Orbital Milling. A Buyers Guide.

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Howard Sparks
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1 A Buyers Guide

About Mirage Machines Mirage portable machine tools optimise the performance of on-site assets by achieving operational excellence, maximising

Our proprietary technology drives the development of the most reliable, durable, efficient and precise portable machine tools on the market, that

Our portfolio of portable machine tools are suitable for a diverse range of on-site machining applications.

generation ship build & repair mining & construction subsea utilities Our products are supported by industry experts who work closely with our

2 About Mirage Machines Mirage portable machine tools optimise the performance of on-site assets by achieving operational excellence, maximising uptime and improving productivity. Our proprietary technology drives the development of the most reliable, durable, efficient and precise portable machine tools on the market, that are capable of delivering the most exacting standards of tolerance with the highest quality output. Our portfolio of portable machine tools are suitable for a diverse range of on-site machining applications. Mirage have been granted ISO 9001:2008 certification for our design and manufacturing systems and we are able to provide full CE certification for our products. Industries Mirage manufacture a range of portable machines for a wide variety of applications and industries including: oil & gas wind power power generation ship build & repair mining & construction subsea utilities Our products are supported by industry experts who work closely with our customers to optimise performance for industry specific applications. With extensive experience within service companies, our teams understand the dynamics of a wide range of industries and have the capability to deliver turn-key solutions that both meet specific requirements and address complex challenges. Contact Us T: +44 (0) F: +44 (0) sales@miragemachines.com Mirage Machines 8-10 Enterprise Way Jubilee Parkway Derby DE21 4BB UK

3 Content 5 Overview & Gallery Wind Power 7 WP2500, WP3500, WP OM2500 (60 to 98 ) 14 OM3500 (60 to 138 ) 17 OM4500 (90 to 178 ) 20 OM6000 (98 to 237 ) 23 OM8000 (138 to 315 )

Introduction to Mirage Machines are a leading manufacturer of orbital milling machines for use in production machining or in situ machining

With a track record of delivering workshop quality tolerances time and again, we are confident that our orbital milling machines can deliver on

The rigid independent base on our machines are easy to set up and provide ultimate stability ensuring maximum performance with every use.

4 Introduction to Mirage Machines are a leading manufacturer of orbital milling machines for use in production machining or in situ machining alike. With a track record of delivering workshop quality tolerances time and again, we are confident that our orbital milling machines can deliver on even the most demanding jobs. The rigid independent base on our machines are easy to set up and provide ultimate stability ensuring maximum performance with every use. In addition to that, our machines offer a range of rotary and spindle cutting speeds to give the perfect finish, no matter what the application. The Mirage orbital milling machines can be used for a wide range of applications including: Wind turbine manufacture Wind turbine rotor blades Pedestal crane and bearing faces Hydroelectric stay ring and wear faces Ship thruster flange faces Dragline bearing faces

5 Our unique concept for the machining of flanges provides fast material

large flanges, wind turbine rotor blades and wind turbine tower flanges.

speeds Drive utilities latest precision bearing technology Drive Power

90-137" WP4500 110-177" OM2500 60-98" OM3500 60-138" OM4500 90-178" OM6000

process time Minimum distortion fast mount hydraulic base Adjustable arm

2300 to 3500mm (90 to 137 ) diameters WP4500 2800 to 4500mm (110 to 177 )

to 98") diameters OM3500 1500 to 3500mm (60 to 138") diameters Precision

Rigid adjustable mounting base OM4500 2500 to 4500mm (90 to 178 )

5 5 Our unique concept for the machining of flanges provides fast material removal with high accuracy, specifically developed for the machining of large flanges, wind turbine rotor blades and wind turbine tower flanges. Rigid, fast set independent base Variable rotary and spindle cutting speeds Drive utilities latest precision bearing technology Drive Power Machine Model Range Hydraulic Wind Power WP " WP " WP " OM " OM " OM " OM6000 OM " " WP2500, WP3500 & WP4500 Accurate and repeatable process time Minimum distortion fast mount hydraulic base Adjustable arm for different diameters WP to 2450mm (70 to 96") diameters WP to 3500mm (90 to 137 ) diameters WP to 4500mm (110 to 177 ) diameters OM2500, OM3500, OM4500 & OM6000 OM8000 OM to 2500mm (60 to 98") diameters OM to 3500mm (60 to 138") diameters Precision flatness tolerances on large diameters High torque anti backlash drive Rigid adjustable mounting base OM to 4500mm (90 to 178 ) diameters OM to 6000mm (98 to 237") diameters OM to 8000mm (138 to 315") diameters

