using additives, which helps to reduce the overall cost.
Advantages:
... inevitable losses of hydraulic and running-in oils do not deteriorate the coolant;
... invariability of quality, which makes it possible to exclude complex analyzes;
... the use of cutting fluid as lubricating oils reduces the overall cost;
... increased reliability, process results and equipment durability significantly reduce the total cost of production;
... versatility of application.
Rational use of universal fluids is preferred by the consumer. An example of this is engine building. One and the same oil can be used for the initial processing of the cylinder block and for their honing. This technology is very effective.

1.2. Washing lines

On these lines of cleaning operations, water-based cleaning solutions should be avoided to avoid the formation of undesirable mixtures with hydrophilic oils. Solid impurities are removed from oils by ultrafiltration, and detergents(energy consumption for water treatment and pumping, analysis of waste water quality) can be eliminated, which will lead to a decrease in the total cost of production.

1.3. Removing oil from metal waste and equipment

Correct selection of additives allows you to recycle oils extracted from metal waste and equipment back into the process. The recirculated volume is up to 50% of the losses.

1.4. Prospects for universal fluids - " Unifluid»

The future is a low-viscosity oil that can be used both as a hydraulic fluid and as a cutting fluid for metalworking. Universal liquid " Unifluid»Developed and tested in German research project sponsored by the ministry Agriculture... This fluid has a viscosity of 10 mm 2 / s at 40 ° C and shows excellent results in automotive engine factories in metal working processes, for lubrication and in power lines, including hydraulic systems.

2. Minimizing the amount of lubricants

Changes in legislation and increasing requirements for protection environment also concern the production of cutting fluid. Given the international competition, the metalworking industry is taking every possible measure to reduce production costs. An analysis of the automotive industry, published in the 90s, showed that the main cost problems are caused by the use of working fluids, and the cost of coolant in this case plays an important role. The real cost is driven by the cost of the systems themselves, the cost of labor and maintenance of fluids, the cost of treating both fluids and water, and disposal (Figure 2).

All this leads to the fact that great attention is paid to the possible reduction in the use of lubricants. A significant reduction in the amount of used cutting fluid, as a result of the use of new technologies, makes it possible to reduce the cost of production. However, this requires that such functions of the coolant as heat removal, friction reduction, removal of solid contaminants, be solved using other technological processes.

2.1. Analysis of coolant requirements for different processes metalworking

If coolant is not used, then, naturally, the equipment overheats during operation, which can lead to structural change and metal tempering, change in size and even equipment breakdown. The use of coolant, firstly, allows heat to be removed, and secondly, it reduces friction during metal processing. However, if the equipment is made of carbon alloys, then the use of coolant can, on the contrary, lead to its breakdown and, accordingly, reduce its service life. However, as a rule, the use of coolants (especially due to their ability to reduce friction) will increase the life of the equipment. In the case of grinding and honing, the use of coolant is extremely important. The cooling system plays a huge role in these processes, as the equipment maintains a normal temperature, which is very important in metalworking. Approximately 80% of the heat is generated during chip removal, and the coolant serves a dual function here, cooling both the cutter and the chips, preventing possible overheating. In addition, some of the fine chips are removed along with the coolant.
In fig. 3 shows the need for coolant for various metalworking processes.

Dry (without the use of coolant) metal processing is possible in processes such as crushing, and very rarely in turning and drilling. However, it should be noted that dry machining with a geometrically imprecise end of the cutting tool is impossible, since in this case heat removal and spraying with liquid have a decisive effect on the quality of the product and the service life of the equipment. Dry machining in the crushing of cast iron and steel is currently used with special equipment... However, in this case, the removal of chips must be carried out either by simple cleaning or by compressed air, and as a result new problems arise: increased noise, additional cost compressed air, as well as the need for thorough cleaning from dust. In addition, dust containing cobalt or chrome-nickel is toxic, which also affects the cost of production; the increased fire and explosion hazard during dry processing of aluminum and magnesium cannot be ignored either.

2.2. Low coolant systems

By definition, the minimum amount lubricant an amount not exceeding 50 ml / h is considered.
In fig. 4 shows circuit diagram systems with a minimum amount of lubricant.

