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
RatioLine G160, G250, G400
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
• 2 work spindles, max.
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
• 2 work spindles, max.
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
• 2 work spindles, max.
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
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Impressive machine construction, precisely tuned
RatioLine G160, G250, G400
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.
RatioLine G160, G250, G400
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
RatioLine G160, G250, G400
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
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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
RatioLine G160, G250, G400
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
RatioLine G160, G250, G400
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 magazine max. 2 x 32 HSK-A40
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
Swing diameter mm 560
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
Tool carrier 1 and 3 X Z Y B
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
Tool system DIN 69893 HSK-A50
Speed rpm 6000 / 1500
Power at 25% kW 9.4
Torque at 25% Nm 19 / 76
Tool magazine max. 4 x 32 HSK-A50
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)
Tool system DIN 69893 HSK-A63
Speed rpm 12000 / 18000 (optional)
Power at 100% / 25% kW 27.5 / 27.5
Torque at 100% / 25% Nm 75 / 115
Tool magazine max. 4 x 20 HSK-A63
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
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
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, weight and connected power with maximum configuration
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
Control INDEX C200-4D (based on Siemens 840D powerline)
18
Technical data G400
Work area
Turning lenght mm 1250 / 2000
Swing diameter mm 630
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)
Tool carrier 1 and 3 X Z Y B
Slide travel mm 320 1250 / 2000 220 360 (degrees)
Rapid traverse m/min 20 40 12 180 (degr./sec)
Turret 1 and 3
Number of stations 12
Cylindrical shaft mounting DIN 69880 mm 40 x 63
Tool drive speed rpm 6000
Tool drive power at 25% kW 17
Tool drive torque at 25% Nm 36
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
Tool magazine max. 4 x 20 HSK-A63
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
Number of stations 10
Cylindrical shaft mounting DIN 69880 mm 40 x 63
Tool drive speed min-1 6000
Tool drive power at 25% kW 11.3
Tool drive torque at 25% Nm 21
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, weight and connected power with maximum configuration
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
Control INDEX C200-4D (based on Siemens 840D powerline)
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
LL90
02.4
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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