6 6 T: +44 (0) F: +44 (0) Mirage Machines Enterprise Way Jubilee Parkway Derby DE21 4BB UK

7 WP2500, WP3500 WP4700 Wind Turbine Rotor Blade - Root End Machining (1.8m - 4.

facility Adjustable drive for different bolt pcd s A portable orbital milling solution for wind turbine root end machining.

Hydraulically driven with geared reduction rotational drive and milling spindle to accept industry standard tooling.

7 7 WP2500, WP3500 WP4700 Wind Turbine Rotor Blade - Root End Machining (1.8m - 4.5m diameters) Fast mount patented hydraulic clamp Minimal blade distortion Accurate and repeatable process time Trolley system - no crane required Portable for blade production facility Adjustable drive for different bolt pcd s A portable orbital milling solution for wind turbine root end machining. The Mirage WP range is designed for ease of use in machining 30-80m rotor blades ( mm bolt p.c.d) in a production environment. Hydraulically driven with geared reduction rotational drive and milling spindle to accept industry standard tooling. The machines have the ability to machine the root end inserts to a precision flatness tolerance while maintaining a portable nature to enable ease of movement around the blade production facility. As the length of blades increases and the bolt pcd s are relative to the increase in blade lengths, the Mirage orbital milling machines have an in built degree of flexibility in the drive and machining elements, to cope with the ever changing blade designs.

8 8 WP2500, WP3500 WP4700 Technical Details - Drive Systems WP2500-H Min Blade PCD mm WP3500-H Min Blade PCD mm WP4700-H Min Blade PCD mm Max Blade PCD mm Max Blade PCD mm Max Blade PCD mm Weight kgs Weight kgs Weight kgs Drive System Details Rotational Drive - Hydraulic Milling Spindle - Hydraulic Min / Max Drive Rotation R.P.M Surface Cutting max diameters Standard Cutting Speed (125mm face mill) Min / Max Spindle R.P.M (standard) Flatness Tolerance Spindle Travel Hydraulic Supply 100 bar (1450 p.s.i) 4.1 Kw 14.1 Kw 0 0-1m/min 400mm/min mm/Ø1m 80mm 50 L/min 5.5 Hp 5.5 Hp Ft/min 16 In/min /Ø Gal/min Blade Clamping Modules Blade Bolt P.C.D Minimum Clamping Diameter Minimum Clamping Diameter Weight Part Number 1800mm 1695mm 1745mm 1250 Kgs WP mm 2010mm 2060mm 1478 Kgs WP mm 2195mm 2245mm 1780 Kgs WP mm 2335mm 2410mm 2150 Kgs WP mm 2625mm 2725mm 2905 Kgs WP mm 3060mm 3110mm 3325 Kgs WP t.b.a t.b.a t.b.a t.b.a WP mm 4060mm 4110mm 3525 Kgs WP (Blade PCD and clamping diameters can be modified to suit specific blade configurations) The machine is supplied complete with: rotational drive ring, rotational drive motor & reduction gearbox, machining facing arm, 90mm column milling spindle, internal hydraulic chuck base assembly, jaw blocks and 3 fixed and 3 hydraulically actuated clamping jaws, toolkit, 160mm face mill cutter and inserts, hose kit and centre hydraulic distributor, all required bolts and storage / shipping box, CE certificate, packing list and operation / maintenance manual.