Using a dosing device, a small amount of coolant (max. 50 ml / h) is sprayed into the metalworking site in fine spray. Of all the types of dosing devices on the market, only two are successfully used in metalworking. Most wide application find pressure systems. Systems are used where oil and compressed air are mixed in containers, and the aerosol is supplied by a hose directly to the metalworking site. There are also systems where oil and compressed air, without mixing, are supplied under pressure to the nozzle. The volume of fluid delivered by the piston in one stroke and the frequency of the piston are very different. The amount of compressed air supplied is determined separately. The advantage of using a metering pump is that it is possible to apply computer programs controlling the entire workflow.
Since very small quantities of lubricant are used, the direct feed to the workstation must be done with great care. There are two options for supplying coolant, which are very different: internal and external. When the liquid is supplied externally, the mixture is sprayed onto the surface of the cutting tool by nozzles. This process is relatively inexpensive, simple to perform, and does not require a lot of labor. However, with external coolant supply, the ratio of the tool length to the hole diameter should be no more than 3. In addition, when changing cutting tools, it is easy to make a positional error. With an internal coolant supply, the aerosol is supplied through a channel inside the cutting tool. The length-to-diameter ratio must be greater than 3 and positional errors are excluded. In addition, chips are easily removed through these same internal channels. The minimum tool diameter is 4 mm, due to the presence of the coolant supply channel. This process is more costly as the coolant is supplied through the machine spindle. Systems with low coolant supply have one thing in common: the liquid enters the working area in the form of small drops (aerosol). At the same time, toxicity and maintaining the hygienic standards of the workplace at the proper level become the main problems. Modern developments of coolant aerosol delivery systems allow preventing flooding of the workplace, reducing losses during spraying, thereby improving the air performance at the workplace. A large number of systems of low coolant supply leads to the fact that although it is possible to select the required droplet size, but many indicators, such as: concentration, particle size, etc., are insufficiently studied.

2.3. Coolant for low flow systems

Along with mineral oils and water-based cutting fluids, oils based on esters and fatty alcohols are used today. Since in systems with a low coolant supply, oils for flow lubrication are used, sprayed in the working area in the form of aerosols and oil mist, the issues of labor protection and industrial safety (HSE) become the priority problems. In this regard, it is preferable to use lubricants based on esters and fatty alcohols with low toxicity additives. Natural fats and oils have a major disadvantage - low oxidation stability. When using lubricants based on esters and fatty acids, no deposits are formed in the working area due to their high antioxidant stability. Table 1 shows data on lubricants based on esters and fatty alcohols.

For systems with low coolant supply, it has great importance correct selection of lubricant. To reduce emissions, the lubricant used must be low-toxic and dermatologically safe, with high lubricity and thermal stability. Lubricants based on synthetic esters and fatty alcohols are characterized by low volatility, high temperature outbreaks, low toxicity and have proven themselves well in practical application... The main indicators for the selection of low-emission lubricants are the flash point ( DIN EN ISO 2592) and Noack evaporation loss ( DIN 51 581T01). t vsp should be at least 150 ° С, and evaporation losses at a temperature of 250 ° С should not be higher than 65%. Viscosity at 40 ° C> 10 mm 2 / s.

At the same viscosity, fatty alcohol-based lubricants have a flash point lower than ester-based lubricants. Their volatility is higher, therefore the cooling effect is lower. Lubricating properties are also relatively low compared to ester-based lubricants. Fatty alcohols can be used where lubricity is not essential. For example, when processing gray cast iron. The carbon (graphite) in cast iron itself provides a lubricating effect. They can also be used when cutting cast iron, steel and aluminum, since the working area remains dry as a result of rapid evaporation. However, too high evaporation is undesirable due to air pollution in the working area with oil mist (should not exceed 10 mg / m 3). Ester lubricants are useful when good lubrication is required and there is a lot of chip waste, such as when tapping, drilling and turning. Ester lubricants have the advantage of high boiling and flash points at low viscosity. As a result, the volatility is lower. At the same time, a corrosion-preventing film remains on the surface of the part. In addition, lubricants based on esters are readily biodegradable and have a class 1 water pollution.
Table 2 provides examples of the use of lubricants based on synthetic esters and fatty alcohols.

The main aspects considered in the development of coolant for low flow systems are listed below. The main thing to pay attention to when developing cutting fluids is their low volatility, non-toxicity, weak effect on human skin in combination with a high flash point. The results of new research on the selection of optimal cutting fluids are shown below.

2.4. Investigation of Factors Affecting the Formation of Oil Mist Coolant for Low Flow Systems

When a system with a low supply of coolant is used in the metalworking process, the formation of an aerosol occurs when a liquid is supplied to the working area, and a high concentration of aerosol is observed when using an external spray system. In this case, the aerosol is an oil mist (particle size from 1 to 5 microns), which has a harmful effect on the human lungs. The factors contributing to the formation of oil mist were studied (Fig. 5).

Of particular interest is the effect of the viscosity of the lubricant, namely the decrease in the concentration of oil mist (oil mist index) with an increase in the viscosity of the coolant. Studies have been conducted on the effect of anti-fog additives in order to reduce its harmful effects on human lungs.
It was necessary to find out how the pressure applied in the coolant supply system affects the amount of oil mist formed. In order to assess the generated oil mist, an instrument based on the Tyndall's cone effect, a tindallometer, was used (Fig. 6).

