SMART MACHINES MADE IN GERMANY PRECISION IN A NEW DIMENSION MICROGANTRY MICROMASTER CUTTING EDGE TECHNOLOGY IN MICRO MACHINING

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1 PRECISION IN A NEW DIMENSION MICROGANTRY MICROMASTER PRECISION FOR SUCCESS PRECISION FOR SUCCESS SMART MACHINES MADE IN GERMANY CUTTING EDGE TECHNOLOGY IN MICRO MACHINING PRECISION IN A NEW DIMENSION

2 ABOUT KUGLER Since 1983 Kugler has been manufacturing ultraprecision aerostatic and hydrostatic machine tools which are among the best in the world. Every company which wants to maintain its leading position in industry is committed to the highest standards. For Kugler this philosophy does not end with the sales, but still applies for consulting and support in all technical aspects of the application as well as for training and in customer service. Kugler has gained experience in the field of high performance laser optics which in respect of quality, punctuality and intensive technical consulting are hardly to match. By cooperation with all renowned research institutes and associations, a product and application know-how at the highest technical level is guaranteed. Our micro job shop is equipped with ultraprecision machine tools in order to meet all common and new ultraprecision machining processes in the field of microlasering, microstructuring, diamond turning and milling processes. All Kugler products leaving the company are accompanied with a test certificate on request. Microtopography systems and laser interferometers on air-bearing precision guideways or indexing heads are used for the inspections. Our comprehensive expertise down to the smallest detail guarantees perfection in all production steps

3 MACHINE BASE AND ENCLOSURE MICROMASTER MICROGANTRY FROM HEAD TO FOOT DESIGNED FOR COMPLEX ULTRA-PRECISION TECHNOLOGIES FOR INDUSTRIAL APPLICATIONS AND FOR R&D VERSATILITY AND CONSISTENT SUPERB PRECISION Extreme rigidity due to granite base Excellent vibration damping Low susceptibility to temperature fluctuations Excellent protection from external influences Spacious machine interior to accommodate numerous options Industry-proven safety cab Protective door with double glazing made from safety glass Ergonomic design for operator safety and comfortable operation Facts and Figures: Travel accuracy linear axes: ± 150 nm over travel 500 mm Resolution of linear scales after interpolation: 15 picometers (10-12 ) SIMULTANEOUS 5-AXIS UP-MACHINING AIR-BEARING ROTARY TABLES AIR BEARING OR HYDROSTATIC TILT-SWIVEL UNITS Quick changeover/retrofit 5-axis operation with fully hydrostatic tilt-swivel unit H-DSE frictionless motion with surface roughness <10 nanometer INTELLIGENT THERMAL MANAGEMENT STABILITY FOR SMOOTH PROCESSES All heat sources thermally and mechanically decoupled from the machine Water cooling of all drives, spindles, hydraulic system, air in work zone, the base frame, and the control cabinet Facts and Figures: Temperature constancy Advance flow: 0.1 K 04 05

4 ACCESSORIES AND SPECIAL OPTIONS DRIVE TECHNOLOGY POSITIONING STABILITY, DYNAMICS, AND PRECISION Double linear motor principle for improved dynamics and symmetrical force action Highest positioning accuracy Maintenance-free operation Virtually unlimited lifetime NO backlash, NO wear, NO stick-slip effect, NO run-in of axes Tilt-swivel axes with torque motors for highest dynamics and speeds High-resolution optical path measuring systems High-speed servo controller with superior control quality ADVANCED AND ULTRA FAST CONTROL POWER CONTROL SYSTEM Central and absolutely synchronous command of the main axes Centralized topology: excellent surface quality for open-die surfaces or 5-axis simultaneous flycutting High-performance real-time control Windows 7 and Kugler user interface KNC² Programming via Standard-G-Codes according to ISO 6983 and additional commands for special options Resistive 24 touchscreen and stainless steel keyboard Hand-held operating panel Suitable post processors for many CAD/CAM systems available ROBOT CHANGER FOR HSK-25 TOOLS 30 or 60 magazine positions for HSK25-E Allows operating several spindles Allows setting up the magazine at runtime COMPACT TOOL CHANGER FOR DIRECT-SHAFT SPINDLES 60 tools with shaft Ø 3 or 4 mm Ultra-compact SPINDLES Aerostatic and mechanical machining spindles for milling, grinding, drilling of steels (also hardened steels for mold making), NE-metals, plastics Tool clamping HSK-25 or direct clamping Air-bearing flycutting spindle for mirrors and grid structures (retro reflectors) Spindle growth compensation MICROMASTER 2-SPINDLE SYSTEM 2 TOOL CHANGERS Facts and Figures: Programming resolution Machining speed Program size Servo frequency 1 nm 10,000 NC-blocks/sec > 500 GB 20 khz 06 07

