Advantages of GMN high frequency spindles The development 4 Advantages of hybrid ceramic bearings 5

Transcription

1 Catalog 8/ Index Index Advantages of GMN high frequency spindles The development Advantages of hybrid ceramic bearings Design Bearing systems, Lubrication system - 7 Coolant through the shaft 8 Utility connections 9 - Typical installation schematic Spindle selection - Standard and Options - Technical data - Motor Describition characteristics - Drives Drive systems, Tachometer, Converter selection 7 - Accessories - Cable Tool interface Safety aspects Spindle nose and Grinding quill interface, Speed limitation - 9 Shrink fit tool holders - Short taper interface HSK style interface, Clamping system - Tool clamping systems Accessories Oil/air lubricator, Chillers - 9 Proper spindle selection Applications - Workpiece cooling Quality assurance Successful specific spindles

2 The Development Increase of power and torque Improvement of the axial and radial stiffness HV-X -/8 HSX -/ HV-X -/8 Radial stiffness Axial stiffness HSX -/ HS -/ HS -/ TSSV -/8 TSSV -/8, torque and stiffness have been constantly increased as the tables indicate. In addition, reliability, load carrying capacity and working life were also improved. The working life of HSX-spindles in comparison to the HS-spindles is on average times longer. Economical With the improvements of power, load carrying capacity and stiffness in the HV-X designs the working range of single spindles is extended over the previous models. These enhancements minimize the number of spindles required to cover a large speed range. The special motor design also permits the use of more economically sized frequency converters to match the application requirements. Selection The GMN product line covers a vast range of speeds, output powers, load capacities and options to meet or exceed all application requirements. Tradition GMN strives to provide it customers with the latest advances and technology in spindle design and concepts. With our "Customer First" mentality we will continue to manufacture our traditional style spindles, components and provide service and support for the older models and designs.

3 Advantages Of Hybrid Ceramic Bearings GMN high frequency spindles utilize hybrid ceramic ball bearings. These bearings have standard steel bearing races and are matched with silicon nitride balls. Advantages of hybrid bearings compared with normal spindle bearings are: Reduced wear The high degree of hardness of the balls, and the nongalling effect of the silicon nitride against metallic material lessens the wear. This is especially important in cases of minimal lubrication. In addition, wear particles will not embbed themselves into the balls to further damage the races. Rigidity Modulus of elasticity is greater than steel, which increases the static and dynamic stiffness. The increase in dynamic rigidity depends on the ratio of bearing preload to the centrifugal force on the balls. Friction Because of the reduced spin-rolls ratios and lower Hertian stresses, friction and respectively operating temperatures are reduced. Axial shaft movement As a result of the lightweight ceramic balls, centrifugal forces are reduced with a corresponding reduction in dynamic movement of bearing races. In addition, movements due to less friction and the lower coefficient of expansion of ceramics are reduced. Reliability of operation The low thermal coefficient of expansion of the ceramic balls lessens the reduction of the radial running fits in the bearings. These fits are less variable at higher temperature differentials between races. Vibrations Radial forces and the moments acting on the bearings produce displacement between the balls and the retainer. Hybrid bearings reduce this effect and produce a positive influence on cage vibrations and stresses. Accuracy High frequency spindles are fitted with bearings produced according to GMN standard grade UP. They are distinguished from international standards due to excellent running accuracy. Radial runout of assembled bearing inner ring. Limits in micron [µm] Bearing bore Tolerance class diameter [mm] P/ABEC 7 P/ABEC 9 UP > > > > > Assembled bearing outer ring face runout with raceway axial runout. Limits in micron [µm] Movement due to centrifugal forces Bearing outside Tolerance class diameter [mm] P/ABEC 7 P/ABEC 9 UP > > > > >

4 Bearing Systems Spring preloaded single bearings HS 8c - 8/. HS 8c - /. HS 8c - /. HS 8c - 9/ Spring preloaded bearing sets all other spindles > Short, rigid construction due to the high-frequency motor being placed between the bearing sets, results in favorable critical speeds, far exceeding the operating speed. > High stiffness and load carrying capacities. > Low vibration levels due to ultra precision bearings. > Minimal temperature variations due to liquid cooling of the motor and front bearings complement. > All mounting and critical datums are hardened and ground for longer service life. > Monitoring of motor temperature via temperature sensors.

5 Lubrication System Oil/air lubrication Lubrication drain Oil pump Oil line Oil/air distributor block Oil metering valve Air line Air metering valve Mixing chamber > High reliabilty in operation due to separate supply to each bearing group and exact quantity of volume. > Ecological compatibility because of minimum oil consumption and elimination of oil mist. > Long life and high load carrying capacity as a result of the use of oils with additives like EP and HT. > Large spectrum of applicable oils. Grease lubrication + air purge Air line 7

6 Coolant Through The Shaft (Option) Coolant through the shaft with gap seal (du) Coolant supply Coolant drain + spent oil > Maximum coolant pressure: bar > Can be operated dry > Horizontal spindle mounting > Withstands pressure pulses > Coolant filtration:. mm Coolant through the shaft with high pressure rotary union (dh) Coolant supply Coolant drain + spent oil > Maximum coolant pressure depends on the spindle type and seal design. Please consult GMN. > Minimum coolant pressure:. bar > Can be operated dry > Horizontall spindle mounting > Pressure pulsing must be avoided > Coolant filtration:. mm On request, horizontal spindle mounting for both options 8

7 HS - / HSX - / HV-X - Style -, Ø A -, View X HS X Oil/air supply Ø W Ø W Ø Ah Coolant inlet Coolant outlet Lubrication drainage straight "GA" style electrical connector ) View Y Y Option angled "GA" style electrical connector ) -, Ø A -, Option "Flange housing" ) Option "Air purge" ) View X Ø W Ø W HSX Ø Ah X Oil/air supply SE HV-X Coolant inlet Coolant outlet Lubrication drainage straight "GA" style electrical connector ) View X View Y View Y Y straight "MAC" style electrical connector ) Option "angled connector" ) with angled "GA" style electrical connector ) with angled "MAC" style electrical connector ) ) Design options see pages,. 9

8 HSP - / HV-P - / HSP..g - Style -, Ø A -, Option "Flange housing" ) Option "Air purge" ) View X SE Ø W HSP Ø Ah X Oil/air supply M 8 - / for vibration sensor both sides of flange HV-P Coolant inlet Coolant outlet Lubrication drainage straight "GA" style electrical connector ) View X View Y View Y Y straight "MAC" style electrical connector ) Option "angled connector" ) with angled "GA" style electrical connector ) with angled "MAC" style electrical connector ) -, Ø A -, Option "Flange housing" ) Air purge ) View X SE Ø W HSP..g Ø Ah X M 8 - / for vibration sensor both sides of flange Coolant inlet Coolant outlet straight "GA" style electrical connector ) View X View Y View Y Y straight "MAC" style electrical connector ) Option "angled connector" ) with angled "GA" style electrical connector ) with angled "MAC" style electrical connector ) ) Design options see pages,.

9 HS-T - Style -, Ø A -, Option "Flange housing" ) Option "Air purge" View X Oil/air supply Ø W Ø Ah X SE Coolant inlet Coolant outlet Lubrication drainage straight "GA" style electrical connector ) View Y Y Option angled "GA" style electrical connector ) ) Design options see page.

10 Typical Installation Schematic GMN-Spindle Drive / Converter Machine control M ~ L L L PE ( ) Converter ON Analogue input PTC C Motor temperature limit Ready Zero speed signal ON and demand speed reached Motor protection Fault indicator Speed or position feedback PTC C Temperature warning Air purge Air supply Oil/air lubrication M M M Cooling system Typical system setup. Actual performance will be spindle and convert dependant.

