ROTAMILL 22Gantry Type Milling Center for 5/6 Axis Machining
High Performance with 6 Axes
Edi
tion
01/2
016
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Rotamill 22 Sets a Course in 5/6 Axis Machining
The machining centre in highly stable gantry design allows maximum precision with highest dynamics. Rotamill makes both: whether processing difficult machinable materials (e. g. in aerospace industry) or complex milling in tool and mould making that require high surface quality and precision.
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Aerospace
Energy technology
Machine construction
Tool and mould making
Prototyping
Turbine
Gear wheel
Motor housing
Swivel housing
Injection mould
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Highlights at a glance
Up to 6 machining axes (X, Y, Z, A, C optional, rotary table) in combination with modern control systems are available for simultaneous machining.
• Complete production in one setting for high productivity and flexibility• Ergonomically optimised machine construction for maximum ease of use• Ideal for tool and mould makers with changing demands on workpiece sizes and piece numbers
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• High dynamic rotational axes (milling head, rotary table) with powerful highly precise direct drives
• The machine base filled with polymer concrete which offering exceptional vibration damping.
• Optimal accessibility of the working space / easy loading
• Big vision panel for the inspection of the working area
• Efficient chip disposal by means of spray nozzles in the machine bed and chip conveyor
• Effective cooling technology for repeatability and high thermal stability
• All around safety system according to DIN/EN 12417
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High grade components:
• Feed axes X-/ Y-/ Z with • high dynamic Siemens AC servo motors, • Ball bearing screws in all axes, size 63 • Multiple linear guides for high acceleration with low friction, each with 6 or rather 8 guiding carriages, size 55
• Control systems: • Standard Heidenhain TNC 530/640 HSCI • Option: Siemens 840D solutionline
• Heidenhain precision guides (in X, Y, Z) and absolute encoders (A-axis and rotary table, optional C-axis as 6th axis in the ram) for most precise position detection
• Tool changer/ chain magazine incl. tool calibration with • Standard: tool places HSK-A 63, • Option: HSK-A 100 • Option: stage of extension with up to 80 tools
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The Rotamill machining centre incorporates a turning option together with high power mil-ling heads that lead the way of high duty machining.With this machine, piece times can be reduced significantly through complete processing in one setting. As a 6 axis version it enables machining of hightech components with dia-meters up to 1.800 mm and a weight up to 5t.The advantages of Rotamill come mainly into effect, where highest machining performance and flexibility are demanded. The direct driven rotary table with 100 rpm (with up to 250 rpm as highspeed version) in combination with effective spindle clamping offers combined turning/milling operations.
Turning/milling centres set standards for economic, precise and customised solutions.
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Motor spindle palletAs main drives the high performance spindles made by CyTec are used, that are cha-racterised by reliable operation and long life service, and are steadily advanced. For each task the appropriate spindle is available:From allround spindles with 21 / 27 / 34 kW up to 60 kW high speed spindle with 24.000 rpm. The new 42 kW turning/milling spindle with 250 Nm and HSK-T100 inter-face enables in addition to milling and drilling effective turning operations. The key: the spindle shaft can be locked by a Hirth serration as clamping device.
Power S1Power S6
Torque S1 Torque S6
Allround applicationsCS-27-180
Nom. power S1 (kW): 27
Max. torque S6 (Nm): 170
Max. speed (rpm): 12.000
Tool interface: HSK-A100*
Heavy duty millingCS-34-180-S
Nom. power S1 (kW): 34
Max. torque S6 (Nm): 220
Max. speed (rpm): 12.000
Tool interface: HSK-A100*
Turning/millingCST-42-180-S
Nom. power S1 (kW): 42
Max. torque S6 (Nm): 250
Max. speed (rpm): 10.000
Tool interface: HSK-T100*
Turning/milling
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Highspeed applicationsCS-21-180-A
Nom. power S1 (kW): 21
Max. torque S6 (Nm): 130
Max. speed (rpm): 18.000
Tool interface: HSK-A63*
Highspeed-ApplicationsCS-60-180-S
Nom. power S1 (kW): 60
Max. torque S6 (Nm): 109
Max. speed (rpm): 22.000
Tool interface: HSK-A63*
Highspeed-ApplicationsCS-60-180-S
40
60
80
100
120
20
40
100
24
00
0
21
00
0
18
00
0
15
00
0
12
00
0
90
00
60
00
30
00
80
60
20
*Other tool interfaces (e. g. Coromant Capto) available on customer demand.
