Máquinas e equipamentos, Resumos de Princípios de Design de Máquinas-Ferramenta

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5-axis

machining centres

F

Contents

F series 02

Machine concept 04

Equipment 06

Mill-Turn 08

Machining units 10

Tool management 12

Workpiece management 14

Supply and disposal 16

Control technology 18

Operation 20

Automation solutions 22

Technical data 24

F series

Designed for

Production

Machine concept

Maximum performance

with lasting precision

Only the perfect combination of rigidity and lightweight

construction results in a machine design that ensures

optimum surface finish and a long tool life. As with

all HELLER machines, the main components of our

new generation F series have been designed using FEM.

The result is a machine bed optimised for rigidity and a

mass-reduced column that ensure reliable productivity

and high dynamics combined with perfect precision.

APC

Automatic Pallet Changer

Basic structure

_5-axis machining centres in horizontal orientation _machine bed in cross-bed design for maximum rigidity even with high clamping loads _traversing column in gantry-design for fast positioning and short idle times _cast iron structural components with topology optimised design for maximum stability and damping in the force flow _pallet changer with lift-swivel principle, designed as a fork-type changer for high clamping load and short pallet change time _chain-type or rack-type tool magazines combined with fast NC tool changer for shortest tool provisioning times

Kinematics

_robust 5-axis kinematics with 5th axis provided by the tool _machine bed supporting the X and Z axes in cross bed design _machine column moves in X-direction and supports the machining unit _machining unit moves in Y-direction, compact and robustly integrated into the machine column _rotary table (B-axis) moves in Z-direction and rotates the workpiece continuously (360,000 x 0.001°) _5th axis designed as swivel head (C-axis, 350,000 x 0.001°) or optionally as tilting head (A-axis, 175,000 x 0.001°)

Drive concept

_linear axes with wide roller guides driven by precision ball screws with cooled drives or drive flanges _direct, absolute measuring systems with low positional tolerance for maximum precision _rotary axes with large YRT bearing and automatic clamping for maximum stability and high tangential moments _rotary table with duplex worm gear for maximum performance in 5-axis machining _direct driven high-speed rotary table for mill-turn applications (optional)

FLEX

Front Loading EXtended

Machine concept 5

PRO equipment package

Maximum performance

_two ball screws in the Z-axis

_increased feed force in the Z-axis

_reduced positional tolerances in all axes

Simultaneous 5-axis machining

_milling technology package (ONE Dynamics) for optimum path guidance and perfect surface finish

_highest dynamics in the linear axes

_fast, backlash-free swivel drive in the 5-axis head

Class-leading specifications

_optimum set-up of all components

_AutoSet function for optimum drive parameters to suit the current clamping load

_AutoCal function for optimum accuracy of 5-axis kinematics

Equipment 7

Mill-Turn

Complete machining

on a single machine

The optional Mill-Turn functionality enables combined

milling and turning on a single machine – giving you even

greater flexibility for the machining of your workpieces.

Machining in a single set-up provides maximum

component accuracy, while the use of a high-torque

rotary table ensures maximum productivity.

F 5000 F 6000 F 8000

Speed S3 40% min -1^700 700 Torque Nm 2,600 2,600 4, Workpiece diameter APC / FLEX (Full circle) mm Ø 900 / Ø 1,300 Ø 1,000 / Ø 1,540 1)^ Ø 1,

1. Stand-Alone (IN-Automation: Ø 1,400 mm)

Machining units

High cutting

performance

Optimum process stability in 5-axis machining is also a

question of having the right spindle. With our new

generation F series you can choose from a range of swivel

head and tilting head designs. Whether it is heavy-duty

cutting of cast iron or steel, high-volume machining of

light metals or vertical, horizontal and tilted turning with

the optional Mill-Turn functionality – we have the right

solution to suit your requirements.

