MILL X 400 / 400 U 600 / 600 U / 800

Transcription

1 GF Machining Solutions Mikron MILL X 400 / 400 U 600 / 600 U / 800

2 GF Machining Solutions : all about you When all you need is everything, it s good to know that there is one company that you can count on to deliver complete solutions and services. From worldclass electrical discharge machines (EDM), Laser texturing and Additive Manufacturing through to firstclass Milling and Spindles, Tooling, Automation and software systems all backed by unrivalled customer service and support we, through our AgieCharmilles, Microlution, Mikron Mill, Liechti, StepTec and System 3R technologies, help you raise your game and increase your competitive edge. Passion for Precision 2 Mikron MILL X

3 Content Market segments and applications 4 Technology and Solutions 6 Complex parts in perfection 8 smart machine 10 Accuracy 12 Hightech motor Spindles 14 Tool magazine 15 Table variants, Tooling and Automation 18 Interface for Automation 20 Chip and mist management 22 Customer Services 23 Postprocessing 3D printed metal parts 24 Technical data 26 GF Machining Solutions 30 Since the beginning of highspeed Milling (HSM), GF Machining Solutions has pioneered the development of this technology. The Mikron MILL X series is the result of this continuous development, bringing together the utmost features that make it the reference solution within the industry. The Mikron MILL X solutions are 3 and 5Axis extreme highspeed Milling solutions for manufacturers of small, precise and complex light parts. From automotive and ICT to medtech, aerospace, machinery and other segments, these solutions serve manufacturers looking for the highest productivity for in their production of small to midsize series of highly accurate complex parts. The machines deliver not only unbeaten machining speed and integrated Automation capabilities; they also allow very quick machine setup in a wide variety of applications and materials, and deliver parts in an unequaled finished state. 3 Mikron MILL X

4 Market segments and applications 3 and 5Axis applications ICT Automotive 4 Mikron MILL X

5 Medical Aerospace General mechanics 5 Mikron MILL X

6 Technology Highspeed Milling (HSM): productive precision and quality for your production + Productivity + Dynamic accuracy at fastest processing speed + Fast setup change for flexible production + Sustainable quality in splitbatch production Part production with highest productivity and quality 6 Mikron MILL X

7 Solutions We have the right solution for you Master the challenges of a wide range of applications and short termmarket requirements Go from blank to finished part on the smallest footprint, thanks to a flexible 5Axis machine and produce your part on one machine in a single clamping + Integrated or thirdparty Automation in smallest footprint + Unrivaled accessibility with or without Automation + Reliable process due to sophisticated thermal management system + Best damping characteristics due to mineral cast machine base + Direct linear and rotating drives for highest dynamic process + smart machine for precision, protection, time and saving energy + Remote line assistance + StepTec Spindle + Heidenhain control 7 Mikron MILL X

8 Complex parts in perfection React fast, drive fast and win the race Flexibility + 24/7 flexible production + Always be able to answer customers shortnotice requests + Change from batch production to express job within minutes Productivity + Fastest 5Axis HSM precision solution + Ideal machine design with automated 5Axis machining creates competitive advantages + Reliable system for 24/7 production Fulfill market demands at any time just in time Go from order to finished part just fast 8 Mikron MILL X

9 Generate profit around the clock within limited production time Best practice Manned production 08 h Express jobs Challenging parts Setup new jobs 17 h Batch production Long running parts Less challenging parts Unmanned production Profitability + Complete machining in one setup + Optimal productivity with minimal manpower + Highest autonomous productivity on smallest footprint + Sustainable precision and surface quality + Generate valueadded profit 24/7 Solution smart machine Machine Tuning Options Competitive cost per part just better Automation Tooling 9 Mikron MILL X

10 smart machine Enhance your process beyond program and machine setup This includes a range of modules that are collectively referred to under the generic term smart machine and that fulfill various functions. In order to make the Milling process intelligent, various requirements have to be implemented. 1 st is establishing comprehensive communication between man and machine, which makes available precise information that the operator requires to assess the Milling process. 2 nd is supporting the operator in the optimization of the process, which considerably improves the performance. 3 rd is the machine optimizing the Milling process, which improves process safety and workpiece quality especially important in unmanned operation. smart machine construction kit system Each of the modules fulfills a specific task. Just like in a construction kit, the user can selects the modules that seem to him to be the best option for improving his process. The facts + Greater accuracy in shorter machining times + Increase in the workpiece surface quality as well as the surface and shape accuracy + Recognition of critical machining strategies + Improved process safety + Higher availability + Better operating comfort + Considerable increase in reliability in unmanned operation Produce your workpieces in a processsecure and precise manner Increase reliability in unmanned operation Boost the service life of the machine Significantly reduce production costs Precision ITC, ITM, OSS support the precise base of your machining center to reach an even more precise final part for your customers. Protection PFP or APS protect and extend the lifetime of your machine and tools. Time OSS and APS and software tools such as rconnect boost your productivity. OSS extreme yields up to 24 percent more speed with improved surface finish and accuracy. Saving energy Econowatt, saving up to 50 percent energy, is a ecological necessity with attractive economic advantages. 10 Mikron MILL X