1400 1400
1015
Interference diameter 2.000 mm
Travel range axesX / Y / Z2.200 / 1.300 / 1.200 mm
Gantry height1.380 mm
Axis dynamicRapid traverse X / Y / Z 50m/min
Acceleration 4 m/s2
Working area spindleVertical distance spindle nose - table top -184 up to +1015 mm
Horizontal distance spindle nose - table center125 up to 1.325 mm
Interference areaDiameter 2.000 mm
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Fork milling head A-axisSwivel angle +/- 110°
Swivel speed 360°/ s
Torque 1.000 Nm
Clamping torque 4.000 Nm
Positioning accuracy +/- 2,5“
Rotary tableFace plate diameter Standard 1.800 mm
Table load max. (centric) 6.000 kg
Maximum speed 100 / 250 rpm
Torque max. 7.200 Nm
Clamping torque 25.000 Nm
Positioning accuracy +/- 2,5“
Machine data
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Examples injection moulds:Examples injection moulds:
1.800 x 730 x 780 mm
1.290 x 1.140 x 410 mm
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Option:
Rotary table with pallet clamping system
NC rotary table and NC milling head
NC-Rotary table and NC-Milling head:• Free of wear gearless direct drive with torque motors
• 3 different face plate diameters available on customers demand (Standard 1800 mm, optional 1500 and 1200 mm)
• High angular acceleration by means of high torque combined with extremely short positioning times
• Integrated clamp function by means of distorsion free hydraulically operated clamping bushes, e. g. for rough machining tasks
• High bearing rigidity by means of free from backlash preloaded axial/radial bearings
• Highly precise absolute value encoders for optimised position control
• As an option, the rotary table can be quipped with pallet clamping systems for quick workpiece exchange
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Automatic head exchange
The Rotamill allows for an automatic head change(e. g. from fork milling head to the vertical turning head). For this purpose three pivotable pickup stations are equipped each with a separate milling head. Thereby the operator can fulfill the demands for optimum relation of surface quality, machining speed and precision. Additionally a dual tool system is available: for milling HSK A100 (HSK A63) and for turning HSK T63 or Sandvik Coromant Capto.
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Options for loading
Loading big parts:A flexible sliding roof and doors that can be opened wide enable the easy loading of large parts with from either front and from above. The sliding roof is moved forward and backward automatically by the travelling X axis.
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Max. workpiece size
1359
Ope
ning
wor
king
are
a 18
8
Portal width 1900
650
1656
1090
Wor
king
are
a 27
46
650
Y-Travel 1300
841
X-Tr
avel
220
0
Z
Ø1498
Ø1550
125,
5
560
Ø13001
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head exchange stationextended
The maximum workpiece sizeis limited by:- the tool length (1),- the lowest Z-position of the spindle (2)- the position/number of the extended
head exchange stations (3)- Tool exchange and calibration
715,
5 (to
ol le
ngth
300
)
1015
,5 (t
ool l
engt
h 0)
Max.workpiece size
not possible in caseof head exchange(2 heads)
These data refer toa 21kW spindle with110mm spindle nose
In terms of high power, efficiency and precision, the high end products of manufacturer Heidenhain are the best sui-ted.
Control systems
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CMS Comprehensive machine protection through Bran-kamp collision monitoring
• Immediate detection of rapid force changes
• Minimises subsequent damage caused by pro- gramming, setup and ope- rating errors
• Enhances the life span of the machine
SGSMonitoring of the linear dis-placement of the spindle
• Sensor on the spindle nose detects thermal linear expansion
• Data are integrated in the CNC control to compensa- te linear deviation
• Resistant to dirt and heat
Extendedprecision control
• Automatic checking and correction of axis accuracy in the space
• Easiest handling and pro- gramming by the operator
• Highest precision in 5 axis machining
EnergySaving
• Energy feedback during braking process
• High power LED lamps substitute conven- tional machine lights
• Extensive energy saving functions
• According to requirements, de-activation of ancillary components
Heidenhain TNC 640 HSCI
• HSCI - HEIDENHAIN Serial Controller Interface
• Shop or DIN/ISO-programming
• Fastest program editing by means of cleartext programming
• Graphic programming
• High performance processor (1,8 GHZ) and regulator
• Significantly higher speed during program process for very good surfaces, interpolation time approx. 0,5 ms
• Higher simulation speed and enhanced display through graphic test run
• Higher performance during collision moni- toring and 5 axis functions
Option: Siemens 840D solutionline
• Easiest interactive programming for turning and milling
• MDynamics as optimal control for the tool and mould maker
• Minimised downtimes and accelerated setting times by means of powerful measuring cycles
• “Advanced Surface II“-programming enables maximum speed and surface quality
• New user interface “SINUMERIK Operate“
• High performance processor (1,85 GHZ) and regulator, 1 GB RAM
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Options/additional features
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Option extended tool magazine
Differing from the standard magazine with 48 tool places, magazines with 60 and 72 places for HSK-A63 are offered
Option minimal quantities of lubricant (MQL)
• Tool life is enhanced significantly• Process periods can be shortened by 30% • Check- and maintenance effort for the coolant is dispensed• Lower heat input into the workpiece
Option turning/milling spindle with shaft clamping
This new 42 kW spindle has a HSK-T interface and an additional Hirth serration, that clamps the spindle shaft rigidly when required. So this model offers not only milling and drilling, but also effective turning operations.