PCUe 100 G DCU 100 M SCU 100 M DCU 63 M SCU 63 M PCTe 100 G DCT 100 M SCT 100 M DCT 63 M SCT 63 M

Tool shank

SK/BT for PCUe/PCTe available as an option | Mill-Turn: HSK-T

Size HSK-A 100 HSK-A 63 HSK-A 100 HSK-A 63

Speed min -1^ 8,000 12,000 15,000 16,000 18,000 6,000 12,000 15,000 16,000 18, Power S6 40 % kW 60 52 45 50 45 60 52 45 50 45 Torque S6 40 % Nm 1,146 400 282 228 121 1,146 100 282 228 121

Standard: DCU 100 M

1

2

Powerful machining units

_machining units with 5th axis provided by the tool with robust swivel head or tilting head kinematics

_8 machining units with high-speed motor spindles for universal use

_2 machining units with gear-driven spindles, perfect for cutting difficult-to-machine materials

_HSK-A 100 tool shank as standard for machining units with motor and gear-driven spindles (HSK-A 63 optional)

_automatic clamping of the 5th axis, optional hydraulic clamping for maximum stability in heavy-duty machining with tilted rotary axes

_sturdy cast iron guide slide with high dynamic rigidity and damping

Swivel head

_high projection length in vertical position for precise machining behind the rotary centre of the rotary table

_compact design and high rigidity thanks to the robust 45° swivel head kinematics and short distance between bearing and tool shank

_dynamic, backlash-free swivel drive with electrically pre-loaded motors

_large C swivelling range of 350° for high flexibility in 5-sided machining

_integrated LED light (WorkLIGHT) as standard and remaining path display as part of the optional SETUP-Assist function

Tilting head

_large swivel range enables machining of negative angles and undercuts

_bearings on both sides provide maximum rigidity during roughing and finishing operations

_HSK-A 100 spindle with a gearbox unit and a maximum torque of 1,146 Nm

_175° swivel range for maximum flexibility in 5-sided machining

Options

SETUP-Assist _assistance system that actively supports the operator when running in processes _remaining path display integrated into the machining units 1 _collision monitoring between machine components and tools 2 _utilisation display for linear axes, rotary table and spindle

HELLER attachment head support (MSK) _precondition for the use of attachment heads, (e.g. angular heads) _enlarged support basis with three-point rest _integrated torque input and media transfer

Machining units 11

1

2

Chain-type magazines 1

_3 chain-type magazines with up to 150 positions

_double chain with high traversing dynamics and sturdy tool holders mounted on both sides

_short tool-to-tool times due to tool provisioning parallel to machining

_tool shank in enclosed holders: protection against contamination and optimum hold during positioning

_tool loading station with optimum accessibility for fast and ergonomic tool loading

Rack-type magazines 2

_2 rack-type magazines with up to 489 positions for machines with HSK-A 63

_4 rack-type magazines with up to 425 positions for machines with HSK-A 100

_small footprint due to space-saving positioning of the magazine alongside the machine

_fast tool handling with highly dynamic tool loader

_integrated rotary station for loading of multiple tools parallel to machining

Tool changer

_rapid tool change for short chip-to-chip times

_two NC axes with lift/swivel principle for high dynamics and long-term precision

_sturdy double gripper for a secure hold with heavy tool weights and moments of weight

_integrated tool provisioning place for supply of the next tool during machining and short tool-to-tool times

Options

_tool loading during machining (HZPR) without affecting the ongoing machining process

_rapid tool breakage detection (SBBK) enables shank tools to be checked for breakage parallel to machining

_cleaning of tool shanks and pockets at the tool provisioning position of the chain-type magazines

_tool coding for automatic storage and transfer of tool data in the tool

_precision laser measurement and checking of the tools in the spindle

Tool management 13

Workpiece management

Automated from

the ground up

Whether with pallet changer (APC) for flexible series production or

in the FLEX version with an interchangeable pallet for maximum

flexibility in terms of workpiece dimensions: the new generation of

the F series comes perfectly prepared for both concepts and offers

you reliable workpiece management. On top of that, the machines

can easily be integrated into standard automation systems.