9 WP2500, WP3500 WP4700 Optional Accessories PP3 - Hydraulic Power Pack - 15 Kw 50 lpm / 20 lpm @ 100 bar 380/440v 3 phase Pendant control for spindle and

Machine mounting and storage Hydraulic machine lift Power pack spill tray 2 fixed and 2 free wheels Fork lifting points SUPPLIED WITHOUT MOVER WP2500-20 for

operated Electromagnetic brake Battery operated - 6 hour charge time 160mm lift Compact space envelope Manufacturers 1 year guarantee Shipping details: 150 x 65

9 9 WP2500, WP3500 WP4700 Optional Accessories PP3 - Hydraulic Power Pack - 15 Kw 50 lpm / bar 380/440v 3 phase Pendant control for spindle and rotation Oil cooler Frame with lifting points SUPPLIED WITHOUT OIL Shipping details: 135 x 70 x 135cm 350 Kgs Trolley - Machine Mounting and Positioning Trolley Machine mounting and storage Hydraulic machine lift Power pack spill tray 2 fixed and 2 free wheels Fork lifting points SUPPLIED WITHOUT MOVER WP for WP2500-H WP for WP3500-H WP for WP4700-H Mover - Machine and Trolley Mover 5600 or 8000 Kgs capacity load mover Pull or push force pedestrian operated Electromagnetic brake Battery operated - 6 hour charge time 160mm lift Compact space envelope Manufacturers 1 year guarantee Shipping details: 150 x 65 x 125cm 405 Kgs Laser-1 Laser for flange flatness High precision laser system for measuring root end flatness once machined. Spin laser technology with target and portable reader

10 10 WP2500, WP3500 WP4700 Flatness Tolerances The flatness tolerances achieved above are independently 3rd party verified by laser on a 61.5m blade root end with the WP3500 drive, a WP hydraulic clamping base and PP3 hydraulic power pack.

11 11 OM ( mm) Precision preloaded linear rotary drive Adjustable fast set clamping base Hydraulic anti backlash drive Radial contour milling feed A unique concept for the machining of flanges which provides fast material removal with high accuracy. Specifically developed for the machining of large flanges, wind turbine rotor blades and wind turbine tower flanges. The machine is supplied complete with drive ring, drive motors and reduction gearbox, facing feed /direction gearbox and pick up gearbox, milling facing arm and 90mm column spindle internal chuck base assembly, jaw blocks and 8 off clamping jaws 4 of which are adjustable, toolkit, hose kit and centre distributor, all required bolts and storage / shipping box, CE certificate, packing list and manual. Optional - Production quick install 3 point mounting system, hydraulic trolley, power pack.

12 12 OM2500 Technical Details Min / Max Turning Diameter Min / Max Clamping Diameter 1500mm (60 ) 1500mm (60 ) 2500mm (98 ) 2500mm (98 ) Rotational Drive Milling Spindle - Hydraulic (standard) Min / Max Rotation R.P.M (standard) Surface Cutting Max Diameter Standard Cutting Speed (125mm face) Min / Max Spindle R.P.M (standard) Flatness Tolderance Spindle Down Feed 3.7 Kw 3.7 Kw m / min 400mm / min mm / Ø1m 80mm 5.0 Hp 5.0 Hp Ft / min 16 / min / Ø Hydraulic 1050 p.s.i (70 bar) 60 L / min 16 Gal / min Feed Rates (single point turning option) Min / Max Facing Feeds (2 off IN / OUT) mm Weights and Dimensions Machine Weight Shipping Weight Shipping Dimensions 900 Kgs 1980 Lbs 1050 Kgs 2310 Lbs L - 220cm - (86 ) W - 174cm - (68 ) H - 58cm - (22 )

13 13 OM2500 Optional Accessories PP3-15 Hp Hydraulic Power Pack WP Hydraulic Mounting Base 50 Lpm / bar - 380/440v 3 phase - pendant control Machine base for production mounting in to turbine rotor blades / towers WP WP Single point turning tool post, carriage and tools Extended milling spindle - 250mm stroke NEG Swivel head milling carriage and spindle WP Tube sheet mounting kit Mount the WP6000 to tube sheets efficiently MM1080ie-20 Tube sheet back facing kit Machine heat exchanger flange back faces in one setup Tooling We can supply all inserted face mills & inserts and special form tools on request

14 OM3500 60-138 (1500-3500mm) Precision preloaded linear rotary drive Adjustable fast set clamping base Hydraulic anti backlash drive Radial contour milling feed A unique concept for the machining

