Precision machining centers from FEHLMANN. Precision machining centers FEHLMANN Precision machining center

In modern production processes, ultra-small quantities are used. And not least of all, this concerns the metalworking industry. Such precision is ensured only by the most advanced equipment - machines with numerical software, and complex high-precision processing - by CNC metalworking centers.

CNC metalworking centers perform a whole range of sequential operations: roughing, finishing; thread cutting; drilling; cooling supply; finishing work, etc. Moreover, this type of equipment has a very high degree of automation. Manufacturers produce both semi-automatic and automated centers. Some models can produce finished products virtually without human intervention.

Design and technical characteristics

Structurally, CNC metalworking centers are divided into vertical And horizontal. This depends on the location of one or more spindles. A separate group includes portal centers capable of processing workpieces of any complexity. Such installations can include up to 180 processing tools and process large parts.

A modern machining center is a rather complex engineering structure. The basis is a massive cast iron frame. It is heat treated to ensure maximum structural rigidity. Ball screws are installed on the frame to feed the workpieces. The feed speed can reach up to 40 m/sec. with the ability to position workpieces along the X, Y, Z axes and with an accuracy of up to 0.010-0.005 mm.

Installed on horizontal and vertical metalworking centers universal turrets, holding 12-16 tools with the ability to change in just 0.2-0.5 seconds in different planes. But portal installations differ not only in the number of processing tools, but also in the system of their high-speed change, more powerful spindles, a variety of interchangeable heads, long narrow tables and generally higher structural rigidity. As a result, this allows them to carry out high-precision processing of massive parts.

Modernization

Industrial development forces even ultra-modern machining centers to modernize. This concerns, first of all, increasing accuracy and productivity while maintaining the rigidity of the entire structure.

Dozens of additional options appear. For example, setting automatic bar feed and a part catcher make it possible to make the process of turning small workpieces completely automated. Installing an additional spindle in place of the tailstock will help increase productivity. Thus, the second end of the workpiece can be processed without rearranging it in the machine.

A very useful option is the ability spindle positioning along the C axis with installation of a tool rotation drive. This makes it possible to drill and tap threads on the sides of the part. And milling of complex curves on the side surfaces is carried out by setting the head to move along the Y axis.

In general, machining center manufacturers are increasingly striving to create highly targeted installations. That is, with technological capabilities for a specific industry. Thus, along with turning and milling centers, equipment of milling and turning types is produced separately.

Types of metalworking centers

Milling machining centers

The equipment processes workpieces using a cutter with high accuracy and impeccable quality. In this case, cutting of bushings, couplings, rings, gears, nuts and other parts is carried out regardless of the surface (shaped or flat).

The principle of operation is as follows. The cutter is fixed in the installation spindle. The CNC system powers it, causing it to rotate. In this case, the workpiece fixed on the table is fed for processing. The movement can be rectilinear, curvilinear or combined.

The cutter itself is a multi-edged tool with teeth. They, in turn, can have various shapes (disc, angular, with a spherical head, etc.) and are mounted in the spindle different ways. The material from which the cutting part is made is diamond, carbide, quick cutter. Many manufacturers, by the way, use their own alloys, which are kept secret.

There are three large groups of metal milling centers: universal, horizontal and vertical.

Universal ones are used for processing light and small workpieces in both individual and mass production. The equipment allows you to mill horizontal, vertical, helical and shaped surfaces. The spindle is located horizontally, and the table moves at different angles.

Horizontal centers are not equipped with a rotating mechanism. The table with the workpiece moves only parallel or perpendicular to the spindle axis.

Vertical installations are equipped with a vertical spindle. The table moves perpendicular to the spindle axis. Some models are equipped with a rotating mechanism, which expands the technical capabilities of the center.

Turning centers

Installations of this type are extremely popular in industries where productivity is of paramount importance. Turning centers are metal-cutting equipment for complex processing of various surfaces and in different ways: milling, drilling, boring, etc. They produce many parts from steel, aluminum, copper, bronze, brass and other metals. The basic installation is capable of processing in three coordinates, but expansion to four or even five axes is possible.

The operating principle of the installations boils down to the following: the cutting tool removes chips from a workpiece installed in the chuck. In this case, the part during processing has the ability to rotate both in one direction and alternately (clockwise and counterclockwise).

