Direct drive, rotary torque tables on the latest 5-axis machining centres give fast and responsive 3+2 (positional) or simultaneous, highly accurate 5-axis machining

GF AgieCharmilles launched a number of innovative Mikron 5-axis machining centres at EMO 2007 exhibition. They are being used by the UK subsidiary in its ‘Five Drive’ 5-axis machine tool campaign. In a report to manufacturingtalk.com, managing director at Agie Charmilles, UK, Steve Sylvester, said: ‘Amongst all the new machines GF AgieCharmilles launched at EMO in September - the new Mikron 5-axis machines are of particular importance and have been integrated into our ‘Five Drive’ campaign’.
GF AgieCharmilles introduced the ‘High Performance machining’ (HPM) Mikron HPM 600U and HPM 800U machines.

Both machines are equipped with direct-drive, rotary torque table technology aoffering fast and responsive 3+2 (positional) 5-axis machining and/or highly accurate (zero backlash) 5-axis simultaneous machining.

Sylvester said: ‘The new HPM 5-axis machines are aimed at high precision, complex part manufacture - and, owing to their automation potential, can be used for one-offs prototyping etc right through to high volume series production.’ For example - both machines can be supplied with a single table - or a twin pallet (table) option.

For increased productivity, the machines can be specified with APC capability (five, six or seven pallets) - or can be integrated easily with robot systems (loading/unloading) to create a flexible manufacturing cell.

The machines also feature the following.
* Portal design.

* High-accuracy 5-axis Step-Tec spindles (15,000 to 30,000 rev/min).

* Heidenhain iTNC 530 CNC.

* Mikron proprietary SMART technology software used to optimise the 5-axis machining process.

In addition to the HPM machines, GF AgieCharmilles also launched the XSM 400U linear 5-axis machine.

Equipped with linear motor drives on its axes, this machine was said at EMO to manufacturingtalk to be: ‘The fastest and most-accurate simultaneous 5-axis machine on the market.’ It features 80m/min fast feed rates and 2.5G acceleration/deceleration.

Mikron told manufacturingtalk.com that the machines are not only fast, they also have linear motors that ensure the following features.

* High-precision and repeatability (sub 3 micron positional accuracy).

* Integrated automation (ATC and APC).

* 5-axis Step-Tec spindles (30,000/42,000/54,000 rev/min).

* SMART technology software.

Sylvester concluded: ‘Mikron has a reputation for pushing the boundaries of milling technology.

The XSM 400U Linear machine is an extension of this - and this machine has no equal.

Whatever 5-axis machine tool customers are looking for - we have the optimum solution.

Offering simultaneous 5-axis machining at an affordable price, a vertical machining centre gives maximum versatility, as the trunnion table can be quickly, and easily, removed for 3-axis work

Yamazaki Mazak has introduced the vertical centre Nexus 510C-II 5X to offer simultaneous five-axis machining at an affordable price. It is an extension of the existing Vertical Centre Nexus 510C-II machine with the addition of a 2-axis trunnion table. The Mazatrol Matrix control system adds to deliver a cost-effective simultaneous 5-axis capability.
The VCN 510C-II 5X has been designed for maximum versatility, as the trunnion table can be quickly, and easily, removed.

This allows the full 3-axis machining envelope of the machine to be used.

The trunnion table has a diameter of 205mm and sits within the existing 1050mm (X) and 510mm (Y and Z) axis travels.

Yamazaki, in a report to manufacturingtalk.com, said it kept the existing VCN 510C-II machining envelope based on research into this market sector.

The research showed that the envelope dimension offered enough capacity for most components likely to be machined on such a machine tool.

Other features retained from the standard VCN 510C-II are as follows.

* The 12,000 rev/min, 18.5kW (25HP) 40 taper spindle.

* 30 position toolchanger (60 position option).

* 1.3s chip-to-chip toolchange.

* 36m/min maximum feedrates in all axes.

The Nexus range has been designed to provide a combination of technology and productivity, and provides a level of performance not normally attributed to machines in this class, said Yamazaki.

The Vertical Centre Nexus range in particular provides improved machining stability, safer operation, and enhanced ease of operation by utilising Yamazaki Mazak’s 6th generation CNC system, Mazatrol Matrix.

