Engineered in Germany built in the USA

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1 Communications Issue 2016//02 UnionChemnitz and KPM are first US manufacturers of fully hydrostatic horizontal boring mills Engineered in Germany built in the USA Horizontal boring and milling machines are currently imported into the USA by the overwhelming majority of manufacturers. UnionChemnitz presents its first HBM built in the USA in cooperation with its sister company KPM at the IMTS The floor-type horizontal boring mill with 6.4 (162 mm) spindle diameter (PCR 160) is unique in the market: it is the first one built in the USA with a complete hydrostatic guidance system. Thanks to the hydrostatic guidance of both the column and the RAM, the machine operates virtually wearfreely and with outstanding precision. UnionChemnitz is the oldest existing machine tool manufacturer in Europe, drawing on more than 160 years experience. In the past 15 years, the company has delivered more than 60 HBMs to North American customers. Now, the state-of-the-art horizontal boring mills are manufactured in the USA. Construction and assembly of the machines take place at UnionChemnitz s sister company KPM in close cooperation with the design department in Germany. Effective five-side machining of demanding workpieces The PCR 160 will be installed at Herkules USA in Ford City, Pennsylvania, in late Herkules USA is a leading manufacturer of machine tools. The main challenge here is machining large and demanding workpieces to very high standards in terms of accuracy and reproducibility. The machine concept was therefore specifically tailored to the customer s requirements by the UnionChemnitz design department. With an X-axis of 138 (3,500 mm) and a Y-axis of 157 (4,000 mm), the horizontal boring mill is designed for effective five-side machining of medium-size to large and heavy workpieces. The HBM will machine high-precision lathe headstock castings and other machine tool components to very tight tolerances, says Jakob Scheiffarth, Plant Manager at KPM. These headstock castings are part of 110-ton capacity lathes that will machine large gas and steam turbine rotors. Headstock castings can weigh up to 15 tons. They have an intricate geometry, combined with very high requirements in terms of accuracy, especially eccentricity and parallelism, to achieve the perfect fit for high-precision radial and thrust bearings. To guarantee the required precision even when performing heavy-duty machining tasks, the machine bed is a special design of welded steel which absorbs vibrations, and the column is strongly ribbed for extraordinary stiffness. The PCR 160 reliably compensates spindle and RAM droop as well as column tilt. In addition to stable heavy-duty machining, the machine is therefore suitable for extremely precise finishing tasks. The rotary and traversing table of the PCR 160 with a length of 98 (2,500 mm) and a width of 79 (2,000 mm) effortlessly handles workpiece weights of 20 t. The table traverses up to 59 (1,500 mm) deep in the V-axis. The B-axis of the table can be adjusted in increments of 0,001 degrees, allowing for very precise positioning of the workpiece and hence excellent machining accuracy. Custom design for additional flexibility Flexibility is essential for the machining of the components manufactured at Herkules USA. The W-axis (boring spindle) and Z-axis (RAM) of the PCR 160 have a combined length of 87 (2,200 mm), allowing for machining operation deep within the workpiece. Imported HBMs often come with a major disadvantage: they are standard, mass-produced machines which can be customized only to a very limited PCR 160: suitable for heavy-duty machining and precise finishing Article continues on the next page» Top News: New precision boring mill KG 03 // HBM machines 80-ton components in a single set-up 05 // Boring, milling and turning with a PCR

2 degree. The PCR 160, in contrast, has been custom-designed by UnionChemnitz experts and built by KPM in close cooperation with the German colleagues specifically according to Herkules USA s requirements: As short machining times are an important factor in the overall efficiency of Herkules USA s production facility, we added special equipment to reduce machining times in the HBM s specific area of application a pick-up station to switch between milling units for various machining tasks and a 60-pocket tool magazine with an automatic tool changer, says Dr. Benedikt Sitte, President and COO of UnionChemnitz. The horizontal boring mill is operated with a Heidenhain itnc 530 HSCI control and can alternatively be equipped with FANUC and Siemens controls. KPM is an expert in implementing customized solutions. We are a vertically integrated supplier of most components