For single production, universal lathes are used. In serial production, revolver centers are in demand. The latter have an automatic processing process. The operator only sets the desired program and selects the material.

The latest models increasingly use laser technology. Such installations have a number of advantages. Firstly, faster processing speed, and secondly, highest security.

Metalworking turning centers are divided into a number of subtypes: with a driven tool, with a sub-spindle, with a driven tool and a sub-spindle, with a Y-axis, with a tailstock and automatic lathes.

Review of the most interesting models

Currently, the leading foreign manufacturers of CNC metalworking centers are Takisawa, DMTG, Yamazaki, Mazak, Trens, Milltronics, Ming Yang Machinery, Long Chang Machinery, HJM Machinery. In Russia - Ivanovo Heavy Machine Tool Plant, Sterlitamak Machine Tool Plant, Ryazan Machine Tool Plant, Vladimir Machine Tool Plant "TEHNIKA".

If we talk about the universal turning and milling type, then one of the best manufacturers here is Takisawa(Japan) with a series of LA and EX centers.
The unique feature of these centers is that they are easy and convenient to carry out both turning and milling operations. Excellent for small-scale and mass production. Allows you to significantly reduce
production costs.

The standard equipment of these units includes:
- direct drive spindle for high-performance processing;
- built-in cooling;
- oil cooling;
- counter spindle with a fully functional “C” axis;
- 3-jaw hydraulic chuck;
- Fanuc drives and CNC system (very stable and reliable, recognized by most manufacturers);
- disc braking system, etc.

Some of the best milling machining centers in the world are produced by the corporation DMTG(China). The VDL series of vertical milling units are relatively inexpensive, compared to analogues, and at the same time multifunctional centers.

Being the cheapest option for 3-axis (4-axis) machining of body parts, the machines are capable of performing a variety of milling operations.

The standard equipment of the machining center includes:
- tool store;
- optical rulers;
- guides.

Distinctive features of these installations:
- high rigidity and stability;
- high-precision guides on all three axes of the machine;
- high speed and accuracy of the spindle;
- speed and reliability of the tool changing system;
- cooling system;
- multifunctional Fanuc CNC system.

Among horizontal metalworking centers, it is worth paying attention to the company’s installations Milltronics(USA).

Models are equipped with engines of varying power. The transmission of rotation from the motor to the spindle is carried out by direct drive, belt drive or gearbox.
The bed is cast iron, cast. Manufactured with additional ribs, giving the structure increased
rigidity.

The main application is processing of body parts. If you equip the center with a 4th axis, this will allow you to perform multi-position processing in one installation. This improves processing quality and productivity.

Models are equipped with a wide range of additional options. Among them are automatic tool change, rotary table, spindle with a rotation speed of up to 15,000 rpm. etc.

Domestic manufacturers also produce good installations. For example, a turning-milling machining center model 500HS Sterlitamak Machine Tool Plant (Russia). The installation with automatic tool change is designed for processing workpieces made of different structural materials. Excellent for both single production and small-scale, serial production.

The machining center is capable of performing external and internal turning, drilling, countersinking, reaming, semi-finish and fine boring of holes, threading with taps and cutters, and milling.

Other model 800VHT The Sterlitamak plant is a purely turning-type installation. Main purpose: combined processing of parts of varying complexity in a contour version.

It is impossible not to mention the universal turning and milling super-center IS800 "Globus" Ivanovo Heavy Machine Tool Plant (Russia).

The 5-axis high-speed machine is used for machining highly complex parts. These are blades, impellers and other products used in the aerospace and aviation industries.

The main distinguishing feature of this machining center from the basic models is the presence of a rotary table. Together with a number of innovative solutions, the Ivanovo plant installation can perform a very large amount of work in a short period of time.

Conclusion

Scientific and technological progress does not stand still. And the latest metalworking centers are increasingly equipped with the so-called non-contact method of processing parts: laser, plasma, etc. However, experts are in no hurry to declare that contact cutting will soon completely disappear. The problem with modern technology is that all these methods are high temperature. And this has a great influence on the structure of any metal. Sometimes laser or plasma treatment not only worsens, but completely destroys all its performance properties. Therefore, until this serious drawback is eliminated, no one will refuse the usual, time-tested cutter.