A 5-axis vertical machining centre features a thermally stabilised head with motor spindle that swivels about the B-axis, while the fifth CNC axis is provided by a horizontal rotary table

Hurco Europe has introduced a 5-axis vertical machining centre (VMC), the VMX42SR. It is based on the manufacturer’s 3-axis machine of the same frame size but has a thermally stabilised head with motor spindle that swivels about the B-axis. A horizontal rotary table provides the fifth NC axis.Typical applications are machining of moulds and dies, aerospace components, medical components and impellers.

Hurco said that the configuration keeps the footprint as compact as possible for a 5-axis machine: 3.55m x 2.18m.

The machine has a special version of Hurco’s new WinMax control software and graphics, which support 5-axis simultaneous interpolation and simplifies programming for five-sided machining.

Hurco quoted to manufacturingtalk.com the example that tool centre point management allows a user to cut the same part anywhere on the 610mm diameter table without having to repost the program.

Advanced simulation graphics on the second of the two Ultimax touch screens eliminate errors when cutting the part.

* Versatility - a high level of shop floor versatility and productivity is afforded by G-Code and conversational programming.

Other features include the following.

* True auto-interrupt/auto resume, which retracts the tool along an oriented tool axis and resumes where the operator left off.

* Toolpath linearisation, which eliminates unwanted loops when cutting the part.

* 3D tool geometry compensation allows the use of different ballnose tool diameters for surface contouring using the same NC program.

A 5-axis, 5-sided large capacity machining centre has spindle speeds up to 20,000 rev/min and can machine parts up to 400mm diameter and 300mm high with a tilt capability up to 150 deg

Among the machine tools to be shown at the UK’s MACH 2008 machine tool exhibition on a 400m2 stand, MAG Cincinnati will exhibit the CFV 5Si 5-axis vertical machining centre and the FTV 840-2500 fixed table, travelling column vertical machining centre. Also at MACH 2008 MAG Cincinnati will exhibit machines alongside products from MAG industrial automation Systems sister companies MAG Fadal, MAG Huller Hiller and MAG Boehringer.
Five axis VMC - from MAG Cincinnati will be the market leading CFV 5Si 5-axis vertical machining centre (VMC) and the FTV 840-2500 fixed table, travelling column VMC.

The CFV 5Si has a dedicated table that delivers full 5-axis, 5-sided large capacity machining capability.

Incorporating 5-axis integrated rotary table technology and spindle speeds up to 20,000 rev/min, the CFV 5Si is capable of producing components up to 400mm in diameter and 300mm high with a tilt capability up to 150 deg.

The CFV 5Si’s high-rigidity cast frame structure combined with linear guideways minimise chatter and vibration to give the user exceptional accuracy, repeatability and surface finish to deliver a flawless finish every time.

The CFV 5Si is available with a choice of state-of-the-art leading CNC control systems to provide both positioning and simultaneous 5-axis machining capability.
To demonstrate this 5-axis capability the CFV 5Si will be machining an impellor at MACH.

* Tavelling column VMC - the MAG Cincinnati FTV 840-2500 is based on the Fixed Table (FTV) machining centre concept with a travelling column.

The 3-axis FTV 840-2500 incorporates a spacious 3140 by 815mm bed that gives the FTV and X, Y and Z axes travel of 1830mm, 815mm and 800mm respectively.

The generous working envelope allows users to produce large components as often required in the aerospace industry or alternately have multiple set-ups on the machine at any one time.

With a rapid traverse of 40m/min and 40 series spindle taper with a standard 8000 rev/min, the highly rigid and productive FTV 840-2500 is the versatile machining centre of choice, said MAG Cincinnati.

* Fadal machining centres - additional vertical machining centres on show at MACH 2008 will be the MAG Fadal VMC 2216FX and VMC 4020FX.

The quality of the range is exemplified by beta i drive motors for high torque and acceleration performance plus Steinmeyer ETA ball screws that reduce heat friction by up to 70% compared to competitor machines.

The VMC2216FX and VMC4020FX have an X-axis travel of 558mm and 1016mm with Y-axis travel of 406mm and 508mm respectively.

