Product category:
Milling, boring and routing machines - manual and CNC
News Release from: DMG (UK) | Subject: HSC 20 linear compact, HSC 55 linear at MACH
Edited by the Manufacturingtalk Editorial
Team on 07 April 2008
DMG redefines high-speed CNC multi-axis
milling
DMG has configured a future-oriented and 'homogeneous' high speed metal cutting machine range for all workpiece dimensions, without any compromises during the machining process.
As well as introducing a brochure on highs speed cutting (HSC), German machine tool group, DMG, has introduced two high speed cutting/high speed machining (HSM) CNC milling machines * High-speed milling - DMG said in its brochure that high sped milling is a major 21st century trend and the Group offers a future-oriented range of HSM CNC milling machines for all workpiece dimensions and machining tasks - through to contiunous path 5-axis milling
This article was originally published on Manufacturingtalk on 21 Jun 2001 at 8.00am (UK)
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The range covers the HSD 20 linear with 200 x 200 x 280mm traverses for smaller workpieces through to precision machining centres, type HSC 105 linear, for large workpieces weighing up to 1,800kg .
The key points of this development include the following.
* A very sturdy design forming the perfect basis for ultra-fast movement sequences.
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* The consequent implementation of high-frequency HSK spindle drives with high rotational speeds as standard.
* Direct drives in all linear and round axes for maximised dynamics and optimal precision.
* CNC with the highest performance class with comfortable 3D functionality.
The basic criteria for an optimum and, as a result, maximised economical chip removal process are quickly enumerated, independent of the material to be machined.
The target being high chip removal volumes, long tool operating lives, and maximum process reliability along with optimum precision and workpiece surface qualities.
DMG said that no major productivity leaps are to be expected in rough milling, but substantial reserves can still be drawn on in precision machining, owing to the comprehensive availability of high-strength cutting materials, such as PKD/CBN or CVD.
HSM permits high chip removal volumes and short manufacturing times.
HSC has less tendency to form burrs, allowing downstream finish machining to be shortened or even entirely substituted, said DMG.
Low cutting and passive forces allow higher dimensional and shape accuracy as well as higher surface qualities to be achieved.
The lower thermal load during HSM positively affects the marginal zone properties of the machined workpieces, said DMG.
HSC machining is more than simply the integration of high rev/min spindle drives.
For this reason, DMG has now configured a future-oriented and homogeneous HSC machine range for all workpiece dimensions.
The company told manufacturingtalk that its HSC machine tools do not allow any compromises during the machining process yet meet all requirements of advanced automation ambitions and eventually set new standards in high-speed machining.
* HSC 20 linear compact high-speed machining centre for machining small wokpieces - the HSC 20 linear offers dynamics, precision, compact design, versatility and intelligence in one high-tech machine tool.
For example, machining centre has the following features.
* The linear drives with precision cooling in the X-, Y- and Z-axis for accelerations up to 2G.
* Direct measuring systems in all axes.
* Actively cooled high-performance 42,000 rev/min spindle with HSK-32 tool holder.
* Extraordinary contour precision (P5 as standard).
* Extremely compact design with a footprint of only 2.5m2.
* Available extensions from 3- to 5-axis machining with a torque motor driven NC swivel rotary table.
In addition to HSC machining with coolant alone, the integration of an extraction system specially adapted to the machine concept turns the HSC 20 linear into a machine suitable for graphite machining or the milling of ceramic green bodies.
A closed-circuit with positive guidance of the fluid motion is created by the extracted and filtered exhaust air, which is returned to the machining compartment via two valves.
Important features of the HSC 20 linear are as follows.
* Maximum flexibility through 5-axis gantry machine - gantry design with integrated NC swivel rotary table for simultaneous machining in 5-axis.
* Compact design with a 2.5 m2 footprint and traverses in X, Y and Z (200 x 200 x 280mm) * Maximum dynamics generated by linear drives with precision cooling in the X-, Y- and Z-axis.
* Direct drive with water cooled torque motors in the A- and C- circular axes.
* Direct measuring systems in all axes for maximum precision.
* Acceleration up to 2G and rapid traverse of 40m/min in the linear axes.
* Highest precision and exact contours as well as surface qualities up to <0.2 micron Ra.