Many types of manufacturing require a variety of multi-task machines to produce parts of varying types, sizes and geometries. In order to achieve maximum performance, a system for automatically changing satellite tables is often required to reduce loading and unloading time. The new FTV series of vertical fixed table machining centers offers high productivity, speed and flexibility.

FTV series machines (Fig. 25) with a spindle taper of ISO 40 and ISO 50 allow precision machining of parts of varying complexity at high speed. The fast feed speed along all coordinate axes reaches 40 m/min, the limit of movement along the X axis is up to 3700 mm.

The machines in this series are equipped with a spindle column moving along the X axis, which allows the use of two-position cyclic pendulum-type loading, which reduces machine downtime. The fixed table allows you to install parts measuring up to 850x3700 mm and weighing up to 5250 kg without reducing the processing accuracy. At the same time, the FTV series machines have a smaller footprint compared to machining centers with a moving table.

An optional table-mounted rotary or globe table (4th and 5th axis) and automatic clamping fixtures can be used.

The beds of these machines, significantly reinforced with stiffeners with beams containing square cavities to minimize deformation, weigh up to 9 tons. The stand, which is a compact, high-strength block to maintain the geometric accuracy of the machine, as well as the cast housings of the transverse support and spindle head provide a high strength-to-weight ratio and structural stability with transmitted power up to 42 kW. This configuration gives a large size along the Y-axis with minimal overhang, which is necessary to ensure maximum rigidity and maximum range of movement along this axis.

Rice. 25. Machining center model FTV850

Unusual tool changer. FTV machines feature a tall Y-axis rack that allows the use of a simple direct grip tool changer mounted on the rack and protected by doors. The high-speed servo-driven chain mechanism has a triangular design and holds 36 or 48 tools (90 tools optional), with secure clamping during changing. Tool change time is 4 seconds for adjacent nests without causing interference in the work area.

High degree of ergonomics. The FTV series was designed not only to create machines with high performance, but also with operator comfort in mind. The configuration of the bed, stand, transverse support and spindle block is structurally designed in such a way that when maintenance The mechanic can easily reach the table and spindle in a standing position. These features, along with easy access to tools at the rear of the machine, make operation comfortable and safe. The control panel is located on a movable block and it can be installed at any point along the table surface.

Coordinate motion drives contain ball screw pairs of large diameter, as well as bearings with roller guides moving along a closed path along all coordinate axes. The machine provides fast feed speeds of up to 40 m/min on all axes.

For all coordinate axes, optical rulers are provided as standard to ensure stable and guaranteed accuracy of movements.

Devices supplied as an option: alternative spindles, tool magazines with increased capacity, a tool magazine mounted on the bed for additional or special tools of increased size, sensors for measuring workpiece dimensions and tool adjustment accuracy sensors, a central partition for two-position pendulum mode, a COTS feed system through spindle, control devices for the 4th or 5th axis, COTS feed control system.

Universal machining centers. Universal machining centers have been developed that combine the advantages of vertical and horizontal layouts in their design. One of the machining centers of this type is shown in Fig. 26. This machine differs from other similar models in the presence of replaceable tool heads, replaced in an automatic cycle. In addition, there is a chain-type tool magazine.

Rice. 26. Universal horizontal machining center with automatic head change, model DS 600

Technical characteristics of the OC model DS 600

1. Movement along the X axis, mm 1340

2.Movement along the Y axis, mm 940

3. Travel along the Z axis, mm 1100

4. Pallet size, mm 900x900

5. Size (diameter) of the table, axis “B”, mm 900

6. Tool magazine capacity, pcs. 54

7. Spindle head magazine capacity, pcs. 10

8. Maximum turning diameter, mm 900

9. Maximum spindle speed, rpm 2500

Horizontal OC of the BLUESTAR model range. Such machines have a fairly simple design and relatively low cost.

The machines (Fig. 27) have a solid cast frame, reinforced with stiffening ribs with high damping properties, which is placed on three vibration supports. The table module is also cast. It is designed to rotate 360°, with a discreteness of 1° and with the ability to attach four pallets measuring 500x500mm.