Both machines are equipped with an automatic tool change (ATC) capacity of 21 tools, spindle speed of 10-8,000 rev/min and a 40 spindle taper as standard with a choice of Fanuc 0i or Fanuc 18i control system.

Designed to deliver a high level of accuracy, the FX range has a positional accuracy of +/-0.005mm and axis repeatability of +/-0.0025mm as standard.

For customers demanding consistently accurate performance, Heidenhain glass scales are available.

To guarantee rigidity and high quality surface finishes when machining difficult materials, the optional high torque 10,000 rev/min spindle combined with the great damping and stiffness of the cast iron boxway undoubtedly, said MAG Cincinnati to manufacturingtalk.com, makes the FX range the ideal economical solution for end users.

* Huller Hille and Boehringer - to meet the needs of manufacturers looking for horizontal machining centres (HMC) the MAG stand will also demonstrate the new MAG Huller Hille nbh 5+ machining centre.

For machining non-ferrous metals and non-metals a 5-axis machining centre a more stiffness to the 5-axis cutting head than is normally associated with machines of this type

Italian machine tool builder, CMS, will be showing its latest 5-axis CNC machining centre - called Antares, at the UK MACH 2008 machine tool show. Antares is intended for machining non-ferrous (NF) materials within a 2600 x 1500 x 1200 mm working envelope. According to CMS UK general manager, Toni Nagiel, the Antares concept deliberately tends towards ‘over-engineering’ to provide a high degree of robustness, reliability and accuracy.
The machines can therefore be used for a wider range of applications than might previously have been envisaged, said Nagiel to manufacturingtalk.com.

Confidence in their capabilities is, he said, being borne out by their increasing use in high-technology industries.

Materials regularly machined now extend from wood, aluminium, epoxy paste and polyurethane, commonly found in the mould-, model- and pattern-making sectors, to include light alloys and carbon fibre, as used for the production of structural components in aircraft, for example.

The Antares design philosophy igives far higher degree of stiffness to the 5-axis cutting head than is normally associated with machines of this type, said CMS.

The usefulness of this attribute is enhanced by the inclusion of a pneumatic brake that can be programmed to clamp the B- and C-axis during operations that do not require fully active 5-axis interpolation.
Universal head - the PX5 universal head, with all five axes acting under simultaneous control from a GE-Fanuc 18i MB5 CNC system, has a fourth, horizontally rotating axis and a fifth that inclines the spindle in the vertical plane, in addition to the three orthogonal linear axes.

The highly specified CNC includes PC Office integrated in the electrical cabinet.

* High speed spindle - drawing on the machine tool builder’s 35 years of experience, a strong spindle shaft, manufactured in-house, is mounted on two pairs of pre-loaded bearings - ceramic for the front pair and steel for the rear.

The high-speed spindle (24,000 rev/min maximum - 12kW or 27,000 rev/min maximum - 6kW) is liquid cooled.

Fast positioning speeds of 70-80m/min are achieved along with acceleration of up to 3.0m/s2.

These are higher if a customer chooses the option of linear motors in X and Y.

* Special machining cycles - CMS has developed special cycles for surfacing work, which are linked to the high-speed cutting strategy from Fanuc.

It allows the programmer to vary cutting feed rates on the same tool path to optimise both roughing and finishing operations, leading to major productivity gains and high levels of surface quality.

Roughing times are typically half those of finishing cycles.

Automatic tool change is from a magazine located on the front face of the traverse.

An eight-tool magazine is standard; a 16-tool version is optional.

According to CMS, the combination of a high performance, powerful electro spindle and high machine rigidity assured by the travelling bridge construction offer users high quality machining across a wide range of materials.

* Extended markets - having extended its target markets well beyond the original woodworking and routing, CMS is benefitting from increased machine sales.

Said Nagiel: ‘We are challenging manufacturers to look again at their previous understanding of what type of machinery they need.

We are regularly showing that, for many high-speed machining applications, equipment with large-volume working cubes such as the Antares can be just as effective as higher-priced, ‘traditional’ 5-axis machining centres’.

Nagiel suggested that if manufacturers would broaded their outlook, they would benefit.

For example, where the standard vacuum bed has provided an unexpectedly easy way for customers to clamp large components and save on tooling costs and downtime.