5 TOOL AND WORKPIECE MEASUREMENT Tool measurement system Measuring probe (mounted next to the spindle) or infrared measuring probe (to be fitted in HSK spindle) INTEGRATED MEASURING TECHNIQUES FOR WORKPIECE SETTING AND MEASUREMENT Camera system for process monitoring Tactile measuring caliper for coordinate measurement Fully integrated video microscope with easy image processing (measuring in the image) Confocal-chromatic optical sensor for distance measurements with nanometer resolution Laser light barrier for micro milling tool setting Ready-to-use measuring cycles for workpiece setting and measurement Full integration of measurement sensors in HMI-software, operation via user interface and G-Codes Confocal sensor 02 HSK Measuring caliper 03 Laser light barrier CLAMPING SYSTEMS COOLING/LUBRICATING SYSTEMS EXTRACTION SYSTEMS Chuck interfaces for easy and highly reproducible change of machine configuration Various vacuum chucks for workpiece clamping CNC-programmable thermo chuck (hot and cold) for clamping in wax or ice Minimum-dosage spraying Flooding lubrication with tempered container for maximum process stability Aerosol extraction system, with reverse flow cooling of the air for perfect temperature stability Extraction of machining debris (chips, vapors) ULTRA SONIC MACHINING High-performance ultrasonic tool Machining of steels in optical quality FAST TOOL SERVO FTS LASERS AND SCANNERS HYBRID MACHINING - COMBINATION OF MICRO MILLING AND LASER ABLATION Manifold laser sources by renowned manufacturers Laser retrofit possible 08 09

6 MICROMASTER MACHINING PROCESSES METHODS & APPLICATION EXAMPLES PATH CONTROLLED MICRO MILLING AND MICRO STRUCTURING PATH CONTROLLED MILLING WITH MICRO TOOLS AND 3 5 MOTION AXES MILLING FLYCUTTING TURNING RADIAL FLYCUTTING OF LINEAR AND CROSSED GRATINGS GENERATION OF LINEAR AND CROSSED GRATINGS BY RADIAL FLYCUTTING WITH MONOCRYSTALLINE DIAMOND FORM TOOLS MACHINING OF MOLD INSERTS WITH CROSSED GRATINGS FOR RETRO REFLECTORS PUNCHING COORDINATE GRINDING UTMOST FLEXIBILITY AND VERSATILITY IN R&D AND IN INDUSTRIAL APPLICATIONS Macroscopic precision component Fluidic mold insert with web structure Guidance for glass fiber bundles Miniature bending mirror Fluidic structure with micro channels EDM electrode Mold insert 10 11

7 MICRO MACHINING AND MICRO STRUCTURING BY CHIPPING Optical grating Micro-structured surfaces Die for fused silica gel casting made from PMMA 5-Axis diamond machined test piece, roughness Rq < 15 nanometer GENERATION OF STRUCTURES BY PLANING AND SHAPING WITH DIAMOND TOOLS High-aspect ratio tool insert for light forming element with diffractive structure MICROMASTER MACHINING PROCESSES METHODS & APPLICATION EXAMPLES 12 13

