002 g baureihe engl0908 - kingsbury.codeomega.co.uk

RatioLine

G 160

G 250

G 400

High-performance

turn-mill centers

2

More precision, more effi-

ciency, more flexibility

Experience machine perfor-

mance and economy in a

new dimension: The INDEX

RatioLine high-performance

turn-mill centers of the

G160, G250 and G400

series prepare you

optimally for everything

that may come along. From

the machining of simple

workpieces to that of

complex parts. From small

lot sizes having a wide

parts range to the highly

automated series

production.

Safety from the

technology leader

As the technology leader,

INDEX with its turn-mill

centers is constantly set-

ting new standards. Every

INDEX machine is the

result of 90 years of con-

struction, production and

application experience.

With each improvement of

our know-how, techno-

logical expertise and

serious, individual customer

service, we can offer

customized solutions for

maximum productivity.

This is what our customers

rely on. Worldwide.

Performance, precision and flexibility

in every dimension

RatioLine G160, G250, G400

4

Innovative machine

concept

The INDEX RatioLine

G series is based on an

innovative machine

concept: A practice-

oriented modular system

design allows you to

assemble without compro-

mise almost any machine

configuration that you may

require for economic and

future-oriented production.

Whether you need a highly

productive or a highly

flexible turn-mill center for

small or large lot sizes:

You can assemble exactly

the machine that is

optimally tailored to

your present and future

requirements.

In any case, we will advise

you individually on the right

configuration of your

machine. This customized

machine will make your

production more

economical.

Ready to meet all demands


5

Highly productive: G160

• 2 work spindles, max.

bar diameter 65 mm

• 3 turrets

• 36 tool stations

(all driven)

• Upper turret with Y/B axis

The ideal configuration

for series production or

for the production of

small lot sizes requiring

minimum setup work.

Highly flexible: G400


bar diameter 102 mm

• 2 turrets

• 24 tool stations (all live)

• Turret with Y/B axis and

two multifunctional units

for live and fixed tools; 64

magazine stations

• 1 programmable steady

rest

Highly suitable for the

highly flexible production

of a wide range of work-

pieces.

High productivity for your machining tasks

6

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Machining center,

including a milling center:

G250


bar diameter 102 mm

• 1 motor milling spindle

also for fixed tools; up

to 80 magazine stations

• Y/B axis

• 12-tool turret (all driven)

This machine replaces a

5-axis machining center

and a milling center.

Two machines in one:

G400


bar diameter 102 mm

• 2 turrets X

• 12 tool stations each

(all driven)

• Z axis movement by main

and counter spindle

Due to its genuine

pendulum machining,

no loading/unloading

times are required for

chuck parts.

7

Your modular building

block system

Precisely your dimension

• Bar diameter 42 to 102 mm

• Chuck sizes 160 to 500 mm

• Turning lengths 800 to 2000 mm

All options

• Bar machining, machining using chucks or shaft machining

• 1 or 2 work spindles

• 1 to 3 turrets

• Up to 2 Y or Y/B axes

• Max. 2 multifunctional milling units

• Up to 2 motor milling spindles

Perfect shaft machining

• Tailstock via CNC axis

• 1-2 steady rests, fixed or freely programmable

8

Impressive machine construction, precisely tuned


Excellent machine bed

• Tubular cast bed

• Rigid, bending-resistant

• Vibration-absorbing

Strong guides

• Large-dimensioned linear slideways

• Wide tracks for enormous metal-cutting performance

Precise position gauging systems

• Direct position gauging systems in all

X axes for high-precision machining

Motor spindle

• Patented air cooling for the main and counter spindles

of identical design. They are cooled precisely where the

heat is generated: directly at the rotor

• Powerful: high torque and high dynamics

9

Y/B axis with

genuine 360°

• 360° swiveling range

(optional)

• Machining at any desired

angle

• Full use of turrets at the

main and counter

spindles

• 5-axis machining for

demanding contours

• Quill design with hydro-

static, zero-backlash and

no-wear bearing for high

precision and optimum

rigidity

The work spindle with

center support (optional)

• The thrust can be pro-

grammed to vary

continuously

Innovations that pay off

Maximum utilization of the tool stock: The same tool can be used at the main and

counter spindles, thus reducing the no. of tools required.

Highly flexible utilization of the working area in the Y direction by means of the A

axis with max. stability and extremely short lever action of the Y axis.

Using the counter spindle as tailstock and an integrated live center support makes

it possible to support the workpieces. When the counter spindle picks up the work-

piece, the center support is simply pushed back into the counter spindle.

