Metalex specialises in the design, engineering, programming, fabrication, manufacture and inspection of complex, close-tolerance parts, assemblies and tooling. The company wanted a machine that could machine a wide range of materials with flexibility, efficiency and precision — all in a single clamping operation.
The company ultimately decided on the Droop+Rein T series— a large-scale powerful milling/turning centre offering high accuracy, thanks to its rigid design and hydrostatic guide concept. The dimensions of the machine are impressive: table length of 18,000 mm; horizontal pass: of 9,000 mm; vertical pass of 7,000 mm; and a working area of 19,000, 9,000 mm and 3,000 mm in X, Y and Z.
The option of 5-axis processing via the integrated C-axis with stepless rotation and the universal fork-type milling head, featuring a B-axis that swivels ±95° is complemented by the sixth axis (W)—a 5,500 mm continuously movable crossbeam, giving the universal approach that the contract machining company required.
The processing centre uses a 100 kW main spindle with a maximum torque of 7,500 Nm, transmitted via vertical and horizontal milling heads; two fork-type milling heads designed for 5-axis operation, as well as a slim outboard bearing for drilling through. If entirely new orders come in, there is an option to use additional heads for milling, turning, grinding and turning.
Its versatile robot magazine, which has space for up to 400 tools, supplies the milling and turning heads with three different tool systems. Integration into Metalex's production and tool management systems is undertaken by the Integrated Production System (IPS), Starrag's ‘building block’ for Industry 4.0 solutions.
The special table construction with two large tables (6,000 by 8,000 mm) ensures efficient machining. This construction means that one table can be used under the spindle while the other is loaded and unloaded outside the work area.
Extra-long workpieces are machined in coupled tandem operation, for which tables are extended to 18,000 mm. Each table also features an integrated rotary table of 6,000 mm diameter. Thanks to the two 111-kW main drives, the components weighing up to 200 tonnes can be turned. The rotary table can also be used as a C-axis for precise positioning when milling and drilling.
