gs 600 - · pdf filedesired static and dynamic characteristics of each individ- ......
TRANSCRIPT
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ALZMETALL - COMPANY INTRODUCTION
is a company with an international reputation and global activities. For more than six decades we have been the leader in technology for drilling, milling and casting.
ALZMETALL products have proven themselves in general machining applications, in the automotive industry, in mould and die business, at the aircraft industry, as well as in many mid-size mechanical engineering enterprises. Our experience is based on over 200.000 machines supplied.
We focus on precision, performance and Quality for all our products. With our own foundry we do not only produce gray cast iron and spheroidal grey cast iron for our own machines, but also are supplier to the machine tool manufacturers and customers worldwide.
Our open company culture encourages innovation and performance by a continuous innovation towards High Tech and customer benefit for added value. Developing the GS-series, we offer highly dynamic and extremely rigid machining centers according to our pretensions: „we drive productivity“.
How to find us
Premises
Airport München“Franz Josef Strauß”
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Highlights
• ALZMETALL-Gantry-Concept (AGK)• Grey Cast Iron and Spheroidal Graphite Cast Iron• Monobloc Travel-System-Carriage with incorporat-
ed Box-in-Box-System • 4-fold Linear Guidance for Travel-System-Carriage
and Z-Axis with integrated Motor-Spindle• 3-fold Torque-Drives for Swivel-Axis (A-Axis) and
Rotary-Axis (C-Axis) at GS 600/5-T und GS 600/5-FDT
• Hybrid-Machining-Applications such as: Drilling/Mill-ing/Turning and Grinding at one Clamping-Set-Up
• Up to 750 kg workpiece weight including Clamping-Set-Up-Device at GS 600E/3 (Static Table)
• Up to 500 kg workpiece weight including Clamping-Set-Up-Device at 5-Axis Machines
Focus on operators needs
• Access to Machine-Table ergonomically configured at working height
• Workpiece loading by front, side and from top access. Crane loading possible
• Mist extraction directly at Machine-Table• Steeply sloping chip tunnel straight below
Machine-Table
User benefits
Streamlined Force-Circuit between workpiece and Cutting-Tool in addition to geometrical and symmet-rical configuration of the Carriage-Travel-System.
 Performing• Thermal consistency at Tool Center Point (TCP)
at X-Y- level without additional Axis compensa-tion
• Significant reduction of Cutting-Tool costs  Optimum• Contour consistency at highest path velocity• Lifetime of Motor-Spindle
 Guaranteed• High-grade Parallel-Path-Precision through two
Servo-Drives at each X- and Y-Axis• Considerably reduced Total Cost of Ownership
(TCO) over lifetime period of Machining Center
Machining Center with options: chip conveyor, cooling unit and coolant filter. These options are either to be installed along the right - or left side of the Machining Center.
AT A GLANCE
5-Axis Machining Center GS 600/5-T
• Working-Space flushing with coolant (option)• Automatic Access-Door feature open/close (option)• Access to all maintenance units at working height
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FEM generated Structural Model - Point of force-input at TCP and simultaneously at Machine-Table
ALZMETALL - THE CONCEPT
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FEM generated Structural Model - Point of force-input at TCP and simultaneously at Machine-Table
Multi-Elements-Simulation
During the development process the Finite-Elements-Meth-od was already applied by building the structure of the machine, patterned from the 3D-Volume–Model born from CAD to simulate vibration characteristics. Thus enabling engineers to determine the optimal dynamic rigidity of the machine under terms and conditions of the daily use at the shop floor.
Development
The „Finite-Elements-Method“ was applied to obtain the desired static and dynamic characteristics of each individ-ual part of the machine and to investigate the collective rigidity of the Machining Center.
Modal-Analysis
Results gained by the Multi-Elements-Simulation of entire machine structure and design had to be confirmed at the prototype of the GS-Machining Center by using the Mod-al-Analysis. The experimental Modal-Analysis procedure is being used to realize and demonstrate the quality of the dy-namic machine characteristics under production conditions.