The table positioning accuracy is 0.0028 O. The discreteness of CNC table rotation (optional) is within 0.001 O. The time for changing pallets is up to 8 – 12 s. The maximum weight of a part on a pallet is 800 kg. The highest spindle speed is 10,000 or 15,000 rpm. Power 18 kW.

Rice. 27. Horizontal machining center of the BLUESTAR range (protective guard removed)

Horizontal processing center ISB1200 – module. Like the two subsequent machines, it is produced by the Ivanovo Heavy Engineering Plant. Distinctive feature is the complete autonomy of the module during complete processing, when various parts are placed on each pallet (Fig. 28). Automated loading of pallets from a high-capacity storage facility implements the principle of unmanned technology. Maximum movement along the axes: X (table transversely) – 2000 mm, Y (spindle headstock vertically) – 1600 mm, W (stand longitudinally) – 1000 mm, Z (spindle extension) – 710 mm, B (table rotation) – 360 o . There are 5 pallets measuring 1200x1200 mm with a load capacity of 400 kg and a changeover time of 100 s. Spindle speed up to 3000 rpm. Tool magazine capacity up to 100 tools. Fanuk or Siemens control system.

Rice. 28. Horizontal processing center ISB1200 – module

Horizontal CNC boring machine model IR1600MF4. The machine with a movable stand (Fig. 29) is designed for complex processing of large-sized body and base parts made of ferrous and non-ferrous metals. It has a transverse movement along the X axis of up to 13500 mm, and a fixed screw and a rotating nut are used in the ball screw pair. The longitudinal movement along the W axis is 1250 mm. Vertical movement of the spindle head along the Y axis up to 2500 mm (up to 4000 mm on request). Travel speeds are 10 m/min. The boring spindle extends along the Z axis by 1000 mm. Spindle speed up to 2000 rpm.

The machine uses a Sinumerik 8400 CNC system from Siemens, which provides contour control in 4 coordinates (X,Y,W,Z), and when equipped with a rotary-moving table, 6 controlled axes are obtained. The maximum load capacity of the table model IRS3500 is up to 40 tons. Its dimensions are 3500x2900 mm.

Rice. 29. CNC machine model IR1600MF4

Horizontal super center IS800 Globe. This machine (Fig. 30) is designed for processing highly complex parts such as blades, impellers, ship propellers and other products of the aerospace and aviation industry with simultaneous 5-axis control.

TO technical specifications This can be attributed to the presence of a circular indexing table (axis B), which rotates 360° with a division error of ± 3.6 seconds. Working surface size 800x800 mm. There is a dividing swing mechanism (axis A) from 20 to 130 degrees. The error is

± 12 arc seconds. The amounts of movement along the X, Y, and Z axes are 1200, 1000 and 1100 mm, respectively.

The spindle speed limit is 12000 rpm. The number of tools in the magazine is 50. The tool change time does not exceed 7 s. The main movement drive power is 30 kW.

Rice. 30. Horizontal super center IS800 Globe

Horizontal machining centers of the MSV series. Machines in this series are designed for processing massive, large-sized parts. An example of the general view of such a machine is shown in Fig. 31.

Depending on the specific model the machines have axial movement values ​​from 810 to 1500 mm. The pallet size is 1000x1000 mm. Spindle taper No. 50. The number of tools in the store is from 40 to 200 pcs.

Rice. 31. Horizontal machining center for machining

large-sized massive parts of the MSV series

Precision machining center model KERN Pyramid Nano. A special direction in the development of modern multi-operational CNC machines is the creation of particularly accurate (precision) models, which are primarily intended for use in processing very precise small-sized parts for instrument making, scientific, aviation and space technology. These include two machines (Fig. 32 and 33), the description of which is given below.

Rice. 32. Precision machining center KERN Pyramid Nano

The machine has hydrostatic drive guides and a frame with increased vibration-damping properties. The number of sockets in the tool magazine, depending on the modification, is 75 or 96 pcs. There is an automatic operator for changing workpieces for 20 nests. Centralized temperature control is provided (guides, drives, frame, spindle, control cabinet). Axis movements for 3 – 5 axis machining: X = 500 mm, Y = 500 mm, Z = 300 mm. Feed limits from 0.01 to 30,000 mm/min., acceleration up to 10 m/s 2. The spindle speed of the HSK 40 model is from 200 to 36,000 rpm with a power of 11 kW. The optional HSK 25 spindle provides 500 – 50,000 rpm and a power of 6.4 kW. Laser control of tool dimensions is provided with an accuracy of ± 1 μm, as well as automatic control of the workpiece, also with an accuracy of ± 1 μm. Of particular note is the positioning accuracy within ±0.3 µm. Machining roughness R a< 0,05 мкм. Вес станка – 7 тонн.