in our machine tools, Jakob Scheiffarth says. We manufacture rotary tables, gearboxes, milling heads and other critical assemblies. We take internally produced, proven modular components and combine them to develop custom, economical manufacturing solutions for our customers. The components are produced with the help of a modern machine inventory comprising a wide range of lathes, milling and grinding machines, as well as measuring devices all in all, the headquarters in Ford City cover 81,000 ft 2 (7,525 m 2 ). Both mechanical and electrical engineering take place in-house. The engineers and technicians at KPM draw on many years experience in manufacturing and assembling machine tools to build the boring and milling machines designed by UnionChemnitz. We have a very skilled team of 110 employees who are experts at machine tools, machining and controls integration, confirms Sam Kube, President of KPM. We even teach the art of hand-scraping to our apprentices. By combining their competences, UnionChemnitz and KPM have reached the goal of their collaborative effort: They are now the only North American manufacturers of fully hydrostatic horizontal boring mills. American customers will benefit from reduced delivery times of these high-performance machines. This is a great potential advantage for their American operations requiring horizontal boring mills, Jakob Scheiffarth states. The P-Series your advantages at a glance Allows for rough machining and high-precision superfinishing simultaneously Double hydrostatic guideways that completely enclose the RAM Dynamically controlled hydrostatic systems Extremely rigid and heavily ribbed column Compensation of spindle and RAM droop as well as column tilt Length compensation of boring spindle and RAM (option) The PCR 160 is the highlight on UnionChemnitz s booth at the IMTS 2016 Horizontal boring mill with a fully hydrostatic guidance system Contact Herkules USA Corp. 101 River Street Ford City, PA USA T: F: husa@herkules-machinetools.com herkules-machinetools.com UnionChemnitz Communications / 02

3 New precision boring mill KG unites precision and flexibility Closing the gap between a classic boring mill and a jig boring machine Highly precise and flexible machining of gear housings UnionChemnitz has developed a new precision boring mill. The KG was designed to fill the gap in the market between a classic boring mill and a jig boring machine in terms of precision as well as price-performance ratio. The machine tool manufacturer used its 160 years of experience to design a precision boring mill whose accuracy is significantly higher than that of a classic horizontal boring mill, yet comes with a classic HBM s flexibility. Machine shops in the USA as well as Europe struggle with their classic boring mills when they have to meet the tight tolerances that more demanding machining tasks require. That is why UnionChemnitz designed a boring mill which unites the advantages of a classic boring mill with those of a jig boring machine. The precision boring mill KG is based on the reliable planer type boring mills by UnionChemnitz. These offer the best design preconditions for highly precise machining results. A myriad of small optimizations and the introduction of a special thermal management result in a completely new level of machining performance UnionChemnitz enters a new, vacant market segment with its new machine. The excellent precision regarding both positioning accuracy and geometrical precision is achieved by optimized ribbing for an increased stiffness of the machine bed and column, linear guideways of the highest quality standards and hand-scraped guides. The increased table stability (GGG50) and the precision-ground table surface allow for extremely accurate machining of the most demanding workpieces. In addition, high-precision measuring devices in all axes monitor the machining performance at all times. Optimized machine concept for increased accuracy The thermal stability of the machine has been increased through various optimizations. One example is the longitudinal compensation of the boring spindle. The improved thermal management also features a cooling unit with a heating and a cooling device, temperature-controlled gear oil cooling, water-cooled main spindle and Y-axis and an air-cooled head assembly. Article continues on the next page» Stable table with precision-ground surface for machining demanding workpieces A good view on the work area: user-friendly operation from the air-conditioned operating platform 03 / UnionChemnitz Communications