The machine is supplied complete with drive ring, drive motors and reduction gearbox, facing feed /direction gearbox and pick up gearbox, Milling facing arm and 90mm column spindle internal chuck

14 14 OM ( mm) Precision preloaded linear rotary drive Adjustable fast set clamping base Hydraulic anti backlash drive Radial contour milling feed A unique concept for the machining of flanges which provides fast material removal with high accuracy. Specifically developed for the machining of large flanges, wind turbine rotor blades and wind turbine tower flanges. The machine is supplied complete with drive ring, drive motors and reduction gearbox, facing feed /direction gearbox and pick up gearbox, Milling facing arm and 90mm column spindle internal chuck base assembly, jaw blocks and 8 off clamping jaws 4 of which are adjustable, toolkit, hose kit and centre distributor, all required bolts and storage / shipping box, CE certificate, packing list and manual. Optional - Production quick install 3 point mounting system, hydraulic trolley, power pack.

15 15 OM3500 Technical Details Min / Max Turning Diameter Min / Max Clamping Diameter 1500mm (60 ) 1500mm (60 ) 3500mm (138 ) 3425mm (135 ) Rotational Drive Milling Spindle - Hydraulic (standard) Min / Max Rotation R.P.M (standard) Surface Cutting Max Diameter Standard Cutting Speed (125mm face) Min / Max Spindle R.P.M (standard) Flatness Tolderance Spindle Down Feed 3.7 Kw 3.7 Kw m / min 400mm / min mm / Ø1m 80mm 5.0 Hp 5.0 Hp Ft / min 16 / min / Ø Hydraulic 1050 p.s.i (70 bar) 60 L / min 16 Gal / min Feed Rates (single point turning option) Min / Max Facing Feeds (2 off IN / OUT) mm Weights and Dimensions Machine Weight Shipping Weight Shipping Dimensions 2976 Kgs 7107 Kgs 6547 Lbs Lbs L - 252cm - (99 ) W - 228cm - (89 ) H - 92cm - (36 ) L - 321cm - (126 ) W - 227cm - (89 ) H - 236cm - (93 )

16 16 OM3500 Optional Accessories PP3-15 Hp Hydraulic Power Pack WP Hydraulic Mounting Base 50 Lpm / bar - 380/440v 3 phase - pendant control Machine base for production mounting in to turbine rotor blades / towers WP WP Single point turning tool post, carriage and tools Extended milling spindle - 250mm stroke NEG Swivel head milling carriage and spindle WP Tube sheet mounting kit Mount the WP6000 to tube sheets efficiently MM1080ie-20 Tube sheet back facing kit Machine heat exchanger flange back faces in one setup Tooling We can supply all inserted face mills & inserts and special form tools on request

17 OM4500 90-178 (2500-4500mm) Precision preloaded linear rotary drive Adjustable fast set clamping base Hydraulic anti backlash drive Radial contour milling feed A unique concept for the machining

17 17 OM ( mm) Precision preloaded linear rotary drive Adjustable fast set clamping base Hydraulic anti backlash drive Radial contour milling feed A unique concept for the machining of flanges which provides fast material removal with high accuracy. Specifically developed for the machining of large flanges, wind turbine rotor blades and wind turbine tower flanges The machine is supplied complete with drive ring, drive motors and reduction gearbox, facing feed /direction gearbox and pick up gearbox, milling facing arm and 90mm column spindle, internal chuck base assembly, jaw blocks and 8 off clamping jaws 4 of which are adjustable, toolkit, hose kit and centre distributor, all required bolts and storage / shipping box, CE certificate, packing list and manual. Optional - Production quick install 3 point mounting system, hydraulic trolley, power pack.