11 Simply better results with the smart machine OSS Surface quality APS situation. Advanced Process System React adequately to the given Spindle vibration monitoring system. Accuracy Time Operator Support System The intelligent system adjusts the dynamic behavior exactly as necessary for the workpiece. rconnect is the central communication platform for rconnect GF Machining Solutions. rconnect ITC Intelligent Thermal Control With ITC the machine has thermal process knowledge. Automatic recalibration. Econowatt Saving energy: an ecological necessity and an economic advantage. Econowatt Intelligent Tool Measurement require reliable and precise Highprecision parts tool monitoring. Power Fail Protection Protects against power failures Job Tool Manager Software for easy management and operation of various jobs. ITM and voltage drops. Safety through a controlled process. JTM PFP 11 Mikron MILL X

12 Accuracy HSM core components Static accuracy Perfect machine design with highest mechanical requirements provides the basis for a highprecision machine. Moreover, GF Machining Solutions spares no effort to implement stateoftheart components to create the best package for your Milling applications. Comprehensive and reliable Milling solution for light material parts produciton as a result of machine design, core components and complete process knowhow 12 Mikron MILL X

13 Dynamic accuracy Stability, highest dynamic drives and ingenious software are primary prerequisites for maximum productivity and best workpiece quality. + Concrete polymer with high thermal inertia and excellent damping properties + Optimized force distribution within castings + Highprecision direct drives and guides for high dynamics and rigidity + Direct path measuring system in the linear and rotative axis + Intelligent software compensation Thermal accuracy The Mikron MILL X series leads precision machining into a new era. Its sophisticated temperature management system comprises separate and independent cooling circuits of all heat sources and machine body as follows: + X, Y, Z, B, Cdrives + Machine body (Ambient Robust) + Spindle with OptiCool or CoolCore technology + Electronics cabinet Highest productive precision is the ultimate result of this solution. Active temperature stabilization enables highest stability and process reliability. 13 Mikron MILL X

14 Hightech motor Spindles HSM core components from StepTec Your reliable and stable Milling process is secured, thanks to an ingenious temperature control system 24,000 min 1 HSKA63 30,000 min 1 HSKE40 OptiCool 36,000 min 1 HSKE50 OptiCool 42,000 min 1 HSKE40 OptiCool 42,000 min 1 HSKE40 CoolCore 60,000 min 1 HSKE32 OptiCool Mikron MILL X Mikron MILL X 400 U Mikron MILL X Mikron MILL X 600 U Mikron MILL X OptiCool HPC 170 / 24,000 min 1 StepTec s OptiCool Spindle series ensures not only that the Spindle remains thermally stable, but that natural heat transfer to the Spindle support (e.g., ZAxis) is limited to the lowest amount possible, in order to preserve the machine s geometry. + Best polar thermal balance around the surface contacting the machine support + Ultra highprecision ceramic hybrid bearings + Heat barrier + Frontal cooling + Highest precision due to optimized thermal balance of the entire machining head + Satisfies the toughest requirements in surface finish, repeatability and reliability Stator cooling circuit StepTec s versatile Spindle for mold and part production. + Versatile Spindle for use in both mold making and production + High chip volume due to large HSKA63 tool interface + Good surface finish in mold making + Great rigidity for machining lightweight material (impeller) with long tools + Full vibration control (V3D) to maximize the feed rate + Constant power up to maximum speed Spindle power POWER (kw) ; ; 22 S6 40% ED ts=2min S Cutting conditions monitoring + Vibration monitoring along each Axis + Temperature monitoring of hot spots (bearings, motor, ambient temperature) Spindle torque TORQUE (Nm) ; ; 22.2 SPEED (1/min) S6 40% ED ts=2min S SPEED (1/min) 14 Mikron MILL X

