TIN-Coated Thread Gages
At an ‘open house’ event earlier this year, HELLER offered visitors a close-up view of its new model F 5000, including its new features and critical components such as motor spindles with HSK-A 63 tool interface and space-saving rack-type tool systems. With their modular design, the new high-performance five-axis machining centers can be configured for a wide range of applications, always ensuring maximum precision and performance in the production of small to medium batch sizes.
Last fall, Heller launched the F 6000, the first five-axis machining center (MC) from its, modular F series (XYZ: 1,000x1,000x1,400 mm). About six months later, another model was introduced: the F 5000 with a work envelope of 800x850x1,100 mm (X/Y/Z) and a smaller footprint. The F 6000 offers the same pallet size of 630x630 mm and maximum clamping load of 2,000 kg, as well as the same traversing speeds and other performance data as the F 5000. That’s because components such as spindles, heads and tables of both new Heller F machines are based on the same modular system.
Swivel heads with motor spindles. The highlights of the new generation of five-axis machining centers, optimized for maximum flexibility and precision, include the fundamentally redesigned swivel heads and integrated motor spindles developed and built by Heller, which are equipped with an HSK-A 100 tool interface as standard and are now available with an HSK-A 63 interface as an option. The dynamic swivel head with 5th axis ensures maximum machining performance. Its drive is based on a backlash-free drive concept and delivers impressive precision. Other useful features include an integrated work light and a remaining path indicator as part of the Setup-Assist function.
Heller offers a variety of spindles to suit different requirements: the Speed Cutting Unit (SCU) in combination with the HSK-A 100 tool interface reaches speeds of 15,000 rpm. As an alternative, Heller offers the Dynamic Cutting Unit (DCU) designed for universal use with 400 Nm and 12,000 rpm. Combined with the HSK-A 63 tool interface, they reach speeds of up to 18,000 rpm. The Power Cutting Unit (PCU) with a 146 Nm, 8,000 rpm gear spindle will continue to be available for ultra-heavy machining.
Another key element of the F series is the revised drive concept of the linear axes, with twin ball screw drive in the Z-axis and a significantly reinforced X-axis. Dr Manuel Gerst, head of development for Heller Group, explained: “With the F 5000 and F 6000, we offer increased dynamics in the linear axes. Additionally, we have further reduced the positional tolerances with the PRO package. The new standard is 5 μm. Tolerances on the rotary B and C axes have also been reduced to 7 arc seconds as standard. Overall, this results in top marks for workpiece accuracy and machining time.”
Heller’s new F series machines also offer a number of features to ensure high ease of operation. Convenient access to the work area and an LED light built into the head add to the user-friendliness. The new Setup-Assist actively supports the operator when running in machining processes and helps prevent collisions between machine components and tools.
Siemens’ new Sinumerik One control is used as a standard for the F series, and offers an optimal working environment in combination with the convenient main operating unit displayed in a 24-inch touchscreen console. Existing NC programs from Heller F and C machines equipped with Sinumerik 840D sl can be transferred directly and easily.
To increase process reliability, Heller developers ensured free chip fall below the spindle and effective removal of chips. Steep stainless-steel covers and a wide chip conveyor assist the operation.
Slim rack-type tool magazines. The new machine design, especially direct chip evacuation at the rear, has significantly reduced the footprint of the Heller F series: it is only about 3,700 mm wide. Combined with Heller’s new rack-type tool magazines, both machines are still extremely compact while offering high tool storage capacity. Despite the ample tool space they provide, they are almost two meters slimmer than the previous models – particularly useful for automating multiple machining centers. Four machines can be placed in a row where previously only three could be installed.
The various expansion stages differ only in length. The rack magazines, designed for HSK-A 100 tools with storage capacities of 200, 260 and 340 tools, are no longer than 7,000 mm. They provide 489 storage positions for HSK-A 63 tools.
The space-saving arrangement of the tools is crucial to the compact dimensions, enabling a high packing density. The integrated preferential storage module significantly reduces tool provisioning times in practical use.
On selected machine sizes and combined with the HSK-A 100 tool interface, the preferential storage module provides space for tools up to 800 mm long. Manual tool loading is easy with an integrated rotary station. It allows up to seven HSK-A 100 or nine HSK-A 63 tools to be loaded in parallel to machining. To optimize ergonomics, Heller designed the racks so that tools can be loaded by crane at any time.
The expanded range of spindles is particularly applicable for aerospace machining. In addition to the proven versions with HSK-A 100 tool interface, the F 5000 and F 6000 can be equipped with motor spindles with HSK-A 63 interface. Speeds up to 18,000 rpm combined with short run-up times make them ideal for machining light metals – for example, complex, integral components for aircraft, machinery, or vehicles.
New tilting heads for flexibility. In terms of kinematics, the range will see a further expansion later this year with the introduction of an alternative to the swivel kinematics, tilt kinematics will be offered with four new, tilting-head machine variants. In line with the modular concept, Heller will again use the motor spindle variants developed in-house. Combined with HSK-A 100, they offer torques up to 400 Nm, while the HSK-A 63 versions focus on speeds up to 18,000 rpm.
Tilting heads offer a significant increase in flexibility for five-axis machining. The tilt kinematics can also be used to machine recesses and undercuts, for example.
Head of development Manuel Gerst explained: “Especially for the production of integral components, which are often required in the aerospace industry, it is very important that the machines used can also machine at a negative angle. Mechanically, this is not possible with swivel heads. We have designed the new tilting heads specifically with these applications in mind. With an HSK-A 63 tool interface and a high-speed spindle, they are predestined for such applications.”
Like the F 6000, the F 5000 five-axis machining center is available with automatic pallet changer (APC) as standard. This is also the first level of the machine’s automation.
In addition, Heller will also offer a Flex version of the machine without the integrated pallet changer. In this version, the F 5000 and F 6000 are approximately one meter shorter. “The Flex version really comes into its own as part of an integrated system with external automation. Combined with linear and rotary pallet storage solutions, machine utilization time can be significantly increased, whilst offering greater flexibility in terms of workpiece size and pallet clamping load,” said Manuel Gerst. The advantages of the Flex version are particularly noticeable on workpieces with long cycle times, as the slightly longer workpiece changeover times compared to the APC version are negligible.
The Flex version is offered in conjunction with external automation. It is possible to add a Heller rotary pallet storage (RSP) as well as a standardized linear pallet storage. By the way: automation can also be upgraded on APC versions. And for those who do not wish to integrate an automation system from the outset, Heller offers the ‘Automation Ready’ option. It allows standardized pallet automation systems to be retrofitted quickly and easily.
With an optional Mill/Turn function, F Series machines can be used for combined milling and turning operations. This is made possible by the high-torque DDT (Direct Drive Turning) rotary table, with speeds of up to 700 rpm. In addition to conventional milling and drilling operations, longitudinal or planar machining of external and internal contours is possible, as is the production of a wide variety of undercuts and recesses – all in a single set-up. Even cutting external and internal threads is possible. This eliminates the need for reclamping on separate turning machines, resulting in improved workpiece accuracy and significantly reduced cycle times, especially for series products.
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