11 Features Designation Features Tool Voltage [V] Connector type interface c du dh DrS DrG WiS SpL Fla GA MAC SV HS-T 8 - /. T 7 x O - * - * O O O x - x - - HS-T - / T 7 x O - x - O O O x O * x - - HS-T - 9 / T 9 x O - x - O O O x O * x - - HS-T - 7 / T x O - x - O O O x O * x - - HS 8c - 8 /. D /8 x - - * - * - * O x - x - - HS 8c - /. D /8 x - - * - * - * O x - x - - HS 8c - /. D / x * - * - * - * O x - x - - HS 8c - 9 / D 8/ x * - * - * - * x O - x - - HSX 8 - /. D / x O - * - * O O O x - x - - HSX - / D 8/ x O - x - O O O x O * x - - HSX - 9 / D 9/ x O - x - O O O x O * x - - HSX - 7 / D /8 x O - x - O O O x O * x - - HSX - / D / x O - x - O O O x O * x - - HSX - / 7 D / x O - x * O O O x O * x - - HSX - / D /8 x O - x * O O O x + * x O - HSX - / D /8 x O - x * O O O x - * x O - HSX - / D 8/ x O - x * O O O x - * x O - HSX - / D /8 x O - x * O O O x + * - x - HSX - / D /8 x O - x * O O O x - * x O - HSX - / D / x - O x * O O O x - O - x - HSX - / D / x - O x * O O O x + * x O - HSX - / D / x - O x * O O O x - O - x - HSX - / 7 D / x - O x * O O O x + * x O - HSX - 8 / 7 D / x - O x * O O O x + * x O - HSX 7 - / D / x - O x * O O O x - O - x - HSX 7 - / D / x - O x * O O O x - O - x - HSX 7 - / D / x - O x * O O O x - O - x - HSX 7 - / D / x - O x * O O O x - O - x - HSX 7-8 / D /8 x - O x * O O O x - O - x - HSX 7-8 / D /8 x - O x * O O O x - O - x - x Standard c: Hybrid bearings DrS: Speed sensor O Option du: Coolant through shaft WiS: Angled connector * On request dh: High pressure rotary coolant union SpL: Air purge + On request, only with reduced output available DrG: Encoder Fla: Flange housing Colored styles indicate standard features and short delivery times.

12 Features Designation Features Tool Voltage [V] Connector type interface c du dh DrS WiS SpL Fla GA MAC SV HSP - / HSK-C x * - x O * O x O - x - - HSP - / HSK-C x * - x O * O x O - x - - HSP - / HSK-C x * - x O * O x O - x - - HSP - / HSK-C x * - x O * O x O - x - - HSP - / HSK-C x O - x O O O x - * x O - HSP - / HSK-C x O - x O O O x + * x O - HSP - / HSK-C x O - x O O O x - * x O - HSP - / HSK-C x O - x O O O x + * x O - HSP - / HSK-C x O - x O O O x - * x O - HSP - / 9 HSK-C x O - x O O O x + * x O - HSP - / HSK-C x O - x O O O x - * O x - HSP - / 9 HSK-C x O - x O O O x + * x O - HSP - / 8 HSK-C x - O x O O O x - O O x - HSP - / 9 HSK-C x - O x O O O x + * x O - HSP - / 8 HSK-C x - O x O O O x - O O x - HSP - / HSK-C x - O x O O O x + * x O - HSP 7 - / HSK-C x - O x O O O x - O - x - HSP 7 - / 9 HSK-C x - O x O O O x + * O x - HSP 7 - / HSK-C x - O x O O O x - O - x - HSP 7 - / 9 HSK-C x - O x O O O x - O O x - HSP 7-8 / 9 HSK-C x - O x O O O x - O - x - HSP 7-8 / HSK-C x - O x O O O x - O O x - HSP - 8 / HSK-C x - O x O O O x - O - - x HSP - 8 / 8 HSK-C x - O x O O O x - O - - x HSP - / HSK-C 8 x - O x O O O x - O - - x HSP - / HSK-C 8 x - O x O O O x - O - - x HSP - / HSK-C x - O x O O O x - O - - x HSP g - / HSK-C x - - x O x O x * - x - - HSP g - 7 / HSK-C x - - x O x O x * - x - - HSP g - / HSK-C x - - x O x O x * - x - - HSP g - / HSK-C x - - x O x O x * O x O - HSP g - / HSK-C x - - x O x O x * O x O - HSP g - / 9 HSK-C x - - x O x O x * O x O - HSP g - / 9 HSK-C x - - x O x O x - O x O - HSP g - 8 / 9 HSK-C x - O x O x O x - O x O - HSP g - / HSK-C x - O x O x O x - O x O - HSP 7g - 8 / 9 HSK-C x - O x O x O x - O - x - HSP 7g - / 9 HSK-C x - O x O x O x - O - x - HSP 7g - / HSK-C x - O x O x O x - O - x - HSP g - / 8 HSK-C x - O x O x O x - O - - x HSP g - / HSK-C 8 x - O x O x O x - O - - x HSP g - 8 / HSK-C x - O x O x O x - O - - x x Standard c: Hybrid bearings WiS: Angled connector O Option du: Coolant through shaft SpL: Air purge * On request dh: High pressure rotary coolant union Fla: Flange housing + On request, only with reduced output available DrS: Speed sensor

13 Features Designation Features Tool Voltage [V] Connector type interface c du dh DrS DrG WiS SpL Fla GA MAC SV HV-X - / D 9/ x O - x - O O O x O * x - - HV-X - 9 / D /8 x O - x - O O O x O * x - - HV-X - 7 / D / x O - x - O O O x O * x - - HV-X - / 9 D /8 x O - x - O O O x O * x - - HV-X - / 9 D /8 x O - x - O O O x O * x - - HV-X - / 9 D 8/ x O - x - O O O x O * x - - HV-X - 7 / 7 D / x O - x O O O O x O O x * - HV-X - / D /8 x O - x O O O O x + O x * - HV-X - / D /8 x O - x O O O O x O O x * - HV-X - / 8 D 8/ x O O x O O O O x + O x * - HV-X - / 8 D / x O O x O O O O x + O x * - HV-X - / D 8/ x * O x O O O O x - O - x O HV-X - / D 8/ x * O x O O O O x + O - x O HV-X - / 7 D / x * O x O O O O x - O - x O HV-X - / D / x * O x O O O O x + O - x O HV-P - / 9 HSK-C x * - x - O O O x O * x - - HV-P - / 9 HSK-C x * - x - O O O x O * x - - HV-P - / 9 HSK-C x * - x - O O O x O * x - - HV-P - / HSK-C x * - x O O O O x + O x * - HV-P - / HSK-C x * - x O O O O x O O x * - HV-P - / 8 HSK-C x * O x O O O O x + O x * - HV-P - / 8 HSK-C x * O x O O O O x + O x * - HV-P - / HSK-C x * O x O O O O x - O - x O HV-P - / HSK-C x * O x O O O O x + O - x O HV-P - / 7 HSK-C x * O x O O O O x - O - x O HV-P - / HSK-C x * O x O O O O x + O - x O x Standard c: Hybrid bearings DrS: Speed sensor O Option du: Coolant through shaft WiS: Angled connector * On request dh: High pressure rotary coolant union SpL: Air purge + On request, only with reduced output available DrG: Encoder Fla: Flange housing Colored styles indicate standard features and short delivery times.

14 HS - / HS-T - / HSX - / HSP - Style Designation Designation specifications Tool Tool Speed Bearing bore Static Output S-% interface interface max. stiffness at speed D [d] / [W] ) HSK n max W axial radial M S P S n T [d] ) [rpm] [mm] [N/µm] [Nm] [kw] [rpm] HS 8c - 8 /. D / HS 8c - /. D / HS 8c - /. D /.9. HS 8c - 9 / D 8/ HSX 8 - /. D / HS-T 8 - /. T 7.9. HSX - / D 8/ HS-T - / T 7 9. HSX - 9 / D 9/ HS-T - 9 / T HSX - 7 / D /8 HS-T - 7 / T HSX - / D /.8 HSP - / HSK-C 77. HSP - / HSK-C 77. HSP - / HSK-C 9 8. HSP - / HSK-C 9 8. HSX - / 7 D / 7. 7 HSX - / D /8 HSP - / HSK-C 7.8 HSX - / D /8 HSP - / HSK-C 9.8 HSX - / D 8/ HSP - / HSK-C HSP - / HSK-C HSP - / HSK-C HSP - / 9 HSK-C HSX - / D /8 HSP - / HSK-C HSX - / D / HSX - / D / HSP - / 8 HSK-C HSX - / D / 77. HSX - / D / HSP - / 8 HSK-C 9. 8 HSX - / 7 D / HSP - / HSK-C HSX - 8 / 7 D / HSP - / 9 HSK-C HSP - / 9 HSK-C 77. HSX 7 - / D / HSP 7 - / HSK-C. HSX 7 - / D / HSP 7 - / 9 HSK-C. 9 HSX 7 - / D / HSP 7 - / HSK-C. HSX 7 - / D / HSP 7 - / 9 HSK-C. 9 HSX 7-8 / D /8 HSP 7-8 / 9 HSK-C HSX 7-8 / D /8 HSP 7-8 / HSK-C ) See table page. ) See table page. ) For different voltages, see page,.