The final test of the Modal-Analysis accomplished at ALZMETALL verified the high degree of performance of the dynamic requirements in reality. Thus the ALZMETALL GS-Series offers comparable Best-in-Class conditions for high dynamic machining applications.
RESEARCH AND DEVELOPMENT
Development by using Finite-Elements-Method (FEM)
X
YZ
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BASIC DESIGN
Rigidity, Dynamic and Thermal Symmetry „that‘s it what counts“
Extreme rigid, Integral-Basic-Body prepared for:• Frame Side Walls as carrier for both Y-Axis (Y- and V-Axis) • NC – Swivel- and Rotary-Table (A- and C- Axis) or Static-Table• Disc-Tool-Magazine for 40 Tool Positions, alternative twin Disc-Tool-Magazine for [76] Tool-Positions.
Rack-Type Tool-Magazine for [224] Tool Positions [Option].
All statically stressed Basic-Machine-Parts made from EN-GJL 300 (GG 30) and all dynamically stressed Basic-Machine-Parts and components made from EN-GJS 600 (GGG 60).
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• Y- and V-Axis Frame Side Walls as static basic structure. On top mounted Travel-System-Carriage with integrated Z-Axis Monobloc
• Dynamically stressed Basic-Machine-Parts and components made from EN-GJS 600 (GGG60)
• Both Linear-Axis X and Y 4-fold guided, Z-Axis 8-fold guided
TRAVEL - SYSTEM - CARRIAGE
Z-Axis sliding tube
Travel-System-Carriage
Monobloc
Ballscrew 2-fold, Y-Axis
Linear Guidance SystemsLinear-Encoder
Ballscrew
Servo-Drive Z-Axis
Servodrive X-Axis
2-fold Servodrives Y-Axis
4-fold Linear Guidance Systems
• Linear-Axis Y driven by two Ballscrews and two Servo-Drives. X- and Z-Axis each driven by one Ballscrew and one Servo-Drive.
 Excellent Axis dynamics  Cutting edge Parallel-Path-Precision  Thermal stability due to geometrical symmetry with Thermo-Symmetric Motor-Spindle
Design Characteristics
Box-in-Box-System:
Y
Z
X
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TRAVEL - SYSTEM - CARRIAGE
• Small lever arms through Z-Axis Monobloc design
 Increase of stiffness and thus gain of Stability of overall framework
ÂMaximized cutting capacity
• Thermo-Symmetric• Narrow and direct Force-Circuit
 Thermal stability  High grade stability and stiffness with coexistent weight-optimized Axes-Elements
Force Transmission - Symetry
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NC - SWIVEL - AND - ROTARY - TABLE (SDK)
Torque-Motor sectional viewTorque-Motor
Torque-Motor
Swivel- (A-Axis) and Rotary- (C-Axis) Unit GS 600E/5
Rotary-Table DIA. 320 mm (Standard)
Rotary-Table 400 x 400 mm [Option]
Servo-Drive with gear
Counter-Bearing with clamping
Highly self-locking Gear-Motor
GS 600/5 -T and GS 600/5 -FDT
• Direct Rotary Drives (Torque-Motors) for high dynamic and oscillating machining – maintenance free –
• Two internal Torque-Motors at each Frame side wall as NC-Swivel-Axis (A-Axis) – patented-
• NC-Rotary-Table (C-Axis) equipped with Torque-Motor
 Highest swivel and rotational speed  Higher accuracies – no mechanical backlash  Elimination of friction at Drive-Components ÂWear – and maintenance free delivers reduced Total Cost of Ownership (TCO) over lifetime period of Machining Center
• A-Axes Servo-Drive with DC coupled preloaded gear. Counter-Bearing with hydraulic clamping