10

Reducing the setup time - that's the right approach

Tool corrections via the

Y and B axes

Tolerances of the tool

position can be compen-

sated with savings in time

and with µ precision via the

control in the Y and B axes.

Patented W serration for high repetitive accuracy in

tool changing

The patented W serration makes it possible to achieve a

repetitive accuracy of a few µ in tool holder changing.

Machine setup: up to a max. 150 tool pockets

When requiring a wide range of parts and small lot sizes,

with these machine designs, you will always be fully pre-

pared.


11

Integrated handling system: fully automatic

In production with minimum operator intervention,

the optionally integrated WHU/WHW handling system

does the automatic loading and unloading of chuck

parts and shaft parts.

For chuck parts G160 G 250

• Max. workpiece diameter 130 mm 200 mm

• Max. workpiece length 150 mm 200 mm

• Max. workpiece weight 2 x 6 kg 2 x 10 kg

For shaft parts

• Max. workpiece diameter 60 mm 80 mm

• Max. workpiece length 500 mm 700 mm

• Max. workpiece weight 2 x 6 kg 2 x 15 kg

INDEX MBL bar loading magazine

• Max. bar diameter 65 mm

• Max. bar length 4000 mmLoading position

Feeding position

Bar end before

Endposition

12

Four machine examples


Example 1: G160

Components to choose

Work spindle 1+2 G160 G250 G400 1+2

max. bar capacity mm 65 102 102 65

max. chuck size mm 160 315 500 160

Work area

max. turning length mm 800 800 / 1.250 / 800

1.400 2.000

Turret 1-3 1-3 1-3 2

Number of stations per turret 12 (10) 12 12 (10)

Tool drive rpm 6.000 6.000 6.000

(3.000)

Multi functional unit 1 1-2 1-2 1

Tool system HSK A-40 A-50 A-63 /

B-80

max. speed rpm 6.000 6.000 6.000

max. power kW 17 9,4 17

Tool magazines 1-2 1-4 1-2 1

Tooling capacity 32 32 32

Motor milling spindle 1 1 1-2

Tool system HSK A-40 A-63 A-63

max. speed rpm 20.000 18.000 18.000

max. power kW 16 27.5 27.5

max. torque Nm 48 115 115

Tool magazine

x stations max. HSK 2 x 32 4 x 20 4 x 20

Capto 2 x 20 2 x 20

Tailstock

Thrust N 6.000 15.000 14.000

Mounting SK 30 30 30 (40)

Steady rest 1 1 1-2

13

Example 2: G 250 Example 3: G 250 Example 4: G400

Configure

your made-

to-order

machine

1+2 1+2 1+2

90 102 102

315 315 500

3 1 1

1 2

2 4

Examples 1 to 4 show common and interesting solutions. We will be glad to advise you individually on the configuration of your machine.

TURBO H200 - the

programming system for

the workshop

The TURBO H200

programming system gets

you faster to the first part.

• All users - even less

experienced ones - are

given optimum support

• High reliability through

integrated machining

simulation

• The system is available on

the machine control and

for external PCs

You determine

• the contour of the blank

part and of the finished

part on the basis of

interlinked geometric and

machining elements

• the clamping devices and

he clamping orientations

as well as the mounted

tools according to tool

type and tool assignment

TURBO H200 generates

• the division into

machining tasks and

their sequence

• the selection of suitable

tools

• the cutting values that fit

the tool

• the creation of the setup

sheet and the work plan

3-D simulation with

virtual CNC

• The 3-D simulation can be

run independently of the

machine

• The simulation is available

at the machine control as

an option

• The 3-D machine model

shows the actual 1:1

machine configuration

You already see in advan-

ce what process is run-

ning

• Realistic 3-dimensional

volume model of machine

and workpiece

• 1:1 copy of the machine

control guarantees an

accurate sequence and

accurate details

• 100 per cent identical

machine performance

during machining

More reliability,

more economy

• Machine damage is

reliably detected even

before it is produced and

permanently eliminated

• Previously simulated jobs

are started optimally at

the machine and are

optimized with respect

to their runtime.

14

Programming with TURBO


15

Saving time and lowering

costs: The INDEX C200-4D

control concept based on

Siemens 840D powerline

provides you with powerful

and highly advanced control

technology for every

practical application.

Productive power according

to program.

Competent operator

guidance

• Plain text dialog in display

and use

• All spindles and axes at a

glance

• Identical interface in all

machines of the series

• In case of errors: place

and cause of error are

reported

• "Online" error and service

documentation

Expert programming

Far more than 70 user

cycles

• offer practice-oriented

support down to the

smallest detail

• guarantee a secure

program run with

maximum flexibility

• ensure optimum running

and efficient use of the

machine

Quick setup ...