F 5000 F 6000 F 8000

Type APC FLEX APC FLEX APC Clamping surface Nominal size mm 630 x 630 630 x 630 630 x 630 (800 x 800) 630 x 630 (800 x 800) 800 x 800 (1,000 x 1,000) Workpiece dimensions Diameter D Full circle Depth T x Width W mm^

Ø 900

900 x 1,

Ø 1,

Ø 1,

1,000 x 1,

Ø 1,540 2)

Ø 1,

1,400 x 1, Height H mm 1,100 1,100 1,300 1)^ 1,300 1)^ 1,500 1) Clamping load kg 1,500 (2,000) 1,500 (2,000) 1,500 (2,000) 1,500 (2,000) 2, Load pallet changer Total / load difference kg 2,000 (3,000) / 1,500 – 2,000 (3,000) / 1,500 – 4,000 / 2,000 1)

Pallet change time Standard(with increased load) s 15 (18) – 14.5 (17) – 21

( ) = Optional values - = Not available 1) Consider limitations 2) Stand-Alone (IN-Automation: Ø 1,400 mm)

Cooling lubricant supply

_coolant units: paper band filter or backflush filter with high tank volumes available as options

_internal coolant supply (IKZ) through the tool with high pressure 50 bar (optional: 70 bar)

_internal coolant supply with up to 7 pressure steps freely programmable via NC program

_external tool cooling (AKZ) with flushing nozzles (optional) integrated into the spindle

_integrated work area shower with adjustable nozzles for optimum flushing of the work area and cooling of the workpiece

Options

_coolant cooler

_coolant temperature control unit for high thermal stability and precision

_automatic filling of the coolant unit

_oil skimmer for separation of foreign oil from the cooling lubricant tank

_automatic setting station flushing

Supply and disposal

For maximum

chip removal rates

Fast and effective chip removal is a top priority with our

machining centres. The design of the work area prevents

the accumulation of chips and ensures that they are

quickly removed from the machine. You can select the

most suitable conveyor design and coolant unit for

your individual work processes. Precision and process

are assured!

1

2

2

Chip disposal

_F 5000/6000: free chip fall below the spindle and quick removal from the work area

_F 8000: chip removal from the work area to the rear of the machine via spiral conveyors

_chip conveyor either as scraper belt or hinged conveyor, depending on the application (optional)

_steep stainless steel side panels and slat coverings with self-cleaning effect to prevent chip deposits 1

_integrated work area shower to support rapid chip removal

_extraction unit for the removal of coolant mist from the work area (operating principle: mechanical air filter) (optional)

Media supply

_easy maintenance with optimum accessibility, all supply units at a glance

_central oil-air lubrication for key components

_sealing air and selective blow-off of interfaces for continuous, smooth machine operation

_media interface for hydraulic workpiece clamping with up to 250 bar (optional)

_compressed air and water guns integrated into the machine housing at the workpiece loading station and operating station 2

Supply and disposal 17

1 2

Machine control

_high-performance control Siemens SINUMERIK ONE to meet the highest standards of performance and machining precision

_console-design main operating unit and ergonomic control panels around the machine (^1)

_digital drive technology and modern system architecture

_Profinet bus system for ultra-fast real-time communication

_IO link system for direct diagnostics and parametrisation of sensors

Options

_panel-design main operating unit (ITC 2400)

_convenient operating panel at the tool loading station (^2)

_HT 2 or HT 10 handheld operating unit

_additional keyboard

_work area camera

HELLER Operation Interface

_HELLER user interface with 4 function areas for more information at a glance _practical HELLER applications (Xtends) with useful additional functions _24” screen and multi-touch function, ideal for viewing documents and drawings _machine control panel with pushbuttons and 3 overrides for optimum control in all operating situations _third override reduces rapid traverse, helping to eliminate the risk of a collision during manual operation

Options _in-process monitoring (IPM) _damage reduction _tool requirements planning _automatic loading/unloading sequence _maintenance manager _job management _interpolation turning (IPT) _SETUP-Assist (process setup wizard) _PRODUCTION-Assist _HELLER Services Interface (HSI) and other HELLER4Industry products

Control technology 19

Operation

Optimal access to

all working areas

Working with HELLER machines, you can feel every day how

much engineering experience has gone into these machining

centres. Whether at the workpiece setting station, during

tool loading, programming or maintenance – your comfort,

safety and, above all, the productivity of your manufacturing

operations are always in the foreground.