15 Tool magazine Individual solutions tailored to your production needs Tool Automation in every configuration level + Simple, doublerow disc magazine or ATC + Reliable pickup changing system + Feed control via light beam + Orientation of the touch probe Userfriendly tool feeding Productivity and process reliability are ensured by lateral tool feeding + Simultaneous machining and feeding + Simple feed monitoring through large glass panel + Ergonomic access Optionally available in a variety of capacities: Automatic Tool Changer Mikron MILL X 400 Mikron MILL X 400 U HSKE40: 18, 36, 68, 168, 308 tools HSKE32: 20, 40 tools Mikron MILL X 600 Mikron MILL X 600 U Mikron MILL X 800 HSKE50: 15, 30, 60, 120, 170, 220 tools HSKE40: 18, 36, 68, 168, 308 tools HSKA63: 30, 48, 120, 170, 220 tools 15 Mikron MILL X

16 Productivity with pinpoint accuracy 16 Mikron MILL X

17 17 Mikron MILL X

18 Table variants, Tooling and Automation As flexible as needed System 3R MacroMagnum Ø 156 mm System 3R GPS 240 x 240 mm System 3R Dynafix 280 x 280 mm System 3R Dynafix 350 x 350 mm GF Mikron OEM 600 x 600 mm Machine work area X, Y, Z: 500 x 240 x 360 mm Mikron MILL X 400 U 25 kg 18x Machine work area X, Y, Z: 500 x 450 x 360 mm Mikron MILL X kg 10x 7x 7x Machine work area X, Y, Z: 800 x 600 x 500 mm Mikron MILL X 600 U 120 kg 10x 7x 7x Machine work area X, Y, Z: 600/800x600x500 mm Mikron MILL X 600 Mikron MILL X kg 800 kg 4x Mikron MILL X 600 Mikron MILL X kg 1000 kg Table 900 x 600 mm 18 Mikron MILL X

19 Increase your productivity by reducing your setup time with a zeropoint clamping system Increase your quality by improving repeatability with Tooling and Automation Easy loading and unloading of pallet magazine during the machining process Mikron MILL X 400 / 400 U: disctype magazine GF Mikron OEM 800 x 600 mm Erowa ITS Ø 148 mm Erowa UPC 320 x 320 mm 20x Mikron MILL X 600 U: disctype magazine 7x 7x Mikron MILL X 600 / 800: lineartype magazine 4x 19 Mikron MILL X

20 Interface for Automation Customerspecific solutions From the pallet magazine to the robot system GF Machining Solutions has developed a fully integrated pallet magazine as a standard product. With a standardized robot interface, the Mikron MILL X series can be operated with wellknown suppliers robot systems. More parts in less time at lower costs No matter what type of handling system is used, the accessibility of the machine remains outstanding. Together with the modular tool magazines, the compact Milling center becomes a highly productive and flexible production cell including in conjunction with other machines. A complete cell, configured for you 20 Mikron MILL X

21 Solutions for you 21 Mikron MILL X

22 Chip and mist management Clean machining Adapted chip and mist management The form and volume of the chips are determined by the machined material as well as the processing strategy. Whatever your production process, a wide selection of options is available to ensure proper chip evacuation. Liftup chip conveyor with band filter system + Solution for aluminum Milling chips. With slat band liftup chip conveyor and coolant filtration unit + Solution for steel Milling chips with scraper liftup chip conveyor and coolant filtration unit Optimum chip clearance due to steep, smooth cabin walls. Washer jets prevent chip accumulation. Depending on machine equipment and processing strategy, 450 and 950liter filter systems are available. + Coolant tank with chip flushing system + Chip auger + Liftup scraper type conveyor + Liftup slat band chip conveyor + 450liter band and basket filter system + 950liter band filter system + Wash down system Automation door is also washed down. Chip conveyor Already implemented requests + Air/cooling lubricant through Spindle + Additional chip flushing on the Spindle Cooling lubricant/air through Spindle 22 Mikron MILL X

23 Customer Services rconnect: Live Remote Assistance rconnect comprises GF Machining Solutions modular digital services. You stay connected with your machine park, at any time and wherever you are. Select the digital service that best fits your individual needs. Our Live Remote Assistance (LRA) supports you in keeping your commitments. Maximize your uptime Live Remote Assistance provides you direct access to our expert service engineers with the latest technology. The LRA features audio, video, chat, whiteboard, file transfer, system access and screen sharing by using a Windows tablet or your standard PC. Increase your flexibility Know the status of your machines in real time at any location. The rconnect Cockpit is the user interface for your machine operator, maintenance technician or operations manager. It provides the operator with support for daily machinerelated activities. Secure connection based on the latest technology To ensure your security, an encrypted pointtopoint connection is established between your machine and GF Machining Solutions only at your request. Our remote service product is certified with the TÜViT Trusted Product Certificate. Certified by TÜViT Trusted Product 23 Mikron MILL X