Precision machining center KERN Micro. This machine is used to produce precision parts from materials with various properties. It is intended for use in the processing of copper electrodes, non-ferrous and ferrous metals, plastics, hard alloys and titanium.

Rice. 33. Precision machining center KERN Micro

The machine bed is made of polymer concrete. Tool magazine for 20 slots. The axial movements are: X = 250 mm, Y = 220 mm, Z = 200 mm. Feed limits from 0.01 to 6000 mm/min., acceleration up to 4 m/s 2. The model's spindle rotation speed is from 500 to 50,000 rpm with a power of 3.4 kW. Optional spindles have rotation speed limits: 500 – 30000; 20000 – 80000; 30,000 – 90,000 and 60,000 – 160,000 rpm.

It can be noted that the positioning accuracy is within ± 1 µm. Processing roughness within R a< 0,2 мкм.

Machining center with a dual system of actuators, model TWIN. In the development of modern CNC machines, one can note an attempt to eliminate main drawback of these machines, which lies in productivity limitations. This feature of the machines is explained by the sequential scheme of processing parts. With this scheme, processing is carried out with one tool at each time. After completing this technological transition, an automatic replacement is made and the next tool comes into operation.

The parallel multi-tool processing scheme, characteristic of high-performance special machines (including aggregate ones), is practically not used here. For example, multi-spindle attachments complicate machine setup and do not fit well into the dimensions of tool magazines in combination with conventional tool blocks.

An example of the transition to simultaneous processing of two parts is the TWIN CNC milling machine (Fig. 34). It actually contains two milling machine in one mechanical structure with the possibility of synchronous and independent processing.

Rice. 34. Machine model TWIN with dual working bodies

There is only one control system per machine. There are four high-torque table drive motors and two spindle motors with collision sensors, a tool balancing system and a tool condition monitoring system.

There are two tool magazines, controlled nozzles for external coolant supply at a pressure of 20 bar and an internal supply with a pressure of 40 bar. Movement along coordinates X = 400 + 400 mm, Y = 640 mm, Z = 510 mm. The diameter of the rotary tables is 480 mm, the swing of the inclined table is within ± 105 o.

The maximum possible size of processed parts is 775 mm.

A

b

Rice. 35. Options for machine configurations: a – with two spindle heads and a double globe table (machine model HSC from OMV, Italy); b – with three synchronized spindles

3. COMPONENTS AND ASSEMBLY OF CNC MACHINES

1. Machine bed made of polymer concrete.
2. Laser tool measurement.
3. • Increased stability and accuracy.
   • Software for working with three-dimensional images.
   • Control of tool geometry: length, diameter, contour.
4. Tool changer for 90 positions.
5. High speed spindle.
   • Ceramic bearings with oil-air lubrication, automatic tool clamping.
6. Toolholder HVC 140-SB.
   • HSK 40 E for instruments up to 16 mm diameter.
7. Tool holder HVC 150.
   • HSK 50 E.
8. Direct drive.
   • The motor is directly connected to the ball screw through a coupling.
   • Transmission without loss of torque thanks to high torque drives (compared to belt drives).
   • Optimization of drives via CNC to adapt to machine dynamics.
9. Infrared measuring probe.
   • Renishaw OMP-400, m&h 40.000-TX/RX.
   • Heidenhain TS 440.
10. Axle configuration.
    • High rigidity.
    • Increased thermal stability.
    • Ideal ratio of length and width of the X-axis guide.
11. CNC system Heidenhain iTNC 530 smart 04.
    • High-speed cutting functions to ensure the calculation of the movement path with good accuracy and high-speed processing within specified tolerance limits.
    • Remote control for easy operation.
12. Fourth and fifth axes.
    • Electric motors with high starting torque.
    • Rotation speed up to 200 rpm.
13. Automation systems.
    • Exeron provides automation systems based on customer requirements.