4 The precision boring mill meets tolerances of less than 10 µ/2,500 mm (98 ) in terms of planeness and less than 8 µ/m 2 in terms of evenness. At the same time, the KG is extremely flexible thanks to the boring spindle, which allows for the machining of contours deep within workpieces. Compared to a jig boring machine, it offers greater degrees of freedom and therefore a broader range of machining applications. However, the investment cost is significantly lower than that of a jig boring machine. Proven precision: manufacturing of gearboxes Thorsten Mehlhorn, President and COO of Germany-based gearbox manufacturer RSGetriebe, decided to invest in the new precision boring mill in He found himself in a predicament that is familiar to many machine shops: Machining our products requires tight tolerances which cannot be met using a classic boring mill, he says. Acquiring a jig boring machine was not an option for us due to the disproportionately high investment costs on the one hand and the limited degrees of freedom on the other. Instead, Thorsten Mehlhorn looked for an alternative solution and found the new precision boring mill developed by UnionChemnitz. Precision is crucial for the products machined at RSGetriebe: the company is an expert in manufacturing highquality special gearboxes for a broad range of industries, as well as milling heads. Its high-performance custom gearboxes are used by leading companies in the plastics and machine tool industries among others, and for test stands in the automotive industry. workpieces with repeatable precision. The new precision boring mill was installed at the RSGetriebe headquarters in Sonthofen in Since then, it has demonstrated its outstanding accuracy and reliability while machining the housings of milling units for boring mills, as well as many different types of gear housings. Gearboxes with volumes of 1.5 to 2 m 3 (5 to 7 ft 3 ) and weights of up to 6 t can now be manufactured effortlessly. An additional challenge for the machine tool is the mix of different materials which have to be machined at RSGetriebe. For that reason, it is equipped for dry and wet machining. We can machine both steel and cast-iron workpieces with these two modes. That significantly expands the application range of the KG 125, RS- Getriebe s President states. In order to ensure stable temperatures during the machining process, the precision boring mill is equipped with an air-conditioned housing, including a roof and an extraction system. The machining conditions are kept at a constant level; even large temperature variations in the production facility do not affect them. An operating platform is situated within the air-conditioned housing. From here, the work RSGetriebe decided to invest in a new machine tool in order to increase its vertical range of manufacture. The goal: to expand the product range and reduce the number of components acquired by external suppliers. It soon became clear, however, that a classic boring mill would not fulfill RSGetriebe s high machining standards: The size of the workpieces and the metalcutting performance had to be considered in the choice of machine tool, but the required flexibility was a very important factor in the decision process, too. On the one hand, a broad range of workpieces had to be machined; besides milling units, that includes our entire gearbox portfolio. On the other hand, we also needed increased precision, especially for the production of milling heads, Thorsten Mehlhorn recounts. At times, the workpieces at RS Getriebe have to be machined with a precision of under mm ( ) regarding parallelism and coaxiality of surfaces and boring holes. A classic boring mill cannot meet our precision standards without an appropriate measuring strategy, Thorsten Mehlhorn says. The KG, however, reliably obtains the outstanding precision we required and saved us the investment in a costly jig boring machine. The KG with a spindle diameter of 125 mm (5 ) machines even the most demanding Machining of a milling unit with the highest precision Precision meets flexibility: precision boring mill with air-conditioned work area UnionChemnitz Communications / 04

5 area is easily accessible and the whole process can be monitored manually. That is a great advantage for our machine operators in their everyday routine, Thorsten Mehlhorn observes. Since efficiency is an important factor in the manufacturing of gearboxes, Union- Chemnitz installed a pick-up station for changing milling heads. Milling tools are changed automatically during the machining process via a 60-pocket tool changer. RSGetriebe s President Thorsten Mehlhorn is pleased with the increased efficiency in his production facility: The pick-up station, the automatic tool changer and the different milling units have significantly reduced the machining times. Thanks to the new precision boring mill, the vertical range of manufacture at RS- Getriebe has been increased. We have to purchase fewer