15 HS - / HS-T - / HSX - / HSP - Style specifications Designation Designation Continuous power S Voltage at frequency Current Tool Tool interface interface from...up to from...up to n n U ) n f K f max I S I S HSK D [d] / [W] [Nm] [kw] [rpm] [rpm] [V] [Hz] [Hz] [A] [A] T [d]. HS 8c -8 /.. HS 8c - /.. HS 8c - /. HS 8c - 9 / T 7 HS-T 8 - /. HSX 8 - /,..7 7, T 7 HS-T - / D 8/ HSX - / , T 9 HS-T - 9 / D 9/ HSX - 9 /. 7, T HS-T - 7 / D /8 HSX - 7 /., D / HSX - /. 7 8 HSK-C HSP - /. 8 7 HSK-C HSP - /. 8 HSK-C HSP - /. 8 HSK-C HSP - / 8 D / HSX - / HSK-C HSP - / D /8 HSX - /. 8 HSK-C HSP - / D /8 HSX - / HSK-C HSP - / D 8/ HSX - / HSK-C HSP - /. 8 7 HSK-C HSP - / HSK-C HSP - / HSK-C HSP - / D /8 HSX - / D /8 HSX - / HSK-C HSP - / 8 D / HSX - / 9.9 D / HSX - / HSK-C HSP - / 8 D / HSX - / HSK-C HSP - / D / HSX - / D / HSX - 8 / HSK-C HSP - / HSK-C HSP - / HSK-C HSP 7 - / D / HSX 7 - / HSK-C HSP 7 - / 9 D / HSX 7 - / HSK-C HSP 7 - / D / HSX 7 - / HSK-C HSP 7 - / 9 D / HSX 7 - / HSK-C HSP 7-8 / 9 D /8 HSX 7-8 /. 7 8 HSK-C HSP 7-8 / D /8 HSX 7-8 / 7

16 HSP - / HSP..g - Style Designation Designation specifications Oil/air Permanent Tool Bearing bore Static Output S-% lubrication grease interface stiffness lubrication at speed n max n max HSK W axial radial M S P S n [rpm] [rpm] [mm] [N/µm] [Nm] [kw] [rpm] HSP - / HSK-C 77. HSP - / HSP g - / HSK-C 77. HSP - / HSK-C 9 8. HSP - / HSP g - 7 / 7 HSK-C 9 8. HSP g - / HSK-C 9 8. HSP - / HSK-C 7.8 HSP - / HSP g - / HSK-C HSP - / HSK-C 9.8 HSP - / HSP g - / HSK-C HSP - / HSK-C HSP - / 9 HSP g - / 9 HSK-C HSP - / HSK-C HSP - / 9 HSP g - / 9 HSK-C HSP - / 8 HSK-C HSP - / 9 HSP g - 8 / 9 8 HSK-C 77. HSP - / 8 HSK-C 9. 8 HSP - / HSP g - / HSK-C HSP 7 - / HSK-C. HSP 7 - / 9 HSK-C. 9 HSP 7 - / HSK-C. HSP 7 - / 9 HSK-C. 9 HSP 7-8 / 9 8 HSK-C HSP 7-8 / 8 HSK-C HSP 7g - 8 / 9 8 HSK-C HSP 7g - / 9 HSK-C HSP 7g - / HSK-C HSP - 8 / 8 HSK-C HSP - 8 / 8 8 HSP g - / 8 HSK-C HSP - / HSK-C HSP - / HSP g - / HSK-C HSP - / HSP g - 8 / 8 HSK-C 7 ) For different voltages, see page. 8

17 HSP - / HSP..g - Style specifications Designation Designation Continuous power S Voltage V ) at frequency Current Tool interface from...up to from...up to Oil/air Grease Oil/air Grease n n n f K f max f max I S I S HSK [Nm] [kw] [rpm] [rpm] [rpm] [Hz] [Hz] [Hz] [A] [A]. 7 8 HSK-C HSP - /. 8 7 HSK-C HSP g - / HSP - /. 8 HSK-C HSP - / HSK-C HSP g - 7 / HSP - /. 7 HSK-C HSP g - /. 7 8 HSK-C HSP - / HSK-C HSP g - / HSP - /. 8 HSK-C HSP - / HSK-C HSP g - / HSP - / HSK-C HSP - / HSK-C HSP g - / 9 HSP - / HSK-C HSP - / HSK-C HSP g - / 9 HSP - / HSK-C HSP - / HSK-C HSP g - 8 / 9 HSP - / HSK-C HSP - / HSK-C HSP g - / HSP - /. 8 8 HSK-C HSP 7 - / HSK-C HSP 7 - / HSK-C HSP 7 - / HSK-C HSP 7 - / HSK-C HSP 7-8 / HSK-C HSP 7-8 / HSK-C HSP 7g - 8 / HSK-C HSP 7g - / HSK-C HSP 7g - / HSK-C HSP - 8 / HSK-C HSP g - / 8 HSP - 8 / HSK-C 8 HSP - / HSK-C 8 HSP g - / HSP - / HSK-C HSP g - 8 / HSP - / 9

18 HV-X - / HV-P - Style Designation Designation specifications Tool Tool Speed Bearing bore Static Output S-% interface interface max. stiffness at speed D [d] / [W] ) HSK n max W axial radial M S P S n [rpm] [mm] [N/µm] [Nm] [kw] [rpm] HV-X - / D 9/ 7. HV-X - 9 / D / HV-X - 7 / D / 7. 7 HV-X - / 9 D /8 HV-P - / 9 HSK-C HV-X - / 9 D /8 HV-P - / 9 HSK-C HV-X - / 9 D 8/ HV-P - / 9 HSK-C HV-X - 7 / 7 D / HV-X - / D /8 HV-P - / HSK-C HV-X - / D /8 HV-P - / HSK-C HV-X - / 8 D 8/ HV-P - / 8 HSK-C HV-X - / 8 D / HV-P - / 8 HSK-C HV-X - / D 8/ HV-P - / HSK-C 9. HV-X - / D 8/ HV-P - / HSK-C 9. HV-X - / 7 D / HV-P - / 7 HSK-C HV-X - / D / HV-P - / HSK-C 97. ) See table page. ) For different voltages, see page.