• C-Axes Compact-Unit with Servo-Drive and integrated gear
 High grade torsion stiffness  Fast rotary motion of gear through capacious gear transmission at short positional movements of the Axes
 No single-edged wear
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A-AxisC-A
xis
min
. 150
/m
ax. 5
50 m
m
100
mm
500
mm
350
mm
ø 800
mm
ø 640 mm
Machining Space
• Maximum utilization of Machining Space• C-Axis DIA. 640 mm• A-Axis DIA. 800 mm • Swivel range ± 140°• Table Load max. 500 kg• Stainless steel Machining Space cover [Option]
WORKPIECE DIMENSIONS - MACHINING SPACE
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 All components at one cabinet  At ground level ergonomic access  Easy to maintain  Integrated cooling unit for Motor-Spindle at GS 600E
SUPPLY - MAINTENANCE - SERVICING
Switchboard cabinet Pneumatic-System
Lubrication
Hydraulic-SystemCooling unit for Motor-Spindle
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OPTIONS
Table-Set 1) 2)
Clamping surface mm 555 x 320T-slots acc. DIN 650 5 x 14 H12Configuration parallel in X-directionDistance mm 63Table Load max. kg 500Notice Rotary-Table ø 320 mm
Rotary-Table C-Axis 1) 2)
Clamping surface mm 400 x 400T-slots acc. DIN 650 5 x 14 H12Configuration parallelRPM max. 100 1) 1200 2)
Table Load max. kg 500Distance T-slots mm 63
Rotary-Table C-Axis with NPS 1) 2) 3)
Clamping surface mm 400 x 400T-slots withoutConfiguration NPS 4 x 90 °RPM max. 100 1) 1200 2)
Table Load max. kg 500
Clamping surface mm 600 x 630T-slots acc. DIN 650 9 x 14 H12Configuration parallel in X-directionDistance T-slots mm 63Table Load max. kg 750
1) GS 600/5-T2) GS 600/5-FDT
3) NPS = Nullpunkt Spannsys-tem
Further executions on demand
GS 600E/3 3-Axis-Machine with Static Table
400 mm400 mm
400 mm
200 mm
200 mm
400 mm
630 mm
600 mm
Static Table
ø 320 mm
555 mm
320 mm
NC - Swivel - (A-Axis) and Rotary-Tables (C-Axis)
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400 mm
400 mm
CNC-Contr o ls
Heidenhain TNC 640 (standard) Heidenhain iTNC 530 HSCI
KINEMATIK Gauging
Accuracy check and compensation - KinematicsOpt., Heidenhain - C 996, Siemens
3D-Touch Probes
Infrared transmission
- TS 640, Heidenhain- TS 740, Heidenhain - IRP 25.41, m&h Inprocess- OMP 60, Renishaw- TC 50, Blum
CNC-Contr o ls
Siemens SINUMERIK 840 D sl
Electrical Handwheels
- HR 510, Heidenhain- HR 520, Heidenhain- Mini-Handwheel, Siemens
Multiple-Media-Couplingfor Rotary-Table
4-fold on selection air and/or fluids
OPTIONS
320 mm
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Tool-Magazines
Twin-Disc-Tool Magazine for 76 Tool PositionsTool-Magazines
Rack-Type Magazines with 224 Tool positions
Production Package
On selection A, B, C with Scratch-Type-Convey-or, Hinge-Type-Conveyor, Magnetic-Conveyor
Production Package
Coolant Cleaning Unit with Metal-Edge-Filter or Compact-Paper-Filter
Camera and Screen
Camera mounted at Machining Space with trans-mission to external flat screen or Video-Server for process-set-ups and process-controls
OPTIONS
Tool Setting System
Laser System for Tool Setting and Breakage Detection on selection including mechanical Touch Trigger Probes LTS 35.65, m&h, (without mech. Touch Trigger Probes) LC NT, Blum, (without mech. Touch Trigger Probes) TC 76, Blum, (with mech. Touch Trigger Probes)