He continued, ‘Of course, tee-slotted and other tables are available as well, but production staff owe it to their companies to look at all options.

Mockry & Sons Machine Co., Inc., Derby, Kansas, is celebrating its 1011 anniversary and has recently installed a new Mori Seiki NL2500Y 5-axis CNC turning center.

Ron Mockry started the machining job shop in 1994 with his son, Mike, in a 3,000-sq.-ft. facility with three pieces of equipment. Ron’s other son, Tony, joined the company in 1995.

Today, the company has 23 employees, operating across two shifts, in a 10,000-sq.-ft. facility with 11 pieces of CNC equipment.

The new Mori Selki NL2500Y (the first one in Kansas) illustrates the company’s commitment to utilizing technology to improve efficiency and lower costs.

“This is a remarkable machine,” stated Ron Mockry. “We had installed another Mori Seiki in 2002. The improvements were so great, that we were eager to have the new model with the y-axis. We can combine mill and lathe operations that improve our capabilities.”

The new turning center, the fourth Mori Seiki purchased by Mockry & Sons, features: an 8-hp turret motor; a 4,000-rpm spindle; 6,000-rpm live tooling; 12 tools; 5-axis capabilities and 27.7″ turning length capacity.

“We do whatever the customer needs,” noted Tony Mockry. “We can take projects from design to prototypes, all the way through production, assembly and packaging.” Engineering assistance is also offered. The company uses Mastercam software. A QC lab is on site.

Mike Mockry noted that the average tenure of the company’s crew is over five years. “We believe in treating our employees right.”

Between Ron, Mike and Tony, the trio has over 75 years of manufacturing experience.

Mockry & Sons works with aluminum, stainless steel, brass, carbon steel and acrylics.

The company can handle parts up to 20″ x 50″ with 4-axis mills and turning projects from 1/4″ to 13″ in diameter and up to 27.7″ in length.

Industries served by Mockry & Sons include: aircraft; fluid power; automotive services and medical equipment.

The operation is definitely a family affair with six family members working full time and two more working part-time.

The company will be exhibiting three models of five-axis CNC machining centers used in the aerospace and automotive industries and other applications. The machines feature Siemens 840D controls and spindles capable of 30,000 rpm and 134 hp. The company’s PBZ NT and PBZ LC series are available in standard length up to 14 m long and are equipped with fully programmable vises that are said to eliminate the need for hard tooling. Another series, the UBZ NT, is built using a modular concept and can be configured for each particular application, the company says.

The TGC five- and six-axis CNC micro precision tool grinder has a grinding wheel turret arrangement that allows for up to 15 grinding wheels. The grinder is capable of grinding tool diameter ranges from 0.0008″ to 0.551″. Menu-driven software from Numroto and NTI is said to cover the entire cutting tool spectrum from drills and milling cutters to profile tools, including cylindrical or tapered tools with square, corner or full ballnose ends. The machine comes with either a GE Fanuc or NUM control, and it can be configured with auto loading.

A CNC 5-axis gantry milling machine will be mainly used to manufacture carbon fibre products for the aerospace industry, but is also capable of machining steel and other metal products CNC� CNC Repair.

The new H and H ULTRA5 Gantry milling machine using the Siemens Sinumerik 840D CNC, Simodrive 611D digital drives and 1FN3 linear servo motors, on X, Y and Z axes, with 1FT6 motors on A and C, has been supplied and is supported by CNC Design. The machine, designed and built in Australia by H and H Machine Tools, was supplied to CTRM in Malaysia and will be mainly used to manufacture carbon fibre products for the Aerospace industry, but is also capable of machining steel and other metal products, with full 5 axis capability. Axis travels on this machine are: X = 6500mm; Y = 4500mm and Z = 1500mm.

Distance between columns is 5800mm.

Length of working area is 9500mm.

The 20kW (S1) spindle runs at 30,000 rev/min with +/-110 deg of tilt and +/- 360 deg of rotation.

Maximum feedrate is 60m/min As the machine design uses linear motors on X, Y and Z axes, variations in axis travel can be easily accommodated.

For further details, please contact the machine maker: H and H Machine Tools Australia Pty, 45 Fordson Road, Campbellfield (Melbourne), VIC 3061.