19 HV-X - / HV-P - Style specifications Designation Designation Continuous power S Voltage at frequency Current Tool Tool interface interface from...up to from...up to n n U ) n f K f max I S I S HSK D [d] / [W] [Nm] [kw] [rpm] [rpm] [V] [Hz] [Hz] [A] [A] D 9/ HV-X - / D /8 HV-X - 9 /. 7. D / HV-X - 7 / HSK-C HV-P - / 9 D /8 HV-X - / HSK-C HV-P - / 9 D /8 HV-X - / HSK-C HV-P - / 9 D 8/ HV-X - / D / HV-X - 7 / 7. 8 HSK-C HV-P - / D /8 HV-X - /. 8. HSK-C HV-P - / D /8 HV-X - /.8 9 HSK-C HV-P - / 8 D 8/ HV-X - / HSK-C HV-P - / 8 D / HV-X - / HSK-C HV-P - / D 8/ HV-X - / HSK-C HV-P - / D 8/ HV-X - / HSK-C HV-P - / 7 D / HV-X - / HSK-C HV-P - / D / HV-X - /

20 Chip removal processes are defined by the material being processed, tool sizes and recommended cutting speeds. Small diameter tooling requires high speeds, while large diameter cutters need high torque at lower speeds. The "field weakening" characteristics offer high torque at low speeds and are also capable of high spindle speeds utilizing the same spindle. Therefore the spindles can be operated with smaller converters at different levels. The capacity of the converter determines the power profile. The output power of the motor is produced via the converter being programmed to the proper volts/frequency [v/f] ratio specified in the instruction manual or test report of spindle. Operation with reduced output power up to various speeds Drehzahl / Speed n I Drehzahl / Speed n II Rigidity required for the volume of material to be removed and also provide a quality finish, this demands larger shaft diameters, thereby spindles become, which allows for longer and more powerful motors. Because of progress in the development of motors, the power density has been increased to such an extent that, in many cases, the power which can be produced from these proportions is not need for processing. On the other hand, oversized systems cause increase costs because of the size of the frequency converter which are required. Costs of frequency converters can be reduced by accepting the decreased output power and possibly lower frequency. Operation mode S and S-% Operation mode S Nominal power No-load Operation mode S-% maximaler sbereich maximum power range Nominal power No-load 8 sec 7 sec Total time = minutes reduzierter sbereich reduced power range Drehzahl / Speed

21 Characteristics.... HS 8c - 8/. HS 8c - 8/.. P S-%.... M S-% HS 8c - /. HS 8c - /.. 9 P S-% M S-% HS 8c - /. HS 8c - /.. 9 P S-%.8... M S-% HS 8c - 9/ HS 8c - 9/. 7 9 P S-% M S-% ,.. HSX 8 - /. HS-T 8 - /. HSX 8 - /. HS-T 8 - /.. P S-% 9,8... M S-% 9

22 Characteristics...8 HSX - / HS-T - / P S-%... HSX - / HS-T - / M S-% HSX - 9/ HS-T - 9/ P S-% HSX - 9/ HS-T - 9/....8 M S-% HSX - 7/ HS-T - 7/ P S-%.8.. HSX - 7/ HS-T - 7/ M S-%. 7 7 HSX - / P S-%.8.. M S-% HSX - /. HSP - / HSP - / P S-%.. M S-%

23 Characteristics HSP - / HSP - / P S-%. M S-%. HSP - / P S-%.. M S-% HSP - / HSP - / HSP - / P S-%. M S-%. 7 HSX - /7 P S-%.. M S-% HSX - /7 8 HSX - / HSP - / P S-% HSX - / HSP - / M S-%

24 Characteristics 8 HSX - / HSP - / P S-% HSX - / HSP - / M S-% 8 HSX - / HSP - / P S-% HSX - / HSP - / 7 M S-% 8 HSP - / HSP - / P S-% M S-% 8 HSP - / HSP - / P S-% M S-% 8 HSP - /9 P S-% 7 M S-% HSP - /9

25 Characteristics HSX - / HSP - / P S-% 8 HSX - / HSP - / M S-% 8 HSX - / P S-% M S-% HSX - / HSX - / HSP - /8 HSX - / HSP - /8 P S-% 8 M S-% HSX - / P S-% 8 HSX - / M S-% 8 HSX - / HSP - /8 HSX - / HSP - /8 P S-% 9 M S-% 7

26 Characteristics 8 9 HSX - /7 HSP - / P S-% HSX - /7 HSP - / M S-% HSX - 8/7 P S-% 9 M S-% HSX - 8/7 8 HSP - /9 P S-% M S-% HSP - /9 8 HSP - /9 P S-% 8 HSP - /9 M S-% HSX 7 - / HSP 7 - / P S-% HSX 7 - / HSP 7 - / M S-% 8

27 Characteristics HSX 7 - / HSP 7 - /9 HSX 7 - / HSP 7 - /9 P S-% M S-% HSX 7 - / HSP 7 - / P S-% HSX 7 - / HSP 7 - / M S-% HSX 7 - / HSP 7 - /9 HSX 7 - / HSP 7 - /9 P S-% M S-% HSX 7-8/ HSP 7-8/9 P S-% HSX 7-8/ HSP 7-8/9 M S-% HSX 7-8/ HSP 7-8/ P S-% HSX 7-8/ HSP 7-8/ M S-% 9

28 Characteristics HSP - 8/ P S-% 7 M S-% HSP - 8/ HSP - 8/8 P S-% 9 8 HSP - 8/8 7 M S-% 9 8 HSP - / P S-% 8 M S-% HSP - / 9 9 HSP - / P S-% 8 M S-% HSP - / 9 9 HSP - / P S-% M S-% HSP - / 9

29 Characteristics.... HSP g - / P S-% HSP g - /. M S-% P S-%... M S-% HSP g - 7/ HSP g - / P S-%.. M S-% HSP g - / HSP g - / P S-%....8 M S-% HSP g - / 7 HSP g - / P S-%....8 M S-% HSP g - / 8 8

30 Characteristics HSP g - /9 P S-% 7 7 HSP g - /9 M S-% 7 9 HSP g - /9 HSP g - /9 P S-% M S-% HSP g - 8/9 HSP g - 8/9 P S-% M S-% HSP g - / P S-% M S-% 9 HSP g - / 8 HSP 7g - 8/9 P S-% HSP 7g - 8/9 M S-%

31 Characteristics 8 HSP 7g - /9 P S-% 8 9 HSP 7g - /9 M S-% 9 9 HSP 7g - / P S-% M S-% HSP 7g - / HSP g - /8 P S-% 7 M S-% HSP g - / HSP g - / P S-% 8 M S-% HSP g - / HSP g - 8/ P S-% M S-% HSP g - 8/ 8

32 Characteristics HV-X - /.7. P S-% HV-X - /. M S-% HV-X - 9/ P S-%....8 M S-% HV-X - 9/ HV-X - 7/.8 HV-X - 7/ P S-%.. M S-% HV-X - /9 HV-P - /9 P S-%...8 M S-% HV-X - /9 HV-P - /9 P S-%..8.. HV-X - /9 HV-P - /9 M S-%

33 Characteristics HV-X - /9 HV-P - /9 9 P S-% HV-X - /9 HV-P - /9 M S-%..7 7 HV-X - 7/7 P S-% HV-X - 7/7 M S-% 7 8 HV-X - / HV-P - / P S-% HV-X - / HV-P - / M S-% 8 HV-X - / HV-P - / P S-%... HV-X - / HV-P - / M S-% 8 9 HV-X - /8 HV-P - /8 P S-% HV-X - /8 HV-P - /8 M S-%

34 Characteristics 8 9 HV-X - /8 HV-P - /8 P S-% 7.. HV-X - /8 HV-P - /8 M S-%. HV-X - / HV-P - / HV-X - / HV-P - / P S-% M S-% 8 8 HV-X - / HV-P - / HV-X - / HV-P - / P S-% 8 M S-% 8 HV-X - /7 HV-P - /7 HV-X - /7 HV-P - /7 8 P S-% 9 M S-% HV-X - / HV-P - / HV-X - / HV-P - / 8 8 P S-% M S-% 8 9

35 Drive Systems For High Frequency Motors Frequency converter with Volts/Hertz characteristics Motor M S Speed sensor leads Signal leads Signal controller section Digital display Programmable keypad > Output frequency's to Hertz ) > Operating range : > Acceleration/deceleration times within seconds > Motor temperature monitoring > Multiple spindle operation > Option card for monitoring exact shaft speed and "Zero speed" > Option card for "Gap elimination" and "Load monitoring" Signal "Zero speed" Signal "Programmed speed atained" P M Actual speed n Typical power torque curve in relation to speed. Vector control without encoder feedback Motor M S Speed sensor leads Signal leads Signal controller Signal "Zero speed" Drive modul with control system Digital display Programmable keypad > Output frequency's to Hertz ) > Operating range : speed regulation approximately.% > Vector controlled speed drive > Acceleration/deceleration within second Signal "Programmed speed atained" P M Actual speed n Typical power torque curve in relation to speed. Vector control with encoder feedback Motor M S Encoder leads Signal leads Drive modul with control system > Output frequency's to Hz ) > Shaft orientation > Acceleration/deceleration within second Digital display Programmable keypad P M n Typical power torque curve in relation to speed. Full motor torque over the entire speed range without speed fluctuation. 7 ) Depending on the inverter producer some different maxium output frequency's are possible.