Including axis lock

• Approach of tool carriers

“step by step”

• Check of superimposed

machining processes at

standstill

Including T word acknowled-

gement mode

• User control prior to each

turret indexing

All of that is done without

any modification in the pro-

grams

Starts immediately ...

Via block search

• key press resumes process

at the point of interruption

• channel-synchronous

advance to any desired

program point

• REPOS-guided safely to

the (new) starting point

• Start requirements:

the correct machine state

can be established simply

and without collision

Operational safety ...

Absolute encoder systems

know position in any situation

Safety Integrated ...

• maintains axis positions

and clamping positions

even with the protective

hood open

• checks whether safety

device function is working

correctly with respect to

the cycle

• personal protection

quick to react

and flexibility!

• Tool breakage monitoring

system upon request

• Tool control system and

replacement tools possible

• ETHERNET network con-

nection to DNC possible

• Machine data acquisition

(MDA / ODA possible)

• Teleservice possible

INDEX C200-4D

based on Siemens 840D

16

Technical data G160


Work area

Turning lenght mm 800

Swing diameter mm 200

Main spindle, counter spindle D42 D65

Bar capacity (max. bar diameter) mm 42 65

Spindle diameter front bearing mm 85 110

Spindle head ISO 702/1 Size 5 140 (mm)

Chuck diameter mm 160 160

Speed rpm 6300 5000

Power at 100% / 40% kW 20 / 27 20 / 27

Torque at 100% / 40% Nm 105 / 145 105 / 145

Alignment and indexing unit degrees 2.5 2.5

C axis resolution degrees 0.001 0.001

Z axis rapid traverse m/min 45 45

Tool carrier 1 and 3 X Z Y B

Slide travel mm 180 800 140 360 (degrees)

Rapid traverse m/min 22.5 45 10 180 (degr./sec)

Turret 1 and 3

Number of stations 12 10

Cylindrical shaft mounting DIN 69880 mm 25 x 48 30 x 50

Tool drive speed rpm 6000 3000

Tool drive power at 25% kW 8 7

Tool drive torque at 25% Nm 16 30

Multi functional unit 1 or 3

Tool system DIN 69893 HSK-A40, HSK-B50 (optional)

Speed rpm 6000

Power at 25% kW 17

Torque at 25% Nm 37

Tool magazine max. 2 x 32 HSK-A40

Motor milling spindle 1

Tool system DIN 69893 HSK-A40

Speed rpm 20000

Power at 100% / 25% kW 16 / 16

Torque at 100% / 25% Nm 28 / 48


Tool carrier 2 X Z

Slide travel mm 110 800

Rapid traverse m/min 22,5 30

Turret 2

Number of stations 12 10

Cylindrical shaft mounting DIN 69880 mm 25 x 48 30 x 50

Tool drive speed rpm 6000 3000

Tool drive power at 25% kW 5.5 5.5

Tool drive torque at 25% Nm 10 21

Tailstock

Thrust N 6000

Taper DIN 2079 SK 30

Steady rest

Clamping range mm 8 - 80

Dimensions, weight and connected power with maximum configuration

Dimensions L x W x H approx. mm 4435 x 1950 x 1930

Weight approx. kg 7500

Connected power 42 kW, 53 kVA, 80 A, 400 V, 50 / 60 Hz

Control INDEX C200-4D (based on Siemens 840D powerline)

17

Technical data G250

Work area

Turning lenght mm 800 / 1400


Main spindle, counter spindle D65 D90 D102

Bar capacity (max. bar diameter) mm 65 90 102

Spindle diameter front bearing mm 110 140 140

Spindle head ISO 702/1 Size 6 8 8

Chuck diameter mm 200 / 250 250 (315) 250 (315)

Speed rpm 5000 3500 3500

Power at 100% / 40% kW 43 / 57 43 / 57 44 / 60

Torque at 100% / 40% Nm 275 / 363 275 / 363 400 / 610

Alignment and indexing unit degrees 2.5 2.5 2.5

C axis resolution degrees 0.001 0.001 0.001

Z axis rapid traverse m/min 30 30 30


Slide travel mm 300 800 / 1400 200 360 (degrees)

Rapid traverse m/min 22.5 45 10 360 (degr./sec)

Turret 1 and 3

Number of stations 12

Cylindrical shaft mounting DIN 69880 mm 30 x 55 / 40 x 63 / Capto C4

Tool drive speed rpm 6000

Tool drive power at 25% kW 9.4 / 17 (optional)