* 42,000 rev/min high-speed spindle with active cooling as standard, with HSD-32E tool holder.
* Sturdy vibration damping mineral cast stand in a monoblock design.
* Automatic tool changer with 24 magazine positions as standard (option: 60 positions).
High speed/high precision machining centre HSC 55 linear, has a gantry type of machine structure and sets new standards regarding dynamics, flexibility, dimensional precision and surface quality.
* HSC 55 linear - a high-speed precision machining centre is claimed by DMG to set new standards regarding dynamics, flexibility, dimensional precision and surface quality.
Designed as a gantry machine in an extremely sturdy, thermo-symmetrical design, the HSC 55 linear has the following features.
* A 28,000 rev/min high-speed spindle as standard.
* Linear drives in all axes for accelerations above 2G.
* Rapid traverses up to 80m/min.
The HSC 55 linear is also offered in a dual version: either in a 3-axis design with movable table unit or as a 5-axis type with integrated swivel rotary table.
Both table variants are moved by two lateral linear drives (gantry design) and positioned with high precision.
The traverses (in X, Y and Z) are 450 x 580 x 400mm (3-axis), or 450 x 600 x 400mm (5-axis).
The two axes of the swivel rotary table (C- and A-axis) of the 5-axis version are also equipped with direct or torque motors respectively.
The swivel or rotary range is 360 deg in the C-axis, whereas the A-axis turns in a range from +10 deg to -100 deg.
In both cases, the rotational speed achieved is an impressive 120 rev/min.
To ensure sufficient stability during machining of the workpieces weighing up to 200kg, the table is supported by an integrated hydraulic clamping system at a torque of 2,000Nm.
The HSC 55 linear can perfom high-speed milling of hardened steel and high-speed machining of graphite.
Optimum drop of the swarf and chip flow are not the only features taken into account.
All drives and guideways are installed outside of the machining compartment for perfect protection against process-related influences.
The strategic alignment towards HSM is also revealed by the selection of available spindle variants.
In comparison with other high-speed machines in the market, the new DMG 28,000 rev/min spindle is claimed to have a notably higher rigidity.
The spindle gives reduced vibrations during machining to produce better workpiece surfaces and a longer tool operating life.
The increased rigidity also allows the HSC 55 linear to carry out roughing processes at a much higher chip removal rate, said DMG to manufacturingtalk.
As an alternative, the machine is also offered with a 18,000 rev/min motor spindle and, as an option, two additional spindle alternatives with rotational speeds of 42,000 rev/min and even 60,000 rev/min at the same price.
* CNC system - the HSC 55 linear is controlled by the latest DMG ERGOline Control and iTNC 530 CNC from Heidenhain.
The control system reflects more than 20 years of DMG competency in 5-axis machines.
Collision monitoring, for example, ensures dynamic anti-collision monitoring in real time, and, as a result, optimum use of the machining compartment.
3D quickSET, is used to check and correct the kinematics in the compartment and to perform a precision comparison at finger-tip control.
'ATC' permits button-controlled simple tuning of the advance drives to reduce machining time and improve the relevant quality.
'ACC' or the automatic acceleration control, is responsible for automatically adapting the machine parameters to the workpiece weight.
This leads to light-weight workpieces being milled at high dynamics, heavy workpieces with adapted lower dynamics.
The weight is determined by manual entry or an automatic weighing process.
Important features of the of the HSC 55 linear are as follows.
* Highest dynamic and precision through linear drives in all axes.
* 28,000 rev/min HSC spindle with HSK-A63 as standard - high stability during chip removal, better tool operating life, reduced tool costs, perfect surfaces.
* Optimum chip flow and ideal flow behaviour for graphite machining.
* All drives and guideways are arranged outside of the machining compartment.
* Thermo-symmetric design - high long term precision.
* Optional 5-axis machining with gantry drive and swivel rotary table in torque motor technology.
* DMC EGROline control with a 19in monitor and 3D software.
* Heidenhain iTNC 530 CNC for optimum operating comfort and minimised programming times, HSC control features are ATC, AAC, AFC as described earlier.
* DMG(UK) at MACH 2008, NEC, Birmingham, UK, April 21-25, Hall 5, Stand 5228.
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