ETG introduces precision high-speed Ingersoll 5-axis machining centre

2 mins read

​For manufacturers looking to make a step-change in their machining strategies to implement true high-speed high-feed milling with impeccable surface finishes, the Engineering Technology Group (ETG) has now introduced a new line of machining centres from OPS Ingersoll.

The Eagle V5 Competition machine is available as a 3-axis and 5-axis variant, making it the perfect ‘all-rounder’ for high-speed precision machining. Developed as an ‘all-rounder’, the fully sealed OPS Ingersoll V5 Competition is suitable for rough and fine detail machining of graphite and copper electrodes, soft and hard steels as well as aluminium, all in the same technology.

The Eagle V5 Competition has an X, Y and Z axis of 550 by 400 by 400mm that travels over the 650 by 500mm 3-axis table or 400mm diameter 5-axis table with an acceleration rate of 15m/s2 to accommodate the machining of parts up to 500kg and 250kg respectively. Backed up with a 475mm distance from the spindle flange to the top of the 5-axis pallet.

The machine has a 15/17kW HSK E40 spindle that can reach speeds up to 42,000rpm as standard with a higher torque HSK E50 spindle with a maximum speed of 36,000rpm available as an option. The machine is also available with a choice of a 32 tool ATC or an 80-position tool change facility that can be located on either side of the machine to suit the possible integration of left or right-hand automation stations from the same supplier to link two technologies (EDM and HSC), or same technologies from the one system.

The gantry-type 5-axis machine has been impeccably designed to deliver the utmost in precision machining. This design includes a thermo symmetric design, high-precision ball screws, direct Heidenhain measuring systems, direct-coupled AC servo motors and a +/- 0.1degree C temperature-controlled spindle.

Identifying what makes this high-speed machining centre different from standard machine tools, ETG’s Scott Elsmere said: “A typical machining centre has a high mass in the head to absorb vibration whereas this high-speed machine has a lighter head and a heavier mass at the bottom. In the case of the OPS Ingersoll Eagle V5 machine, this is a one-ton mass in the head and a seven-ton mass in the base.

"This gives the machine much higher stability, a high dynamic and along with the CNC control, it helps cornering control as well as acceleration and deceleration – this combination completely removes ‘jerk’. Additionally, whenever the machine moves, we have a constantly moving mass from the gantry-type design.

"The guideways are always supported at four locations and this means the dynamics of the machine never change, regardless of the location of the cutting head, unlike in a C-frame type machine. This makes a difference with precision, repeatability and surface finishes.”

The V5 Competition machining centre is supplied with the Heidenhain TNC640 CNC control unit. Heidenhain exerted considerable resource to developing the control for true high-speed machining and the result is a control unit that has optimised motion control for enhanced precision.

From an optional perspective, customers looking to reach the very epitome of precision can add the 3D Tuning Cycle option for increased contour accuracy and speed, the K-OPT kinematic system that calibrates the drift of the machine kinematics and also the DCM automatic cycle dynamic collision monitoring system to prevent collisions.

Taking precision to a level that is the envy of the industry is the incorporation of a Renishaw infra-red OMP400 touch probe for low-contact in-process part measuring, which is complemented by the Blum laser LC50 DIGILOG non-contact tool measurement system. Both sitting securely in a clean area, the Blum DIGILOG measures tool length and diameter and it detects any in-process tool breakages.