18 18 OM4500 Technical Details Min / Max Turning Diameter Min / Max Clamping Diameter 2500mm (98 ) 2500mm (98 ) 4500mm(178 ) 4000mm(157 ) Rotational Drive Milling Spindle - Hydraulic (standard) Min / Max Rotation R.P.M (standard) Surface Cutting Max Diameter Standard Cutting Speed (125mm face) Min / Max Spindle R.P.M (standard) Flatness Tolderance Spindle Down Feed 3.7 Kw 3.7 Kw m/min 400mm/min mm/Ø1m 80mm 5.0 Hp 5.0 Hp Ft/min 16 /min /Ø Hydraulic 1050 p.s.i (70 bar) 60 L/min 16 Gal/min Feed Rates (single point turning option) Min / Max Facing Feeds (2 off IN / OUT) mm Weights and Dimensions Machine Weight Shipping Weight Shipping Dimensions 2976 Kgs 7107 Kgs 6547 Lbs Lbs L - 271cm - (107 ) W - 231cm - (91 ) H - 97cm - (38 ) L - 375cm - (147 ) W - 83cm - (33 ) H - 79cm - (31 )

19 19 OM4500 Optional Accessories PP3-15 Hp Hydraulic Power Pack WP Hydraulic Mounting Base 50 Lpm / bar - 380/440v 3 phase - pendant control Machine base for production mounting in to turbine rotor blades / towers WP WP Single point turning tool post, carriage and tools Extended milling spindle - 250mm stroke NEG Swivel head milling carriage and spindle WP Tube sheet mounting kit Mount the WP6000 to tube sheets efficiently MM1080ie-20 Tube sheet back facing kit Machine heat exchanger flange back faces in one setup Tooling We can supply all inserted face mills & inserts and special form tools on request

20 OM6000 98-237 (2500-6000mm) Precision preloaded rotary drive Adjustable fast set clamping base Hydraulic anti backlash drive Radial contour milling feed A unique concept for the machining of

20 20 OM ( mm) Precision preloaded rotary drive Adjustable fast set clamping base Hydraulic anti backlash drive Radial contour milling feed A unique concept for the machining of flanges which provides fast material removal with high accuracy. Specifically developed for the machining of large flanges, wind turbine rotor blades and wind turbine tower flanges. The machine is supplied complete with drive ring, drive motors and reduction gearbox, facing feed /direction gearbox and pick up gearbox, milling facing arm and 90mm column spindle, internal chuck base assembly, jaw blocks and 8 off clamping jaws 4 of which are adjustable, toolkit, hose kit and centre distributor, all required bolts and storage / shipping box, CE certificate, packing list and manual. Optional - Production quick install 3 point mounting system, hydraulic trolley, power pack.

21 21 OM6000 Technical Details Min / Max Turning Diameter Min / Max Clamping Diameter 2500mm (98 ) 2600mm (102 ) 6000mm(237 ) 5900mm(232 ) Rotational Drive Milling Spindle - Hydraulic (standard) Min / Max Rotation R.P.M (standard) Surface Cutting Max Diameter Standard Cutting Speed (125mm face) Min / Max Spindle R.P.M (standard) Flatness Tolerance Spindle Down Feed 3.7 Kw 3.7 Kw m/min 400mm/min mm / Ø1m 80mm 5.0 Hp 5.0 Hp Ft/min 16 / min / Ø Hydraulic 1050 p.s.i (70 bar) 60 L/min 16 Gal/min Feed Rates (single point turning option) Min / Max Facing Feeds (2 off IN / OUT) mm Weights and Dimensions Machine Weight Shipping Weight Shipping Dimensions 3200 Kgs 7950 Kgs 7040 Lbs Lbs L - 300cm - (119 ) W - 228cm - (89 ) H - 92cm - (36 ) L - 321cm - (126 ) W - 227cm - (89 ) H - 236cm - (93 )

22 OM6000 Optional Accessories PP3-15 Hp Hydraulic Power Pack WP3500-6 Hydraulic Mounting Base 50 Lpm / 20 Lpm @ 100 bar - 380/440v 3 phase - pendant control Machine base for production mounting in

22 22 OM6000 Optional Accessories PP3-15 Hp Hydraulic Power Pack WP Hydraulic Mounting Base 50 Lpm / bar - 380/440v 3 phase - pendant control Machine base for production mounting in to turbine rotor blades / towers WP WP Single point turning tool post, carriage and tools Extended milling spindle - 250mm stroke NEG Swivel head milling carriage and spindle WP Tube sheet mounting kit Mount the WP6000 to tube sheets efficiently MM1080ie-20 Tube sheet back facing kit Machine heat exchanger flange back faces in one setup Tooling We can supply all inserted face mills & inserts and special form tools on request