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Option suction device
For the protection of the working area and of the ope-rator, an effective suction system on the machining head is available. Dust, steam, smoke and chips are discharged on the spot. By means of a linear drive the suction ring is posi-tioned directly to the workpiece surface, so that all generated emissions are removed properly.
Option extended Y travel
The Y travel/working range can be extended, in this example to 1600 mm. So the machining of cubic workpieces with a lateral length of 1500 mm is possible.
Option pallet change system
The advantages of automatic pallet change systems:• no downtimes for loading and unloading of the workpieces
• workpiece preparation outside the machine with optimised flexibility
• enhancement of productivity through external workpiece measurement
• extended safety in the working area through unmanned operation
Option special heads
For individual applications which are different from the normal machining tasks, special attachment heads are available as an alternative to the common M21 milling head: • drilling/boring heads• compacte S8 milling heads e. g. for the manufactu- ring of models and prototypes • skimming/turning heads• grinding heads
Y-travel 1600
X-travel2200
800 800
135
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841
Workpiece
dia
gon
al2121
15
00
�
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Dimensions / Technical Data
Rot. table Ø 1800
Hei
ght m
in. 4
319
Hei
ght m
ax. 5
147
Clearance
Mac
hine
leng
th 4
501
6774
Doors closed 2990
Doors open 4890
Machine width 4055
6326
6547
working area 1878
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Travel range Axes X / Y / Z 2.200 / 1.300 / 1.200 mm
Working area spindle Vertical distance spindle nose - table top -184 up to +1015 mm
Horizontal distance spindle nose - table center 125 up to 1.325 mm
Gantry height 1.380 mm
Interference area Diameter 2.000 mm
Feed force X / Y / Z 10.000 N
Axis dynamic Rapid traverse X / Y / Z 50.000 mm/min
Acceleration 4 m/s2
Fork milling head A-axis
Swivel angle +/- 110°
Swivel speed 360°/ min
Torque 1.000 Nm
Clamping torque 4.000 Nm
Positioning accuracy +/- 2,5“
Motor spindles Technical data see page 9
Tool magazine
Tool places HSK-A 63 / HSK A-100 48 / 39
Tool weight max. HSK-A 63 / HSK A-100 8 / 15 kg
Tool length max. 300 mm
Tool diameter HSK-A63 / HSK-A 100 100 / 125 mm
Rotary table
Face plate diameter Standard 1.800 mm Option 1.200 / 1.500 mm
Table load max. (centric) 6.000 kg in milling mode, 2.000 kg in turning mode
Maximum speed 100 rpm (optional 250 rpm)
Positioning accuracy +/- 2,5“
Clamping torque 25.000 Nm
Torque max. 7.200 Nm
Distance measurement all axes X / Y / Z / C / A / B direct, absolute encoder (Heidenhain)
Machine control Standard: Heidenhain iTNC 640 HSCI
Option: Siemens Sinumerik 840 D solution line
Chip disposal
in Y direction Drag link or slat band conveyor
Capacity of paper band filter device 1.600 litres
Coolant pressure CTS / ECS 60 / 20 bar
Filter performance 400 litres/min
Setting-up data
Place requirement X / Y / Z (each without coolant device)
6.500 / 6.200 / 5.200 mm
Machine weight 36.000 kg
Total power input 125 KVA
Mains connection 3 x 400 V / 50 Hz
Compressed air supply 6 bar
EDEL Entwicklung und Vertriebs-GmbHCarl-Zeiss Str. 7 D-72124 PliezhausenTelefon: +49 7127 929499-0 Telefax: +49 7127 929499-9 E-mail: [email protected] Internet: www.edelgmbh.de Edition 01/2016
Production plant
Service center