Tool drive torque at 25% Nm 19 / 36 (optional)

Multi functional unit 1 and 3


Speed rpm 6000 / 1500

Power at 25% kW 9.4

Torque at 25% Nm 19 / 76


Motor milling spindle 1 X Z Y B

Slide travel mm 300 1840 286 360 (degrees)

Rapid traverse m/min 22. 5 45 47 360 (degr./sec)


Speed rpm 12000 / 18000 (optional)

Power at 100% / 25% kW 27.5 / 27.5

Torque at 100% / 25% Nm 75 / 115


max. 2 x 20 Capto C6

Tool carrier 2 (bottom) X Z

Slide travel mm 140 775 / 1375

Rapid traverse m/min 22.5 45

Turret 2


Cylindrical shaft mounting DIN 69880 mm 30 x 55 / 40 x 63 / Capto C4


Tool drive power at 25% kW 9.4

Tool drive torque at 25% Nm 19

Tailstock

Thrust N 15000

Taper DIN 2079 SK 30

Distance between centers mm 830 / 1430

Steady rest

Clamping range mm 12 - 152 20 - 165 50 - 200


Dimensions L x W x H approx. mm 4170 x 2275 x 2220 5025 x 2275 x 2220

Weight approx. kg 13500

Connected power 68 kW, 81 kVA, 107 A, 400 V, 50/60 Hz


18

Technical data G400

Work area

Turning lenght mm 1250 / 2000


Main spindle, counter spindle D90 D102 D102

Bar capacity (max. bar diameter) mm 90 102 102

Spindle diameter bearing mm 140 170 170

Spindle head ISO 702/ 1 Size 8 11 11

Chuck diameter mm 315 400 400 (500*)

Speed rpm 3500 3000 3000 (290*)

Power at 100% / 40% kW 43 / 57 50 / 70 53 / 67 (30 / 60*)

Torque at 100% / 40% Nm 275 / 363 900 / 1300 675 / 900 (1275 / 2000*)

Alignment and indexing unit degrees 2.5 2.5 2.5

C axis resolution degrees 0.001 0.001 0.001

Z axis rapid traverse m/min 30 30 30

* with additional drive 35% (only main spindle)


Slide travel mm 320 1250 / 2000 220 360 (degrees)

Rapid traverse m/min 20 40 12 180 (degr./sec)

Turret 1 and 3


Cylindrical shaft mounting DIN 69880 mm 40 x 63


Tool drive power at 25% kW 17


Multi functional unit 1 and 3

Tool system DIN 69893 HSK-A63, HSK-B80 (optional)

Speed rpm 6000 / 1500

Power at 25% kW 17

Torque at 25% Nm 36 / 144

Tool magazine max. 2 x 32 HSK-A63 / 2 x 24 HSK-B80

Motor milling spindle 1 and 3

Tool system DIN 69893 HSK-A63 / Capto C6

Speed rpm 12000 / 18000 (optional)

Power at 100% / 25% kW 27.5 / 27.5

Torque at 100% / 25% Nm 75 / 115


max. 2 x 20 Capto C6

Tool carrier 2 X Z

Slide travel mm 210 1250 / 2000

Rapid traverse m/min 20 40

Turret 2


Cylindrical shaft mounting DIN 69880 mm 40 x 63

Tool drive speed min-1 6000

Tool drive power at 25% kW 11.3


Tailstock

Thrust N 14000

Taper DIN 2079 SK 30, SK 40 (optional)

Steady rest 1 and 2

Clamping range mm 35 - 220 22 - 150


Dimensions L x W x H approx. mm 5350 x 2760 x 2616 6300 x 2760 x 2616

Weight max. approx. kg 21000

Connected power 120 kW, 140 kVA, 200 A, 400 V, 50 / 60 Hz


19

1680

G250 / 800 mm

4170

2275

1425

G250 / 1400 mm

5025

2275

1675

2760

5350

G400 / 1250 mm

1475

2760

6300

G400 / 2000 mm

RatioLine G250

RatioLine G400

RatioLine G160

1950

4435

G160 / 800 mm

1364

INDEX Corporation

14700 North Point Boulevard

Noblesville, IN 46060, USA

Tel. +1 (317) 770-6300

Fax +1 (317) 770-3166

www.index-usa.com

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INDEX-Werke GmbH & Co. KG

Hahn & Tessky

Plochinger Straße 92

73730 Esslingen, Germany

Tel. +49 (711) 3191-0

Fax +49 (711) 3191-587

www.index-werke.de

002 g baureihe engl0908 - kingsbury.codeomega.co.uk

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