36 Tachometer TA For automatized processing equipment an active signalling system is required, signalling when the processing spindle has stopped, e. g. for changing tools or protective functions. For this purpose a speed sensor in the spindle is required and an amplifier for signal analysis.,8 8 8,7 Gasket Voltage selector Track B V Dimensions in mm NAMUR without explosion protection Without interface Interface RS 8 Supply voltage A (Count) Signal inputs B (Count) Control inputs Batch counter with scailing factor Tachometer with limits and scailing Interface RS 8 Output P Output P Sensor supply TA. AX With relay Electronic outputs Voltage / 8 VAC Voltage / VAC Voltage... VDC Block diagram Model Contact Function T,R+ T,R- V +V RS 8 Encoder supply P P Output max. V Terminal - Terminal / Control inputs Fuse B A Signal inputs Supply - Terminal Supply voltage Supply voltage Output P Output P Output P Output P 7 Signal input A (Count) 8 Signal input B (Count) 9 Control input (Tacho) Control input (Programming disabled) Control input (Batch counter Reset) Encoder supply +... V Encoder supply V Option RS 8 (T,R-) Option RS 8 (T;R+) Assignment 8

37 Tachometer TA Display Digit size Display of measuring unit Display of switching outputs P, P 7-segment LCD-display (TN) with background light On two lines Display of tachometer display: 7 mm Display of limit value: mm /min /s /h Illustration as normally open or normally closed Supply voltage As ordered consumption VA, W Encoder supply... VDC, ma Counting rate - Tachometer Hz or khz Counting rate - Batch counter Hz, Hz, khz Data storage > years (via EEPROM) Fixing Clamping frame Front measures 8 x 8 mm, casing for front plate installation Mounting depth mm Connections Two plug-in screw terminals With poles (grid,8 mm) and with 9 poles (grid,8 mm) Core cross-section Max., mm Casing material Makrolon 8 Keypad Short-stroke keys and front membrane Front membrane Polyester membrane Weight AC-model: g DC-model: g Ambient temperature... + C Storage temperature C Humidity Max. relative humidity 8%, non-condensing Protection according to DIN From the front, in built-in state with seal IP Operational requirements According to contamination factor General rating EN Protection category Overvoltage category According to EN Protection category II According to EN Protection category II Interference immunity According to EN 8- Severity grade - Emitted interference According to EN 8- Technical data 9

38 Converter Frequency converters with Volts/Hertz Type Frequency Current output Dimensions [mm] Mains ) f max I ) max I S-% I S ( / Hz) Built-in device IP Cabinet IP [Hz] [A] [A] [A] B H T B H T RS. AC V (±%) KT 7.. AC... 7 ), 8V. 9 (-%/+%) ) ) The maximum output voltage of the inverter is limited by the input voltage. ) Max. s. ) With dynamic braking mm higher. Available options which are also spindle dependant. Gap eliminator* Dynamic braking Digital display Speed controller All applicable electrical standards and codes together with manufacturers recommendations and instructions must be adhered to. All converters supplied by GMN are programmed and interfaced to the applicable spindle. * Integrated at RS.

39 Converter - Selection table Designation Designation Frequency converter V/f - characteristics vector control K RS RD ) RD ) VHF.. with encoder ) without encoder with encoder ) HSX 8 - / HSX - / HSX - 9 / HSX - 7 / HSX - / HSP - / HSP - / HSP - / HSP - / HSX - / HSX - / HSP - / HSX - / HSP - / HSX - / HSP - / HSP - / HSP - / --- HSP - / HSX - / HSP - / --- HSX - / --- HSX - / HSP - / HSX - / HSX - / HSP - / HSX - / 7 HSP - / --- HSX - 8 / 7 HSP - / HSP - / HSX 7 - / HSP 7 - / HSX 7 - / HSP 7 - / HSX 7 - / HSP 7 - / HSX 7 - / HSP 7 - / HSX 7-8 / HSP 7-8 / HSX 7-8 / HSP 7-8 / HSP - 8 / HSP - 8 / 8 HSP - / HSP - / HSP - / ) Line reactors are required between spindle and converter if line lengths are longer then meters and frequency exceed Hertz. ) Only for spindles with encoder.

40 Converter - Selection table Designation Frequency converter V/f - characteristics vector control K RS RD ) RD ) VHF.. with encoder ) without encoder with encoder ) HS 8c -8 / HS 8c - / HS 8c - / HS 8c - 9 / HS-T 8 - / HS-T - / HS-T - 9 / HS-T - 7 / HSP g - / HSP g - 7 / HSP g - / HSP g - / --- HSP g - / --- HSP g - / HSP g - / HSP g - 8 / 9 HSP g - / HSP 7g - 8 / HSP 7g - / HSP 7g - / HSP g - / HSP g - / HSP g - 8 / ) Line reactors are required between spindle and converter if line lengths are longer then meters and frequency exceed Hertz. ) Only for spindles with encoder.

41 Converter - Selection table Designation Designation Frequency converter V/f - characteristics vector control K RS RD ) RD ) VHF.. with encoder ) without encoder ) HV-X - / HV-X - 9 / HV-X - 7 / HV-X - / 9 HV-P - / HV-X - / 9 HV-P - / HV-X - / 9 HV-P - / HV-X - 7 / HV-X - / HV-P - / HV-X - / HV-P - / 8 8 HV-X - / 8 HV-P - / HV-X - / 8 HV-P - / HV-X - / HV-P - / HV-X - / HV-P - / HV-X - / 7 HV-P - / HV-X - / HV-P - / ) Line reactors are required between spindle and converter if line length are longer then meters and frequency exceed Hertz. ) Only for spindles with encoder.

42 Cables We can supply properly sized electrical power cables for connecting the spindle to the frequency inverter. Shield of solder-coated wires Filler Copper strands, bright SAK C SAK... 8 STK Type For nominal leads Monitoring leads current [A] SAK 8 8 Copper strands x. mm, shielded x ( x. mm ), shielded SAK Copper strands x. mm, shielded x ( x. mm ), shielded SAK Copper strands x mm, shielded x ( x. mm ), shielded SAK Copper strands x mm, shielded x ( x. mm ), shielded SAK C Copper strands x mm, shielded x ( x. mm ), shielded SAK Copper strands x mm, shielded x ( x. mm ), shielded SAK 8 8 Copper strands x mm, shielded x ( x. mm ), shielded STK x. mm, shielded Type Sheating Min. bend radius Min. bend radius stat. [mm] dyn. [mm] SAK 8 Isolation TPE/PUR, AD.9 mm Colour black SAK Isolation TPE/PUR, AD 8.7 mm 9 Colour orange SAK Isolation TPE/PUR, AD. mm Colour orange SAK Isolation TPE/PUR, AD mm 8 Colour orange SAK C Isolation PTPE/PUR, AD mm 8 Colour yellow SAK Isolation TPE/PUR, AD mm 8 Colour orange SAK 8 Isolatrion TPE/PUR, AD mm Colour orange STK Isolation spezial PVC, AD. mm abrasion proof, resists oil and gasoline In order to obtain the legal electromagnetic compatibility the cable length has to be limited. The applicable recommendations have to be met during designing and setting into operation.