To assess the oil mist, the tindallometer is positioned at some distance from the nozzle. Further, the obtained data is processed on a computer. Below are the results of the assessment in the form of graphs. From these graphs, it can be seen that the formation of oil mist increases with increasing spray pressure, especially when using low-viscosity fluids. A doubling of the spray pressure causes a corresponding increase in the volume of the resulting fog also doubles. However, if the spray pressure is low and the starting characteristics of the equipment are low, then the period for which the amount of coolant reaches the required rates to ensure normal operation increases. At the same time, the oil mist index increases significantly with decreasing coolant viscosity. On the other hand, the starting performance of spraying equipment is higher when using a low viscosity fluid than when using a high viscosity cutting fluid.
This problem is solved by adding anti-fog additives to the coolant, which reduces the amount of fog generated for liquids with different viscosities (Fig. 7).

The use of such additives makes it possible to reduce the formation of fog by more than 80%, without impairing either the starting characteristics of the system, or the stability of the coolant, or the characteristics of the oil mist itself. Studies have shown that mist formation can be significantly reduced with the correct spray pressure and viscosity of the coolant used. The introduction of the appropriate anti-fog additives also leads to positive results.

2.5. Optimizing Low Coolant Systems for Drilling Equipment

Tests were carried out on materials used in systems with low coolant supply (deep drilling (length / diameter ratio greater than 3) with external coolant supply), on drilling equipment DMG(Table 3)

A blind hole must be drilled in a workpiece made of high-alloy steel (X90MoSg18) with high tensile strength (from 1000 N / mm 2). High carbon steel drill SE- rod with a cutting edge with high bending resistance, coated PVD-TIN... The coolant was selected in order to obtain optimal process conditions, taking into account the external supply. The influence of the viscosity of the ether (coolant base) and the composition of special additives on the service life of the drill was investigated. The test bench allows you to measure the magnitude of the cutting forces in the z-direction (depth) using a Kistler measuring platform. Spindle performance was measured over the entire time required for drilling. The two methods adopted for measuring the loads in a single drill made it possible to determine the loads throughout the test. In fig. 8 shows the properties of two esters, each with the same additives.

Roman Maslov.
Based on materials from foreign publications.

For good chip evacuation during drilling, coolant must be supplied through the tool.

For good chip evacuation when drilling, coolant must be supplied through the tool. If the machine is not equipped with a spindle coolant system, it is recommended to supply coolant through special rotating adapters. When the hole depth is less than 1xD, the use of external cooling and reduced modes is allowed. The diagram shows the coolant consumption for different types drills and materials. Coolant type Recommended emulsion 6-8%. When drilling of stainless steel and high strength steels, use a 10% emulsion. When using IDM drill heads, use 7-15% emulsions based on mineral and vegetable oils for drilling stainless steel and high temperature alloys. Drilling without coolant It is possible to drill cast iron without coolant with the supply of oil mist through the drill channels. Drill head wear symptoms Change in diameter 0> D nominal + 0.15mm D nominal (1) New head (2) Worn head Vibration and noise increases greatly flow rate Coolant flow (l / min) Minimum coolant pressure (bar) Drill diameter D (mm) Drill diameter D (mm) For special drills larger than 8xD, a high coolant pressure of 15–70 bar is recommended.

Main advantages

• Efficient power transfer allows for increased depth of cut and greater precision in threading.
• Higher cutting performance with spindle bearings large diameter.
• Shorter tool lengths and a retractable spindle provide faster approach and improved machining accuracy.
• Front double doors are used for the operator's convenience and also improve the aesthetic appearance of the machine.

Rigid and stable construction of the machine.

• The computer-optimized cast iron construction (FG 260) ensures consistent material removal and low vibration machining.
• The design of the feed mechanism provides additional rigidity, which can improve the processing precision.
• Higher rapid feed rates minimize idle time.
• Available with automatic tool changer (ASI).
• The ease of operation and maintenance of the JV series machines can significantly improve production efficiency.

Milling head.

Each spindle sleeve is installed in a temperature controlled environment.

The presence of bearings with an optimal preload allows you to maintain the specified accuracy over a long period of operation.

Through-spindle coolant system (optional).

Provides a continuous flow of coolant through the spindle directly to the cutting edge of the tool to achieve excellent quality surface treatment. The use of a coolant filtration system is recommended to avoid the ingress of chips and dirt into the coolant as it passes through the spindle, tool holders and cutting tools... There is a choice between a drum-type magnetic filter for removing ferrous metal chips and a cartridge filter for removing ferrous and non-ferrous metal chips.

Spindle cooling system.

Coolant is supplied around the circumference of the spindle. Coolant nozzles are positioned to direct the flow exactly to the cutting edge, which ensures quick heat dissipation and no roughness on the finished part surface.