24 Postprocessing 3D printed metal parts Technologies combination as a goal Freedom of design Additive Manufacturing Perfect surface Highspeed cutting (HSC) Milling / highspeed part production Additive Manufacturing (AM) is a hot industrial topic as applications are numerous and promising and initiatives are multiplying all over the world. GF Machining Solutions has embraced AM as a leading technology providing new opportunities for its customers, and understands how it complements traditional technologies. Combining AM and for example a Mikron MILL X Milling machine is the most efficient option if you want to build parts with a perfect surface finish. The future is in complete solutions combining performant technologies in an efficient way, and GF Machining Solutions is your partner on the path to the future. And just as we have pioneered the Automation of traditional machining technologies we are blazing a path for AM Automation. Revolutionize your manufacturing process Decrease your lead time Complete freedom of design 24 Mikron MILL X

25 Your most efficient option 25 Mikron MILL X

26 Technical data Machine Mikron MILL X 400 Mikron MILL X 400 U Workarea Longitudinal X mm Lateral Y mm Vertical Z mm Swivelling axis º Rotary axis º /110 n x 360 Feed rate Rapid traverse X, Y m/min Rapid traverse Z m/min Rapid traverse (swivel) rpm Rapid traverse (rotary) rpm Working spindle (40% ED, S6) 60,000 rpm, HSKE32 kw / Nm 42,000 rpm, HSKE40 kw / Nm 30,000 rpm, HSKE40 kw / Nm 8.5 / / / / / / 8.8 Work table Table Pallet/clamping surface Pallet/clamping surface Pallet/clamping surface Max. table load mm mm mm mm kg Dynafix 280x280/350x350 GPS 240 x 240 UPC 320 x MacroMagnum 156 ITS Tool magazine HSKE32 HSKE40 tool holder tool holder 20/40 18 / 36 / 68 / 168 / /40 18 / 36 / 68 / 168 / 308 Automation Pallet size / Number Pallet size / Number Maximum additional load Piece Piece kg GPS 240 / 10x Dynafix/UPC / 7x 90 MacroMagnum 156 / 18x ITS 148 / 20x 25 Weight Machine Pallet magazine kg kg 6, , Control unit Heidenhain itnc 530 HSCI itnc 530 HSCI 26 Mikron MILL X

27 Machine Mikron MILL X 600 Mikron MILL X 600 U Mikron MILL X 800 Workarea Longitudinal X mm Lateral Y mm Vertical Z mm Swivelling axis º Rotary axis º /110 n x Feed rate Rapid traverse X, Y m / min Rapid traverse Z m / min Rapid traverse (swivel) rpm Rapid traverse (rotary) rpm Working spindle (40% ED, S6) 42,000 rpm, HSKE40 kw / Nm 36,000 rpm, HSKE50 kw / Nm 30,000 rpm, HSKE40 kw / Nm 24,000 rpm, HSKA63 kw / Nm 13.5 / / / / / / / / / / / / 28 Work table Table Pallet/clamping surface Pallet/clamping surface Pallet/clamping surface Max table load mm mm mm mm kg 900 x /800 x Dynafix 280x280/350x350 GPS 240 x 240 UPC 320 x x /800 x 600 1,000 Tool magazine HSKE40 HSKE50 HSKA63 tool holder tool holder tool holder 18 / 36 / 68 / 168 / /30/60/120/170/ / 48 / 120 / 170 / / 36 / 68 / 168 / /30/60/120/170/ / 48 / 120 / 170 / / 36 / 68 / 168 / /30/60/120/170/ / 48 / 120 / 170 / 220 Automation Pallet size / Number Pallet size / Number Maximum additional load Piece Piece kg 600 x 600 / 4x 800 x 600 / 4x 500 GPS 240 / 10x Dynafix/UPC / 7x x 600 / 4x 800 x 600 / 4x 800 Weight Machine Pallet magazine kg kg 9, , ,900 1,800 Control unit Heidenhain itnc 530 HSCI itnc 530 HSCI itnc 530 HSCI 27 Mikron MILL X

