The machine is able to provide a complete in-cycle production sequence involving 3D turning, boring and milling, precise contour milling and 5-sided machining on very complex components, including the precision machining of customised gear forms.
Not only does the multi-axis ‘Box-in-Box’ bridge-type centre have the capability to combine more traditional multi-stage operational sequences into a single cycle, but also has the ability to create high orders of precision, contouring form and geometry. This is achieved due to the original design, the standard of build and construction around its patent-pending ‘4-Guideway System’ where the bridge is carried inside the machine structure. The more traditional bridge-style method is to mount the bridge on top of the side supports with just two guideways. As a result, the Alzmetall design is able to maximise the benefits of the latest software advances in control technology.
For example, in the production of customised gear tooth forms, such as those incorporated in compact double helical, herringbone gears and bevel gears, the machine has the ability to automatically compensate for factors such as residual deviation on any material.It does this by utilising the advantage of Heidenhain’s TNC640 control and the incorporation of its Load Adaptive Control (LAC) package. This package is able to optimise control parameters and enables any possible deviations or minor errors in the cycle to be maintained within 10 microns, for instance, along the flank of a gear tooth.
C- and A-axes can be sensitive to differing machining loads and variations in ‘moments of inertia’ that can contribute to a lower dynamic performance and resulting reduction in contouring accuracy.By incorporating LAC parameters in the control such as for 3D tool radius compensation, these are optimised in response to any variation in the loading of the rotary axes.
The 31 tonne, 5-axis GS 1400/5-FDT bridge-type machining centre has strokes of 1,200 mm in X by 1,300 mm in Y and 800 mm in Z with a rapid traverse of rate of 82 m/min in each axis. Positional accuracy is within 5 microns. The A-axis has +/- 140° and swivel and rotary axes are powered by a direct torque drive motors delivering a 30 m/min pivoting speed. The 800 mm turntable (1,000 mm option) has a loading of 3 tonnes with 2,400 Nm of torque available. The larger table has 3,400 Nm of torque.
The spindle is powered by 82 kW, 14,000 rpm motor with 500 Nm of torque with tool magazine options between 33 and 250 pockets. Tools up to 125 mm dia (250 mm with adjacent pockets left empty) can be exchanged in 7 secs chip-to-chip.
