HSM reduces light alloy machining costs

Minimising piece part manufacturing costs whilst maximising process stability are key objectives for component manufacturers. These objectives can be got by making the most of high speed machining.

The world of CNC machining is changing.

For example, in the automotive and aerospace manufacturing sectors - the use of light alloys, e g, aluminium and magnesium, is increasing with many parts machined from 'near-net shape' castings.

Minimising piece part manufacturing costs whilst maximising process stability are key objectives for component manufacturers.

These objectives can be achieved through capitalising on high speed machining techniques.

The new DMC 63 H horizontal machining centre from Deckel Maho incorporates a revolutionary Box in Box machine dynamics concept.

DMG's 'Box in Box' design principle in the DMC 63 H is equal to the gantry concept incorporated in the DMC 65 V and DMC 85 V linear high speed vertical machining centres, just rotate the whole thing through 90 deg.

All machining axes are arranged through a minimisation of moving masses, the work piece is mounted on a stationary table and the only variable mass to be moved is the cutting tool and tool holder.

These are controlled within fine limits, when compared to the maximum component weight allowable on a machine table when the moving axis is also moving the work piece.

The Box in Box concept is well suited to dry machining and allows axis acceleration of 1g and rapid traverse rates of 80m/min thus maximising spindle utilisation.

The DMC 63 H offers a long Z-travel (560 mm) with high rigidity.

Arranged in a closed vertical carriage, three linear guiding systems guarantee optimum dynamic stability.

The time for drilling work is drastically reduced by this unique centre sleeve concept.

Another advantage of this concept is that the large dynamic force of the spindle carriage decreases tool wear and tear.

All axes incorporate 50mm Dia.

internally cooled recirculating ball screws, maximising thermal stability.

The X axis benefits from two digitally synchronised ball screws, another feature of the Box in Box design taken from the successful DMC 65 V.

Through its axis arrangement and the free chip clearance, the DMC 63 H fulfils all requirements for the HSC dry machining, with a large clearance between the table and spindle allowing the clamping of large work pieces with simultaneous application of tools with excessive length.

The performance data of the DMC 63 H is outstanding: it provides a spindle speed of 12,000 rpm (or 20,000 rpm as an option) in its standard design.

In conjunction with an acceleration of 1 g (acceleration due to gravity) and traverse rates of 80 m per min, this spindle speed enables a massive reduction of the machining time.

In addition, the chip-to-chip times are minimised to 3.7 seconds.

With its dynamic features, the ultra fast horizontal machining centre DMC 63 H is the ideal product to supplement the field-proven range of the high-precision centres DMC 60 H hi-dyn and DMC 80 H hi-dyn.

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