28 Mikron MILL X 400 / 400 U Machine 2. Mist extraction unit 3. Liftup chip conveyor (scraper and slatband types) 6. Cooling unit 7. CoolCore cooling unit 8. Endless belt filter system (950 liters) 9. Band filter system (950 liters) 10. Basket filter system (450 liters) 11. Band filter system (450 liters) 12. Endless belt filter system (450 liters) 13. Coolant thermal control 14. CO² fire extinguishing system 16. Pressurerelief damper Mikron MILL X 600 / 600 U / Mikron MILL X

29 Productivity for you 29 Mikron MILL X

30 GF Machining Solutions EDM (electrical discharge machining) AgieCharmilles wirecutting, diesinking and holedrilling machines For over 60 years we have been at the forefront of every EDM development: designing and refining the EDM process and building machine tools that deliver peerless part accuracies, surface finishes, cutting speeds and process reliability. Today, our AgieCharmilles wirecutting, diesinking and holedrilling machines are recognized throughout the world as the best in the business. Our continuous research and development in digital generator technology, control systems and integrated Automation systems are evidence of our commitment to keeping your EDM operations on the leading edge of technology. Milling Mikron highspeed (HSM), highperformance (HPM) and highefficiency (HEM) Milling centers Customers operating in the mold, tool and die and precision component manufacturing sectors stake their reputations on being able to quickly and costcompetitively meet their customers demands. That s why they invest in GF Mikron machines. Incorporating the latest and most advanced technologies and premiumperformance components, Mikron HSM, HPM and HEM machines help you increase your production capabilities and improve your productivity. Designed and built for speed, accuracy and reliability, the machines, like you, are proven performers. Laser AgieCharmilles Laser texturing machines Laser texturing is a fullydigitized surface engineering process that has huge potential. The technology enables precise 2D and 3D textures or engravings to be machined accurately and directly onto complex parts or molds to improve and alter their aesthetic appeal, functionality and performance. The process is infinitely repeatable and offers many distinct environmental and economic advantages over conventional texturing processes. Laser Additive Manufacturing (AM) GF Machining Solutions has partnered with EOS, the global leader for highend AM solutions, to integrate this innovative technology and further develop it into its current solutions to fully benefit the mold industry, by focusing on injection efficiency: optimized cooling design to reduce cycle time, lower energy consumption, higher quality of plastic parts. Liechti dedicated aerospace and energy machining centers Aerospace and power generation turbine manufacturers increasingly turn to Liechti dedicated five and sixaxis machining centers to machine complex, highprecision airfoils on blades, disks, blings, blisks/ibrs and impellers. It s easy to see why because these machines, with their specific profile machining technology, specialized CAD/CAM software and engineering competence for ultradynamic machining in titanium, Inconel, nimonic, titaniumaluminide and highalloy steels, yield productivity gains as much as 30 percent, thanks to reduced machining times. In the globally competitive aerospace and power generation manufacturing sector, that s definitely worth shouting about. StepTec Spindles At the heart of every GF Mikron machining center is highperformance StepTec Spindle. StepTec Spindles are essential core components of our machining centers. Highly accurate and thermally stable StepTec Spindles ensure that our machines can handle everything from heavyduty roughing to finefinishing operations. Tooling and Automation System 3R Tooling, Automation and software Productivity is the key to manufacturing success, and automating a manufacturing process is a proven method of increasing its efficiency, effectiveness, quality and reliability. System 3R s integrated Tooling, Automation and software solutions ranging from simple workpiece pallet and electrode changers through to flexible manufacturing and robot handling systems are guaranteed to help you increase their competitive advantage. Customer Services Operations Support, Machine Support and Business Support To help you get the most and the best from your machine tools and equipment, we offer three levels of support. Operations Support covers our range of original wear parts and certified consumables (EDM wires, filters, resins, electrodes etc.) to ensure that your machines are performing at the highest levels. Machine Support maximizes, through our bestinclass technical support, preventive services and quality spare parts, your machine tool uptime. Business Support is designed to help you make a real stepchange in your productivity and performance with solutions tailored to your specific needs. 30 Mikron MILL X

31 31 Mikron MILL X

32 GF Machining Solutions At a glance We enable our customers to run their businesses efficiently and effectively by offering innovative Milling, EDM, Laser, Additive Manufacturing, Spindle, Tooling and Automation solutions. A comprehensive package of Customer Services completes our proposition. GF Machining Solutions Management SA, 2017 The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change.