43 Safety Aspects For Tool Selection Unbalanced state Every spindle shaft and every tool incorporates a degree of unbalance,which causes sinuous vibration during rotation. To reduce the effect of unbalancing forces, the unbalancing mass of all rotating parts has to be limited. Shafts of GMN high frequency spindles are always balanced. As a result of higher cutting speeds this process is also required for tools. We recommend for precision cutting a permissible residual unbalance for tools according to the following diagram: We recommend consulting our application engineering staff when tools which are extremely long and heavy are to be used. Let GMN analyses your spindle and tooling requirements with our specifically designed computer software. In addition to the critical frequencies the static and dynamic stiffness and load carrying capacity of each single bearing can be calculated. Through proper analysis the correct spindle can be selected or tips for improvement of tools can be made. Permissible residual unbalance [gmm] 8 7 Grease lubricated spindles Oil/air lubricated spindles Operating speed [rpm] GMN Calculation program WINSPI Critical speed GMN high frequency spindles are designed so that the critical speeds remain above the maximum speed. When using inappropriate tooling the critical speed can be decreased to a level within the operating speed range. This can lead to poor part quality, decreased spindle performance, as well as jeopardizing the safety of the operator and machine. Centrifugal forces acting on tools Centrifugal forces created by high rotating speed not only act as unbalancing forces but also induce stress into the tool. Especially inserted tooth milling cutter are very dangerous. When the attachment fails, indexable inserts can fly away like projectiles. Vibration level Vibration level max. spindle speed Spindle without tool max. operating speed Speed. critical speed Spindle with oversized tool. critical speed Vibration monitoring Vibration monitoring equipment can lessen the risk of damage to both the spindle and machine, and also help prevent personnel injury by early detection of wear and looseness in both the spindle and tooling. wendet werden. When selecting and installing monitoring equipment it should be noted that vibration from the machine and related components must be filtered out or ignored, so as to prevent unnecessary shut down of the machine. Speed

44 Cutting Speed Spindle type Spindle nose Surface speeds at maximum spindle speed [m/s] ) Identification Ho SW HSX - /... 7 D 8/ HS 8c - 9 / HV-X - /... 7 D 9/ HSX - 9 / HV-X - 9 / D /8 8 HSX - 7 / HV-X - 7 / D / 8 HV-X - 7 / HSX - / HSX - / HV-X - / D /8 HV-X - / HSX - / HV-X - / D /8 HSX - / HSX - / HV-X - / D 8/ 8 HV-X - / HV-X - / HSX - / HV-X - / D / 8 HSX - / HSX 7 - / HV-X - / D / HSX - / HSX 7 - / HSX - 8 / HSX 7-8 / D /8 Wheel dimensions E 8 8 [mm] F G 8 Quill - Ø [mm] K 8 Wheel mount KI KI PS PS PS PS PS MU MU MU MU MU see type Close-fit hole d 8 attachment [mm] M M M M M8 M L 7 9 L 8 7 Quill stiffness [N/µm] Grinding quill diameter K [mm] 8 Grinding quill length H [mm] ) Please note: Speeds may be limited due to the critical frequency of the spindle/quill system. Selection code: Example: Grinding quill [Quill-Ø K] x [Quill length H] [Spindle nose identification] [Wheel mount] Grinding quill x D /8 PS Close-fit screw [Thread M] - [Wheel width F] Close-fit screw M- Clamping chuck [Key-bolt-Ø] x [Clamping length] [Spindle nose identification] Clamping chuck x D 8/

45 Spindle Nose And Grinding Quill Interface GMN Spindle nose - Standard design Designation d W M L L [mm] Toleranz [mm] [mm] [mm] Ø W Ø d L Ø M L D / M (x.7) 8 +. D / +. M (x ) 9 +. D 8/ 8 +. M8 (x.) +. D 9/ 9 +. M9 (x.) +. D / M (x.) 9 +. D / +.7 M x D / M x D / M x +. D / +.7 M x +. D 8/ M8 x +. D / +.8 M x +. D / +.8 M x +. D / M x +. GMN Clamping chuck Ø S Ø K o Ø S T SW SW L Ø d L L M M Ø W Spindle nose Chuck D [d] / [W] K x T L [mm] S [mm] S [mm] SW SW D / x D 8/ x D 9/ x x 8 8 D /8 x 8 D / x 8 Grinding wheel attachment (Examples) Type : Cemented wheel (KI) Type : Close-fit-screw quill (PS) Type : Quill-threaded mounted points (PS) Ø G Ø K SW Ø d H Ø E M Ø d Ø G Ø K SW Ø W M Ø d Ø E Ø G SW Ø W Ø E M Ø W Ø K Ø d F H L L Ho F H Ho L L F H Ho L L Type : Quill with nut (MU) Ø G SW Ø E M Ø K Ø d Close-fit hole for type and Ø W L L F H Ho L L 7

46 Speed Limitation For Spindles With Grinding Quill Maximum speed [rpm] Spindle nose identification: D 8/ H [mm] Spindle type K [mm] < HSX - /... and 8 9 HS 8c - 9/... and Spindle nose identification: D 9/ H [mm] Spindle type K [mm] < HV-X - /... and HSX - 9/... and Spindle nose identification: D /8 H [mm] Spindle type K [mm] < HV-X - 9/ HSX - 7/ Spindle nose identification: D / H [mm] Spindle type K [mm] < HV-X - 7/ HV-X - 7/ HSX - / HSX - / Spindle nose identification: D /8 H [mm] Spindle type K [mm] < HV-X - /... 8 HV-X - / HSX - /... 8 Spindle nose identification: D /8 H [mm] Spindle type K [mm] < 8 HV-X - /... HSX - /... and 8 8

47 Speed Limitation For Spindles With Grinding Quill Maximum speed [rpm] Spindle nose identification: D /8 H [mm] Spindle type K [mm] < 8 HSX - /... and Spindle nose identification: D 8/ H [mm] Spindle type K [mm] < 8 HV-X - /... and HV-X - /... and 8 HSX - /... and 9 HV-X - /... Spindle nose identification: D / H [mm] Spindle type K [mm] < 8 HSX 7 - /... and 8 HSX - /... and 7 8 HV-X - /... and 8 Spindle nose identification: D / H [mm] Spindle type K [mm] < 8 HV-X - /... and 7 8 HSX 7 - /... and 7 HSX - /... and 8 HSX - 8/... and Spindle nose identification: D /8 H [mm] Spindle type K [mm] < 8 HSX 7-8/ and

48 Shrink Fit Tool Holders High speed machining requires tooling which is rigid, accurate, balanced and also economical. Shrink fit type tool holder systems have been used successfully in high production machining centers applications with HSK and Milling Machine Tapers. As a result of proven advantages of the shrink fit method, GMN has developed a manual change style holder design. Clamping method There are several heat shrinking systems available. The most economical for the manual type tool holders is the HOT AIR method. Dimensions Tungsten carbide Prad Ø Ø 7, Ø W Ø d M Step # Applying heat to the tool holder which is mounted in an adapter 9 L H L L Spindle type HS 8c-8 /, HS 8c- /, L L L d W M [mm] [mm] [mm] [mm] [mm] [mm] 8 M Step # Inserting the tool into the heated holder HS 8c- /,, M HSX - / HS 8c- 9 / 8 M8 HSX - 9 / 7 9 M9 HSX 8- /, HSX - 7 / 8 8 M HSX - / 9 8 M x, HSX - / 7 Step # Cool down period Ordering information: Shrink fit holder d / W x Ex. HSX -7/: d () / W (8) x. The indicates the clamping diameter. The standard and smallest clamping diameter is mm. Larger diameters are available upon request. Step # Remove tool holder from adapter

49 Shrink Fit Tool Holders Tungsten carbide mounted abrasive points Tungsten carbide milling cutters Application restrictions Ø h The proper operation of a spindle is determined by effects of tooling lengths, weights, and geometry. The positive qualities of the shrink fit holders and tungsten carbide tooling described in this section are not to be construed as declaration for all applications. GMN is pleased to offer our analytical services to determine the proper selection for spindles and tooling. The use of tungsten carbide tools is economical due to the cylindrical form and rigid because of the high modulus of elasticity. max. speed [rpm] 8 N quill length H [mm],8 µm, µm, µm, µm µm The diagram illustrates the calculated stiffness model for a typical spindle shaft with a mounted abrasive point show in Blue. Using shrink fit mounted tungsten carbide tool shanks, and applying a radial load of N at the end of the tool, the calculated deflection is. µm, if the tool were made of standard tool steel and mounted in a collet chuck the deflection would be.8 µm. Another advantage of use of carbide significantly lowers the natural frequency of the system. Combining tungsten carbide tools with shrink fit style holders is a technically superior/low cost solution for attaining the critical attributes required ib high speed machining. radial rigidity [N/µm] 8 7 quill length H [mm]