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Services
Machining Center Installation, Set-Up, Production Assistance and Maintenance
Mist Extraction Unit
Attached to Machine-Basic-Body
OPTIONS
[ ] Options
• Rotary-Table (C-Axis) various configurations• Mutiple-Media-Coupling for Rotary-Table (C-Axis)• Motor-Spindles RPM-Range 30.000 RPM/42.000 RPM• Disc-Tool Magazine up to 76 Tool Positions• Tool Magazine Rack-Type up to 224 Tool Positions• Chip Conveyor: Scratch-Type-, Hinge-Type-,
Magnetic-Conveyar 1) • High pressure Coolant Units up to 150 bar 1) • Electrical Handwheels• 3D-Touch Probes• Automatic Workpiece-Changing-System• Tool Setting and Detection Systems• Workpiece-Pallet-Changing-System• Robot-Systems• Custom-Made Solutions• Services
1) Optional placement along the right- or left side of the Machining Center
Services NC-Program-Training, Operator-Training for Heiden-hain and Siemens
Machining Center Acceptance Workpiece according to ALZMETALL-Standard, on selection Customer-Workpiece (option)
Remote Diagnosis, Remote Maintenance
and for NC-Programming-Support
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Type GS 600E/3 GS 600E/5 GS 600/5-T GS 600/5-FDT
Working RangeTraverse Path 460 / 600 / 400 mmStatic TableDistance Spindle - Static-Table min./max. 100/500 mmClamping Surface (w x d) 600/630 mm9 T-Slots acc. DIN 650 at X-Direction 14H12 x 63 mmMachine-Table Load 750 kgNC-Swivel-and Rotary-TableDistance Spindle - Table min/max. 150/550 mm
Drives at Swivel- and Rotary-Axis conventional indirect Torque direct
Swivel Range of A-Axis ± 140 ° ± 140 °Swivel Speed at A-Axis 30 min-1 90 min-1
C-Axis Rotation 360 ° endlessC-Axis RPM max. 50 min-1 100 min-1 2700 min-1
Diameter Machine-Table C-Axis Ø 320 mm Ø 320, [400 x 400] mmT-Slots acc. DIN 650 14H12Star-Shaped Configuration 4 x 90 ° 4 x 90 ° [ 5 x parallel|, Distance 63 mm]Machine-Table Center Bore Ø 50 H7 mmTable Load max. 500 kgC-Axis Rotary-Diameter at A-Axis Center Ø 640 mmA-Axis Swivel Diameter (Swing) at X-Axis Center Ø 800 mm
Distance A-Axis-Center to Rotary-Table 100 mmFeed-Drive-System X-, Y-, Z-AxisDigital AC-Servo-Motors, maintenance freeMax. Rapid Travel X-, Y-, Z-Axis at TCP 30 [60] m/min 60 m/minFeeding Force X-, Y-, Z-Axis at CDF 40% 4 - 4 - 5 kNMotor-Spindle-DriveHigh Frequency Motor-Spindle Cutting-Tool Interface HSK-A63 HSK-T63Motor-Spindle-Power at CDF 25% 26 [16] [44] [17] kW 13 [24] kWVariable Speed Range max. 18.000 [10.000] [30.000] [42.000] min-1 10.000 [18.000] min-1
Motor-Spindle Torque at CDF 25% 116 Nm [102] [40] [11] Nm 80 [92] NmTool-Magazines Tool positions, Type 40 Disc, [76 Twin-Disc] [224 Rack-Type]Max. Tool Diameter, Chain fully loaded 80 mmMax. Tool Diameter, Chain neighbour posi-tions unloaded 130 mm
Max. Tool Length 300 mm [150 at upper Disc]Max. Tool Weight 4 kg [10 kg at Rack-Type]Tool-Change-Cycle (approx.) 2 sChip-to-Chip Cycle 4,5 sLinear Encoders X-, Y-, Z-Axis indirekt absolut, directPositional Tolerance TP acc. DIN/ISO 230-2 (VDI/DGQ 3441) ≤ 0,007 mm
Angle Encoder System A-, and C-Axis direktMachine Weight excl. Options 6800 kg
CNC-Controls Heidenhain TNC 640, [Heidenhain iTNC 530 HSCI], [Siemens 840 D sl]
Heidenhain TNC 640 [Siemens 840 D sl]
[Option]
TECHNICAL DATA
