Delivering cycle-time reductions of up to 30%, the compact machine offers significantly improved performance in a footprint virtually the same as that of its predecessor. New also is the vertical orientation of the heavily ribbed, low-vibration cast bed, which optimises chip flow and provides more space in the working area, especially for the lower tool turrets. Arranged in mirror image, each has an independent, ±45 mm Y axis, as well as 14 live tool stations rated at 16 kW/16 Nm and 7,200 rpm maximum speed.

The identical main and counter motor spindles are fluid-cooled, have a bar capacity of 65 mm and a chuck diameter of 165 mm. Rated at 31.5/32 kW and 125/170 Nm, they provide rotational speeds of up to 6,000 rpm.

A notable feature is the upper tool carrier, which has a ±65 mm Y axis and a 360° B axis. On one side there is a tool turret with another 14 positions, and on the other an HSK-A40 milling spindle. The spindle’s drive comes with a considerable increase in speed. Whereas the previous G200 was limited to 2,000 rpm, the latest 22 kW/52 Nm version provides speeds up to 7,200 rpm.

For maximum productivity, it is possible to utilise all three turrets simultaneously at either the main spindle or counter spindle, without interference. For example, a drill in a lower turret can machine a bore in a workpiece at one spindle, while the other lower turret and the upper tool carrier balance-turn the outside diameter.

The B axis can swing the upper tool carrier so that its turret is in a horizontal orientation, from where it can move into the work area up to 30 mm below the spindle centreline. Diametrically opposite tools can then mill, drill or turn workpieces in both spindles, simultaneously if required. This feature enables the machining of front-end and reverse-end faces with straight tools, which is more accurate and less costly than using right-angle tool holders.

Additionally, the 845 mm travel of the upper tool carrier is sufficient for the entire maximum turning length to be traversed without having to rotate the B axis, which is often not the case with other machine concepts, says the company.

Based on the Siemens S840D sl control, the Index Xpanel Industry 4.0-ready operating concept with real-time program simulation simplifies use of the CNC system. For example, many elements of the control panel have been integrated into the display and can be used directly via the 18.5” touchscreen.

Another useful feature on the control panel is that active buttons and switches are backlit by LEDs, while currently inactive ones remain unlit. Furthermore, an optional PC in the control cabinet allows NX CAM to run directly on the machine, which is particularly useful for applications requiring extensive milling.