50 Short Taper Interface Short taper interface Ø Q Ø d Ø K max Direct quill interface Collet clamping method Quills and grinding wheel attachments (examples) Taper : Ø P Quill with threaded mounted wheel mandrel H L Grinding quill, solid Material: steel or tungsten carbide Cemented or glued on wheel Grinding quill () piece construction Tungsten carbide pin mated to steel pilot Cemented or glued on wheel Tungsten carbide Steel Designation d L P H Q K max [mm] [mm] [mm] [mm] [mm] [mm] T T T

51 HSK Style Interface "Hollow tapered shanks with flat contact surfaces" are standard per DIN 989. The different "FORM'S" of a particular size are based on a similar shank size (d) dimension. The tool flange is dictated by the mode of tool change. HSP/HV-P style spindles allow the use of tools with short hollow shanks, type "A" and "C". Form "C" was developed specially for manual tool changing systems. Form "A" is distinguished by the "V" groove provided for automatic tool changing systems. Form "A" can also be used with the manual tool change system provided in the HSP/HV-P style spindles. This reduces the need for additional tool holders if automatic tool changing systems are already in place. Tools according to Form B, D, E and F cannot be used in the HSP/HV-P style spindles, they are designed for different applications. HSK Form C according to DIN 9 89 d I b I 9 d d Form A I f I I Nominal size Taper-Ø d d Taper length I I I I I9 b f = d [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] ) ) During the development of this catalog style HSK was not yet a DIN Standard.

52 Clamping System Hollow taper shanks with flat contact surface Driving slots Access hole in the shaft Drive dogs in shaft Access hole in the hollow shank Drive slots in the hollow shank Advantages: > High static and dynamic rigidity > High tool change accuracy and repeatability > Low axial movement during speed variations > Increased pull-in force as speed raise > High torque transmission > Reduced hazard due to internal drive dogs The frictional contact between the tool shank and shaft face provides excellent torque transmission. The internal drive dogs provide additional holding power to keep the access holes aigned in the shaft and tool when overloaded. Manual actuating Hollow shank and axial plane surface Air gap Fitting position F A F S F R Clamping position The claws of the gripper assembly are actuated outward, when the radially positioned differential threaded rods are actuated, and force component F A axially into the tool holder, thus pulling the tool holder shank against the shaft face, and pressing the tapered portion of the shank to it's elastic limits against the shaft's internal taper via component F R. The manual system is designed so that during installation a gap exist between the shank face and the shaft. The required rigidity is produced through the stress against the taper and axial surfaces generated by the force of the clamping system.

53 Tools Shrink fitted tool shank Hydraulic expansion chuck Shrink fitted type holders for cylindrical tool shanks are similar to monolithic holders: > high radial rigidity > high runout accuracy > high transferable torque > high repeatability during tool change A preheater is required. Hydraulic expansion chucks offer high runout accuracy. Tools can be replaced quickly. A device for exchange is not necessary. Reduction bushings allow smaller shank diameters to be clamped, this can effect the run out. The oil cell across the tool shank leads to vibration damping and improves the surface quality. Fine boring tool Collet chuck Reversible carbide tipped inserts must be positively locked or the strain caused by the centrifugal forces at high speeds, on the screws alone can lead to vibration and shearing. For safety reasons the permitted peripheral speed must be analyzed and maintained. Asymmetry causes unbalance. To avoid inadmissible vibrations tools have to be balanced to an acceptable degree. Collet chucks are an economical alternative for light duty machining at low speeds, with low accuracy requirements. Special designs are required for high speed machining. Collet chucks are readily available and require a minimal effort to change shank sizes.

54 Oil/air Lubricator PRELUB Safe start due to pre-lubricating The unit is designed for the optimised supply of lubricant to GMN spindles. The () lubricating points allow for the connection of one, two or three spindles. The pre-lubricating cycle guarantees a safe start during machine start-up. The seperate monitoring of the oil level assures trouble free completion of the operation. The supply lines can be laid so that they rise or drop. The line length has to be between... m. The units > PRELUB MV - lubricating point connections > PRELUB MV - lubricating point connections > PRELUB MV - lubricating point connections are with integrated oil/air mixing distributor. The oil/air mixing distributor for PRELUB style MV has to be ordered seperately. The mixing distributor can be mounted in up to max. m away the unit. Refer to the spindle operating instruction manual or test certificate for oil quality, cycle times and pressures. Equipment > Air/filter regulator ( µm) with air gauge > Interface with the machine tool control system to signal readiness for operation after checking - oil level - oil pressure and oil release pressure - air pressure - pre-lubricating cycle > Timer for matching cycle time to oil viscosity and spindle data > Lubricating point connections for PVC tubing, O.D mm > Operating voltage V, / Hz Option V, / Hz > Air supply G /" p min = bar, p max = bar > supply and monitoring via connector > Installed in control cabinet 8 x 8 x mm (W x H x D) Enclosure IP > Colour: RAL 7 (grey) > Fuse protection for V: A; V: A Oil/air mixing distributor Air inlet valve Pump Control unit Pump motor Air/filter regulator 8 Air G/" X X SERVICE H H RESET Oil Outlets oil/air Ø closed in version MV Outlets air Ø in version MV, closed in other versions 8 Outlet oil Ø in version MV, closed in other versions Door hinge side

55 Oil/air Lubricator PRELUB Oil/air mixing distributor ( outlets) Diagram of pre-lubrication ~ ~ Ø 7 Oil G/8'' Pre-lubrication cycle Switch on > Switch on the oil/air lubricator Normal cycle > Carrying out the pre-lubrication cycle before the enable signal to the spindle is given for operating: - several lubricating pulses within a short time (pre-lubrication cycle) - transition to the normal cycle, that means cycle time as during spindle operation > The spindle is enabled after the pre-lubrication cycle time is finished (depends on the length of the line) Control of the air pressure Enabled Ø Lubricating line to spindle 7 Air G/'' Air flow restrictor The reliability and reliability of operation of the oil/air lubricator PRELUB has been confirmed for many years in a lot of applications. Nevertheless manometric switches can be mounted additional in the lubricating lines on customer's requirements. The evaluation is made directly by the machine control. Accessories Required accessories for the installation and commissing such as tubing, pressure gauge and filtered lubricating oil are available. Maintenance Compressed air and lubricating oil must be pre-filtered as describe in the operating instruction manual. Replacement filter cartridges are available for both filter elements. 7

56 Chillers GMN high frequency spindles utilize the most powerful motors available for their size. The current draw through the windings causes extreme temperature rises, which are limited by the insulation. In order to obtain peak performance the heat must be dissipated. We can provide the proper size self contained units for removing the motor and bearing heat losses. > The units operate with FCKW free refrigerant R7c > Coolant temperature C... C Style T > Control hysteresis Style T: ± K, Style F: ± K > Option: for control of axial shaft growth temperature can be controlled to Style T: ±. K, Style F: ±. K > Acceptable ambient temperature + C... + C > From C per K will result in a % loss in output capacity > Option: single supply units for multi spindle applications > Fluid level monitoring, flow switch and fault indicator for protecting spindles > Colour: grey according to RAL 7 ) > A rust inhibitor must be added to the cooling solution Style F Cooling capacity ) Type Tank capacity Supply Dimensions [kw] S-% S [l] voltage ) L x B x H [mm] K.9-T ).9. x V, Hz x x ). x V, Hz 7 x x 8 K.-T ). 8 x V, Hz 7 x x K.-F ). 7 9 x V, Hz 7 x 7 x 7 K.-F ). 7 9 x V, Hz 7 x 7 x 7 K.7-F ).7 9 x V, Hz 7 x 7 x 7 K 7.9-F ) 7.9 x V, Hz 7 x 7 x 7 K.-T for spindle power [kw] ) Permanently adjusted to C. ) Fault indicator includes additional high and low pressure monitoring. ) At max. C ambient temperature. ) Different voltages and frequencies on request. ) Different RAL colours on request. 8