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TECHNICAL DATA MOTOR - SPINDLES RPM - Power - Table
16P S6/25%
Md S6/25%
1.500 10.000 n (min -1)
P S6/40%
Md S6/40%
P S1
Md S1
14
11
70
90102
Md
(Nm
)
P (k
W)
GS 600E/3, GS 600E/5, GS 600/5-T
[RPM max. = 10.000 min -1] Option
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24
P S6/25%
P S6/25%
Md S6/25%
Md S6/25%
2.100
2.500
18.000 n (min -1)
18.000 n (min -1)
P S6/40%
P S6/40%
Md S6/40%
Md S6/40%
P S1
P S1
Md S1
Md S1
22
22
17
17
70
65
100
84
116
92
Md
(Nm
)
Md
(Nm
)
P (k
W)
P (k
W)
GS 600E/3, GS 600E/5, GS 600/5-T
GS 600/5-FDT
RPMmax. = 18.000 min -1 (Standard)
[RPMmax. = 18.000 min -1 Hirth-Gear-Indexing for turning Operation] Option
13P S6/25%
Md S6/25%
1.500 10.000 n (min -1)
P S6/40%
Md S6/40%
P S1
Md S1
11,59
7
7383
Md
(Nm
)
P (k
W)
GS 600/5-FDT
RPM max. = 10.000 min -1
Hirth-Gear-Indexing for turning Operation (Standard)
17P S6/25%
Md S6/25%
15.000 42.000 n (min -1)
P S6/40%
Md S6/40%
P S1
Md S1
13
10
6,4
8,311
Md
(Nm
)
P (k
W)
GS 600E/3, GS 600E/5, GS 600/5-T
[RPM max. = 42.000 min -1] Option
44P S6/25%
Md S6/25%
7.200 30.000 n (min -1)
P S6/40%
Md S6/40%
P S1
Md S1
40
30
28
3640
Md
(Nm
)
P (k
W)
GS 600E/3, GS 600E/5, GS 600/5-T
[RPM max. = 30.000 min -1 ] Option
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appr
ox. 2
.300
mm
max
. 2.8
00 m
m
incl. Options A) und B) approx. 3.250 mm
Coolant Unit
Inductor Unit
approx. 1.900 mm
appr
ox. 3
.150
mm
incl
. Opt
ions
E) ,
appr
ox. 4
.010
mm
appr
ox. 6
00 m
m
R 1.150
approx. 1.350 mm
A)B)
E)
F)
C)D)
GS 600
MACHINING CENTER DIMENSIONS
Machining Center (Single Unit) - Transport Dimensions) GS 600
• Width approx. 1.900 mm• Depth approx. 3.750 [4210] mm• Height approx. 2.370 mm
Options
A) Chip ConveyorB) Chip TrolleyC) High pressure Coolant UnitD) Coolant cleaning systemE) Rack-Type Tool-MagazineF) Mist Extraction Unit
Please observe: Options A, B, C, D and E are either to be installed along the right- or left side of the Machining Center!The cooling unit and the inductor unit are variable placeable!
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MACHINING CENTER DIMENSIONS
Machining Center (Single Unit) - Transport Dimensions) GS 600
• Width approx. 1.900 mm• Depth approx. 3.750 [4210] mm• Height approx. 2.370 mm
AUTOMATION SOLUTIONS
PowerCell Robot-Loading-System and Zero Point Tooling System with 24 workpiece-pallets
Robot-Loading-System for workpiece-pallets with external Rack-Type-System
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ALZMETALL Werkzeugmaschinenfabrik und Gießerei Friedrich GmbH & Co. KGPostfach/P.O. Box 1169D-83350 Altenmarkt/Alz · GermanyHarald-Friedrich-Straße 2-8D-83352 Altenmarkt/Alz · Germany Tel./Phone +49 86 21 88-0Fax +49 86 21 88-213E-Mail: [email protected]: www.alzmetall.com
Also contact us for further Machining Centers of the CS-Series, Drilling Machines-Series and Custom made Cast-Iron-Products.
• GS 800/3• GS 800/5-T• GS 800/5-FDT
• GS 1000/3• GS 1000/5• GS 1000/5-T
• GS 1000/5-FDT• GX 1000/5-AF• GX 1000/5-LOB
• GS 1400/3• GS 1400/5-T• GS 1400/5-FDT• GX 1400/5-AF
• CS 600• CS 1200• CS 1200 P
PRODUCT RANGE - PLEASE CONTACT US
Machining Centers
Machining Centers Machining Centers
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