23 OM8000 138-315 (3500-8000mm) High precision and load capacity drive bearing Twin high torque hydraulic drives Induction hardened V rails Adjustable fast set clamping base Radial milling feed A

23 23 OM ( mm) High precision and load capacity drive bearing Twin high torque hydraulic drives Induction hardened V rails Adjustable fast set clamping base Radial milling feed A unique new concept in ﬂange facing with the machine having the capability to orbital mill ﬂanges. The machine is supplied complete with drive ring, drive motors and reduction gearboxes, split half support ring, facing feed gearbox, milling facing arm and 132mm column spindle, linear support bearing and mounting plate, internal chuck base assembly, jaw blocks and 8 oﬀ clamping jaws - 4 of which are adjustable, toolkit, hose kit and centre distributor, all required bolts and storage / shipping box, CE certiﬁcate, packing list and manual.

24 OM8000 Technical Details Min / Max Facing Diameter Min / Max Clamping Diameter Rotational Drive - twin hydraulic (5.0 Hp) Milling Spindle - Hydraulic (standard) Min / Max Rotation R.P.

24 24 OM8000 Technical Details Min / Max Facing Diameter Min / Max Clamping Diameter Rotational Drive - twin hydraulic (5.0 Hp) Milling Spindle - Hydraulic (standard) Min / Max Rotation R.P.M (standard) Surface Max Diameter Min / Max Spindle R.P.M (standard) Spindle Down Feed Hydraulic 1050 p.s.i (70 bar) 3500mm (138 ) 3500mm (138 ) 7.4 Kw 3.7 Kw m/min 25 85mm 60 L/min 8000mm(315 ) 6985mm(275 ) 10.0 Hp 5.0 Hp Ft/min Gal/min Feed Rates Standard Cutting Speed (125mm face) 400mm/min 16 /min Weights and Dimensions Machine Weight (not including the base) Shipping Weight Shipping Dimensions 3500 Kgs 8950 Kgs 7700 Lbs Lbs L - 300cm - (119 ) W - 228cm - (89 ) H - 92cm - (36 ) L - 321cm - (126 ) W - 227cm - (89 ) H - 236cm - (93 )

25 OM8000 Optional Accessories Tooling We can supply all inserted face mills & inserts and special form tools on request PP3-15 Hp Hydraulic Power Pack 50 Lpm / 20 Lpm @ 100 bar - 380/440v 3 phase -

25 25 OM8000 Optional Accessories Tooling We can supply all inserted face mills & inserts and special form tools on request PP3-15 Hp Hydraulic Power Pack 50 Lpm / bar - 380/440v 3 phase - pendant control WP WP Single point turning tool post, carriage and tools Extended milling spindle - 250mm stroke NEG Swivel head milling carriage and spindle WP Tube sheet mounting kit Mount the WP6000 to tube sheets efficiently MM1080ie-20 Tube sheet back facing kit Machine heat exchanger flange back faces in one setup

26 26 Rental Managed from our specially designed UK facility, Mirage Machines offer a comprehensive and ever expanding range of portable machine tools specifically for rental by our customers, on a flexible daily, weekly or monthly basis. Whether you have machine shortages due to breakdown, a peak demand shortage or require a one-off application, our rental equipment can be there when you need it most. Training & Site Support Mirage have developed a range of specialist training packages, delivered by our experienced training team at our UK facility, or on-site across the globe, for all aspects of in-situ machining for your site service technicians. The team is made up of dedicated and specially trained service personnel, for your support and training in all in-situ applications of Mirage kit. With vast experience of application in demanding situations, let our team train and support your technicians for success. Servicing & Refurbishment Our team of dedicated, time served engineers offer a wealth of skills and experience in building and maintaining machine tools of all types. If you have a requirement for servicing or refurbishment, we can reverse engineer a bespoke solution for you, regardless of original manufacturer, condition or age. Maintain the quality of your machining assets and keep them on-line with our machine maintenance, servicing and refurbishment packages. T: +44 (0) F: +44 (0) sales@miragemachines.com Mirage Machines 8-10 Enterprise Way Jubilee Parkway Derby DE21 4BB UK

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