57 Chillers Condenser Fan Drier M Pressure indicator HD ND Flow meter Thermal expansion valve M Cooling pump Spindle Coolant circulation: > The recirculating pump in the chiller moves coolant from the reservoir to the spindle back to the tank. > The coolant absorbs heat as it passes through the spindle. > The coolant returns to the chiller and passes through the evaporator/heat exchanger where heat is absorbed from the coolant into the refrigerant. > The "refrigerated" coolant then returns to the reservoir. Compressor M Level indicator Eva porator Water reservoir Temperature controller Refrigerant circulation: > Cool refrigerant gas is pumped out of the evaporator/ heat exchanger by the compressor and compressed into a high temperature, high pressure gas and delivered to the condenser. > In the condenser the gas condenses into a liquid as it dissipates heat to the air being blown across the condenser fins. > The cooled, high-pressure liquid refrigerant then passes through the expansion valve to the low-pressure side of the evaporator. The refrigerant absorbs heat from the coolant passing through the evaporator as it changes from a liquid to a gas. Parallel connection: > Multiple spindles operating from a single chiller unit. > Spindles of different sizes, cooling and flow requirements should be connected in parallel. > It is important to select the correct chiller with sufficient cooling and flow capacity for all the spindles being used. > Individual flow monitoring units are required for each cooling loop. Series connection: > Multiple spindles operating from a single chiller unit. > Spindles of the same sizes, cooling and flow requirements should be connected in series. > Do not plump more than two () spindles in series. > A single flow monitoring unit is required for a series setup and mounted at the end of the run. Please contact GMN for assistance in choosing the proper sized chiller unit. 9

58 Typical Applications Grinding raceway in ball bearing outer race, v ~ 8 m/s Grinding or precision hard milling ball raceway in socket end of universal joint Grinding bore in ball bearing inner race, v 8 m/s ~ Grinding roller raceways in double-row needle bearing, v m/s ~ Grinding bore with small internal taper, v m/s ~ Grinding bore and bottom face with coolant supply through shaft, v ~ m/s alternative through precision hard milling Quill-threaded mounted points Grinding bore and conical seating in fuel injector, v m/s ~ Grinding bore in collet chuck, v m/s ~

59 Applications And Processes Standard values for precision milling Material Cutting material Cutting speed Feed rate Surface finish vc [m/min] fz [mm] RzDIN [µm] Cold work tool steel CBN heat-treated, HRC Hot work tool steel, HRC Cermet tensile strength 8 N/mm Nodular graphite iron CBN heat-treated, HRC 8 Turbine blades steel Tungsten carbide,.... tensile strength N/mm coated St 7 Tungsten carbide,.... tensile strength 9 N/mm coated Gray cast iron, alloyed Tungsten carbide,.... coated Standard values for drilling into solid material Material Cutting material Cutting speed Feed rate Form error vc [m/min] fz [mm] EKF [µm] Turbine blades steel Tungsten carbide, tensile strength N/mm coated ) Heat-treatable steel Tungsten carbide,. tensile strength 8 N/mm coated ) Gray cast iron, alloyed Tungsten carbide,.... tensile strength N/mm coated ) ) Coolant through tool. Standard values for boring Material Cutting material Cutting speed Feed rate Form error vc [m/min] f [mm/u] EKF [µm] Turbine blades steel Cermet ) tensile strength N/mm Heat-treatable steel Cermet ) tensile strength 8 N/mm Gray cast iron, alloyed Cermet ) tensile strength N/mm ) Initial condition rough-finished, with supported tool, with coolant. Main source for the data: "Hochpräzisionszerspanen mit geometrisch bestimmter Schneide, FQS-Schrift 9-, Beuth-Verlag GmbH"

60 Applications And Processes Turn-milling Process variations Turn-milling describes a method or processing a rotating workpiece via a rotating tool with geometrical determined cuts, e.g. milling cutter. Advantages > high cutting speed when operating next to the rotating axis of the workpieces > low forces of gravity while manufacturing unbalanced parts because of low rotational velocity of the workpiece perpendicular > perfect chip breaking due to interrupted cut Specific attributes for process > improved surface quality because of large differential relationship of speed between tool and workpiece turned groove > improved surface quality because of controlled overlapping of cut traces parallel to the axis without overlapping of cut traces times overlapping of cut traces Richtwerte Standard values für das for Drehfräsen turn-milling Material Cutting material Cutting speed Feed rate Depth of cut vc [m/min] fz [mm/u] ae [mm] Ball and roller bearing steel, CBN ) hardened, HRC Heat-treatable steel P )...7. HRC Austenitic steell P with TiN 7... X CrNi 8 9 medium temperature- CVD-coating ) ) Cooling/lubricating: dry ) Cooling/lubricating: oil mist

61 Proper Spindle Selection Flowchart for selecting the optimum spindle Symbols and values Operation tooling Material of workpiece Cutting speed a) feed per tooth b) cutting width c) cutting depth Tool a) material b) diameter c) number of teeth Maschine max. feed rate ap vc. n = d. ae ae [mm] Cutting width vf = fz. n. z ap [mm] Cutting depth d [mm] Tool diameter fz [mm] Feed rate per tooth z Number of teeth vf machine vf calculated no vf machine n = fz. z ja d.. n vc = n [/min] Spindle speed vf [mm/min] Feed rate vc [m/min] Cutting speed Pc [kw] Effective power Q [cm/min] Volume of material K [cm /kw min] Spec. material removal rate ae. ap. vf Q = Q Pc = K Selection of spindle after determining n and Pc Notice: Effective power as high as required, rigidity as high as feasible. Standard values for K Structural steels... Alloy steels...8 Cast iron... Casting steel... Aluminium alloy...7

62 Workpiece Cooling Dry machining Advantages: > no cost for coolant > no swarf contamination low costs for disposal > slight expenditure for sealing machine and spindle > environmently compatible Disadvantages: > lower tool life > reduced rate of metal removal > surface finish quality Liquid cooling/lubrication Advantages: > higher surface finish quality > size control > long tool life > large rate of metal removal Disadvantages: > costly machine sealing > high costs for chip disposal and used coolant Spray cooling/lubrication Advantages versus dry machining: > improved tool life and surface finish quality > increased rate of metal removal > feasible surface protection of workpiece Disadvantages versus dry machining: > costly spindle sealing Disadvantages versus liquid cooling/lubrication: > more difficult chip removal

63 Quality Assurance Test certificate Operating instructions The record supplied with every GMN spindle contains actual data about axial and radial rigidity, vibration values, power and temperature. Other measurement conditions and limiting values differing from the GMN test standard can be accommodated. Operating instructions are available in English and German. They are also obtainable in other languages on request. Training,, Gauging distance Courses with theoretical and practical content for using GMN spindles and fittings and carrying out repair work are offered. Initial operation Size HSK HSK HSK HSK HSK Test bar Gauging distance mm mm 8 mm mm mm Spindles and spindle systems can be commissioned by GMN technical personnel on request; outside Germany, this may be carried out by our authorised service companies. It is a prerequisite that the spindle is correctly installed using correct meterials, fluids and initial start-up preparation.,, Test bar, Gauging distance Repair service We recommend that the spindles are repaired by us or our authorized repair shops. The GMN spindle repair service offers cost-effective, rapid and professional work. We also have the necessary special equipment, such as balancing instruments, vibration and rigidity measuring instruments and devices for assembly and dismantling. Gauging distance: x face hole diameter, max. mm Radial rigidity Axial rigidity

64 Successful Specific Spindles TSE 8cg - / n max rpm P (S) kw at rpm M (S),9 Nm Tool interface: face clamping and draw thread Speed sensor Permanently grease lubricated Hybrid ceramic bearings Integrated automatic balancing system TSE g - / n max rpm P (S) kw at rpm M (S) 8, Nm Tool interface: taper on both sides Encoder for closed-loop drive ~ V SS, cycles/rev. Permanently grease lubricated HSP s - / n max rpm P (S) kw at rpm M (S) 8 Nm Tool interface: HSK-C 8 Speed sensor External cooling TSE cg - /.7 n max rpm P (S),7 kw at rpm M (S) Nm Tool interface: face clamping and draw thread Permanently grease lubricated Hybrid ceramic bearings