Automatic tool changer with two gripping hand.

The use of a simple and reliable cam-driven double-grip arm mechanism ensures accurate and fast tool changes.

During an automatic tool change, the shortest path is randomly selected.

• Standard equipment: magazine for 20 tools
• Optional: magazine for 24/30 tools
• Cone BT-40.

Fully protected guides.

The guides and ball screws are fully protected by covers to prevent the ingress of chips and coolant. This protection facilitates maintenance and maintains target accuracy over extended periods of continuous operation.

High precision feed mechanism.

The guides of the machine have a reliable design, high rates of movement speed and accuracy. The JV series machines use high-precision linear guides and large-diameter preload ball screws for axial cross feed. The mounting and supporting surfaces of the linear guides are machined with the highest possible precision, which ensures better fit guides and minimum deviations in all axes. The large distance between the guides guarantees an optimal distribution of the cutting force. Ball screws are pre-tensioned for maximum accuracy and are directly connected to variable speed AC feed motors.

High resolution feedback system and laser calibration of the cross feed axis ensure maximum positioning and interpolation cutting accuracy and pass rigorous technical checks.

Lightweight chip removal system with coolant.

The JV series machine comes with a coolant pump for high pressure... Coolant is supplied through nozzles at various points in order to remove the chips. The chips are transported to the rear of the machine where there is a separate container for collecting the chips. The presence of such a system facilitates the cleaning and maintenance of the machine. Direct integration with central system removal of shavings of the enterprise.

Rotary automatic pallet changer.

To achieve high productivity and reduce spindle downtime, the machine is equipped with an automatic pallet changer, the pallet change time is 8 seconds. The pallet changer is compatible with a 4th axis or hydraulic support clamp. The hydraulic system provided for the automatic pallet changer is compatible with most customer-supplied hydraulic clamping devices. A one-piece coupling is used for a firm hold. The automatic pallet changer is equipped with a minimum of mechanical parts for easy maintenance.

Specifications

Main advantages

• Spindle with built-in motor
• Through-spindle coolant system
• Rotary table with integrated torque motor

Bed and column

• The nodular cast iron construction guarantees optimum rigidity and stability.
• Finite element analysis was used to create the machine components to ensure optimum machine performance.

Spindle with built-in motor

• The maximum rotational speed of the high-speed and high-torque spindle with integrated motor is 15,000 rpm.
• A wide range of maximum power is available at 800-1000 rpm.
• A high pressure continuous coolant system (up to 50 bar) through the spindle is standard on the machine and ensures efficient machining of workpieces, long term the service of the tools and the heat resistance of the workpiece.

Feed drives

• Roller guides are subject to less elastic deformation under heavy loads and guarantee excellent vibration absorption.
• The presence of shrouds of ball screws protects against the ingress of chips.
• The axial feed drives include a ball screw, which is driven by a directly connected feed motor.
• Feedback for positioning on the axis is provided by an absolute encoder.

Rotary table

• Compact rotary table with integrated high-torque motor with torques up to 878 Nm.
• The pallet is positioned and fixed on the table by means of a reliable hydraulic clamping cone system.
• With clamping cones, an intensive air jet is generated during pallet changes to prevent the accumulation of chips in the cone.
• High precision axial and radial roller bearing is used for precise positioning and ensuring rigidity.
• The table is fixed by means of a disc spring, and released by means of a hydraulic system.
• Zero clearance is achieved thanks to the built-in torque motor.

Pallet changer

• The machine is equipped with a shuttle-type automatic pallet changer with a high degree of reliability.
• The automatic pallet changer is controlled by an electric proportional control valve, which is used to lift and lower the pallet smoothly and quietly.
• The loading station is easily accessible and clearly visible through the closed security door.

Automatic tool changer (ASI)

• The machine is equipped with a chain tool magazine, which provides a quick and reliable tool change.
• The standard equipment of the machine includes a partition of the ASI device, designed to prevent chips from entering the magazine.
• To select tools, the fixed address method is used, in which the shortest path is selected.

ASI features:

• Standard set: 40 tools
• Optional: 60 tools
• Time from tool to tool: 2 sec
• Time from chip to chip: 4 sec

Integrated hydraulic unit

• An integral hydraulic swivel unit (optional) is located in the machining area and is used to clamp the corresponding attachments.
• In this way, the swivel unit rotates with the pallet, facilitating the clamping process on the side of both pallets.

Coolant supply system

• Thanks to the continuous supply of coolant through the spindle, efficient machining of the workpiece is carried out, as well as increased tool life.
• The function of coolant supply around the spindle is standard (up to 50 bar).
• Optionally, the machine can be equipped with a scraper-type chip conveyor with a drum filter filtration system or a magnetic filtration system with a paper filter and oil separator.

Specifications