8 MACHINING EXAMPLE STEEL MASTER SYSTEM OPTICAL SURFACES IN HARDENED STEEL MOLDS FOR AUTOMOTIVE LIGHTING DIAMOND MACHINING OF STAVAX (1.2083, AISI 420) (52 HRC) ULTRASONIC DIAMOND MACHINING OF HARD AND BRITTLE MATERIALS ULTRASONIC DIAMOND TURNING OF TUNGSTEN CARBIDE WC MACHINING PARAMETERS AND RESULT FOR WC: MATERIAL WC500 (CO 0%) DIAMOND TOOL: R 1.0 MM SPINDLE SPEED: 12 RPM ROUGHNESS: RA = 3.61 NM Mold insert for mobile lense, Ø 1 mm MATERIAL WC500 (CO 12%) DIAMOND TOOL: R 1.0 MM SPINDLE SPEED: 12 RPM ROUGHNESS: RA: 1.7 NM EXAMPLES DIRECTLY MACHINED IN STEEL, RETROREFLECTOR, DIFFRACTIVE GRATING, CONVEX SPHERE Concave WC-mould insert for hot embossing of glass ULTRASONIC DIAMOND MACHINING OF SELECTED MOULD STEEL EXAMPLES FOR ULTRASONIC ASSISTED MACHINING OF MOULD INSERTS FROM STEEL ESU (52 HRC) INJECTION MOULDED INSERT WITH OVERLAY MICROSTRUCTURE VISUAL INSPECTION OF THE SURFACE STRUCTURE Stavax steel mirror Interference contrast image of the machining structure MOLD INSERT CONVENTIONAL MACHINING MOLD INSERT - ULTRASONIC ASSISTED DIAMOND MACHINING ON KUGLER MICROMASTER Aspheric base shape of the mould insert Material: Stavax , 52HRC Roughness Ra < 5 nm Superimposed microstructure JOINT RESEARCH PROJECT LEDO Light distribution of the LEDO headlight demonstrator lens (By courtesy of Automotive Lighting Reutlingen GmbH) 14 15

9 LASER MICRO MACHINING WITH FOCUSED ULTRA SHORT PULSE LASER BEAM MACHINING OF LAMP ELECTRODES WITH 2-AXIS GALVO SCANNER MICROMASTER HYBRID SYSTEM MICRO CHIPPING & LASER MICRO MACHINING HIGHEST ECONOMIC EFFICIENCY & UTMOST FLEXIBILITY THROUGH COMBINATION OF BOTH MACHINING PROCESSES IN ONE SYSTEM Flexible chip extraction (1) Rotary axis in A-position (2) 2-axis galvo scanner ARGES Racoon 16 (3) Confocal sensor of the optical measuring head (4) Machining of cavities and channels Micro structuring and texturing of surfaces MACHINING OF STENTS WITH USP LASER PROCESS PARAMETERS: Mean power USP-Laser: 20 W Wave length: λ = 532 nm (green) Pulse repetition rate: PRF ~1 MHz Focus diameter: ~20 μm Source: Internet, LZH 16 17

10 WHERE SMART PEOPLE CREATE SMART MACHINES EXPERIENCE & COMMITMENT TO OUR CUSTOMERS MADE IN GERMANY! KUGLER IS CERTIFIED ACC. TO ISO 9001:2008 KUGLER WORKS ROHS COMPLIANT TECHNOLOGY TRANSFER HIGH-GRADE ULTRA-PRECISION PRODUCTS ULTRA-PRECISION / MICRO JOB SHOP METROLOGY AND QUALITY ASSURANCE RESEARCH We have a passion for high-tech Kugler regularly participates in government and EC-funded research projects. The topics are principally in the field of precision engineering (ultra-precision machining, micro cutting, laser machining), process development and product engineering, metrology, mirror optics, optical systems and beam line components, and in laser technology. The engagement in joint research projects serves to promote the company s own technological development. Furthermore technology-leading machine tools and extensive application know-how offer our customers competitive advantages by providing superior solutions and concepts and cost-attractive applications in the micrometer and nanometer range

11 KUGLER GERMANY SINCE 1983 Heiligenberger Str Salem, Germany Fon Fax PRECISION IN A NEW DIMENSION PRECISION IN A NEW DIMENSION