Emco designs Hyperturn 65 Powermill for complete machining operations of complex workpieces

The Hyperturn 65 Powermill's 29 kW and 250 Nm counter spindle has enough power to machine the workpiece simultaneously with two tools, while the 29 kW, 79 Nm milling spindle provides 12,000 rpm, enabling complete machining of complex workpieces. The B-axis direct drive arms the machine with dynamics and contour capabilities for 5-axis simultaneous machining. The additional Y-axis on the lower turret makes extensive milling work possible at the same time as machining with the milling spindle. HSK-T63 interface 20, 40 or 80-piece tool magazines are available. As an alternative to the VDI30 or VDI40 12-position tool turret, Emco offers a next generation of turret with BMT interface and direct drive. Higher stability and precision, and performance data similar to a milling machine, the company says, enable the complete machining of turning/milling workpieces. Machine versions with a milling spindle and turret including milling drive (SMBY/SMBY2) have a cross slide beneath with a 12-position radial turret for 12 driven tools working up to speeds of 5,000 rpm. Automatic bar machining and/or delivery of unit loads can be achieved via a robot or Emco gantry loader as an efficient automation solution. Emco has fitted the Hyperturn 65 with the advanced Siemens Sinumerik 840D-sl control unit with an intuitive user interface for easy programming. The Emco CPS Pilot can generate time and cost savings during machining as the software enables users to plan, program, simulate, and optimise production runs on their PCs using a 3D model of the machine. The extremely rigid and compact welded-steel construction machine base, which is the core of the machine, is filled with vibration-damping material. Reinforcing materials provide additional rigidity in zones that are subject to intense stress. The high drive power of the main, counter or milling spindle can thus be fully exploited while achieving precise manufacturing and surface quality. The high drive power of the spindles, combined with optimal torque curve, ensures economic efficiency in cutting steel, as well as high speed cutting of aluminium. Highly dynamic integrated spindle motors, mounted on large precision bearings, allow for a wide range of speeds with true running. A symmetrical headstock, in combination with temperature sensors at the bearings and integrated liquid cooling, ensures thermal stability. All linear movements take place in preloaded, highly precise roller slides. This is reflected in the feedrates, zero backlash, service life, lubricant consumption and positioning accuracy, says Emco. A sealing system at the guide shoe removes the problems associated with extremely dirty working environments. As an additional safeguard, cover plate strips made of spring steel are clipped onto the guide rails to attain a closed sealing surface. Technically speaking every spindle is also an axis. It can be brought into any position and positioned with defined feed motion, facilitating production of complex contours at the periphery or front surface. The software required to program these movements (cylinder interpolation and/or transmit) is already included in the delivery. Synchronised thread cutting and polygonal turning are part of the machine's basic equipment. The powerful milling spindle with HSK-T63 tool interface can be used for both turning and drilling/milling work. The milling spindle can be continuously swivelled within a range of ±120° and clamped anywhere. With a useful Y-travel of +120/-100 mm, even the most complex of machining work can be carried out. This includes gear-cutting operations, turning/milling work for crankpins, 5-axis machining, and much more. The tools can be prepared according to the customer's requirements with a 20-piece pick-up magazine, or a 40 or 80-piece chain magazine. The Y-axis has been realised by two interpolating axes. This results in a distribution of the cutting force in two levels and adds stability to heavy duty turning and milling. This means the lower turret with integrated milling drive can also be used for complex milling operations at all 12 positions, combined with a Y-axis with ±50 mm travel. In the tailstock version, the Hyperturn is particularly suited for mass machining of shaft parts. The tailstock is completely NC controlled and can be positioned using a recirculating ball spindle. This enables the movement interpolating with other axes, saving machining time. The ergonomic work area provides good access to the individual components, while generous free space allows optimum chip flow even when machining critical materials. All guides are covered with sheets made of Niro to prevent damage. The flush front enclosure with its large viewing window is inspired by the Emco Linearmill 600 and MMV 2000 milling machines. The Hyperturn 65 PM machine housing provides all-round protection against chips and is coolant proof. The operating panel can be slid horizontally as far as the centre of the machine door and the control panel can be swiveled 90° vertically and up to 10° horizontally. The drive and control package, which is entirely digital, is able to handle up to 10 channels and 31 axes. Technology cycles simplify both turning, as well as milling operations. By the means of co-ordinate transformations, any number of machining processes can be achieved in the space.