components. On top of that, we have raised the quality of our products and reduced the unit costs at the same time. Thanks to the greater degrees of freedom, we were able to strongly improve on non-productive time, Thorsten Mehlhorn reports. His summary: The KG series by UnionChemnitz with its increased accuracy is a very interesting investment option compared to a jig boring machine. The machine s precision is nearly identical and it offers much higher degrees of freedom and greater traverse. Technical Data: KCG 125 in Operation at RSGetriebe Traverse: X-axis 2,000 mm (79 ) Y-axis 1,600 mm (63 ) Z-axis 1,500 mm (59 ) W-axis 550 mm (22 ) Table load: 6 t Table size: 1,000 x 1,250 mm (39 x 49 ) Main drive: 31 kw Boring spindle diameter: 125 mm (5 ) Tool changer: 60 pockets For more information, visit: unionchemnitz.com/kg-series Contact RSGetriebe GmbH Oberstdorfer Str Sonthofen Germany T: +49 (0) F: +49 (0) info@rsgetriebe.com rsgetriebe.com Positioning accuracy: (according to VDI / DGQ 3441, valid in air-conditioned environment only) Positioning uncertainty P linear : < 8 µm Average pos. tolerance spread P smaxlinear : < 6 µm Reversal error U maxlinear : < 3 µm Positioning deviation P alinear : < 4 µm Positioning uncertainty P rot : < 8 arcsec Average pos. tolerance spread P smaxrot : < 5 arcsec Reversal error U maxrot : < 4 arcsec Positioning deviation P arot : < 6 arcsec Job shop efficiency: machining 80-ton components in a single set-up Boring mills with turning function for extra large workpieces Magna Machine Co., based in Cincinnati, Ohio, is not simply a job shop. Its ability to handle large workpieces up to 80 t makes Magna unique. Starting with maintenance and repair for paper mills and chemical processors, the company became a specialist in machining large and heavy parts for a broad range of industries, among them energy, steel, mining and plastics. Services range from repairs to manufacturing turn-key products. Machining components of extraordinary size and magnitude, such as rotor hubs and support bases for wind turbines, calls for an exceptional line-up of machines on the shop floor. These are the roots of Magna Machine s successful partnership with UnionChemnitz. In 2012, Magna Machine set about an ambitious expansion project. The production floor was to be expanded to cover 125,000 square feet and equipped with a crane with 80 t lifting capacity. As a second step, Scott Kramer, President of Magna Machine, planned on further increasing the size of workpieces that can be machined. We had twelve UnionChemnitz machines of various sizes in operation, and we were very satisfied with their performance, he explains. However, the market took us towards larger components. We wanted to acquire a boring mill that would allow us to machine parts of up to 27 ft in diameter. Based on his positive experiences so far, he decided to invest in yet another boring mill by the German HBM expert. UnionChemnitz custom-built a horizontal boring and milling machine of the type PCR 160 with a boring spindle diameter of 6.3 (160 mm). It traverses 50 ft (15,000 mm) in the X-axis, 20 ft (6,000 mm) in the Y-axis and 59 in the Z-axis (1,500 mm). As set-up is always time-consuming and tedious, but especially so when handling exceptionally large and heavy workpieces, the aim was to allow for different machining tasks to be performed in a single set-up. The PCR 160 was therefore fitted with special equipment, providing multiple machining capabilities. In addition to boring and milling, a 157 x 157 (4,000 mm x 4,000 mm) high-speed rotary table allows The boring mill reduces cycle times and eliminates multiple set-ups Article continues on the next page» 05 / UnionChemnitz Communications

6 Job shop efficiency: machining 80-ton components in a single set-up for turning operations. Specially made boring, milling and turning heads are automatically attached from a pick-up station. We wanted the boring mill to perform multiple machining tasks in a single set-up. Now we can machine parts up to 27 in diameter on this one machine, Scott Kramer says. The boring mill reduces cycle times and increases quality by eliminating multiple set-ups. Scott Kramer s plan to increase both the size and the efficiency of the production facility was realized to his full satisfaction. Magna Machine now operates 14 Union- Chemnitz machines altogether. With its long experience and unrivalled expertise, UnionChemnitz has been a reliable partner to Magna Machine since 1999, supporting its successful transformation to achieve greater machining capacity and quality. The exceptional strength and rigidity of the PCR 160 in comparison to other boring mills is one of its major advantages, according to Scott Kramer. The machine bed is an extremely robust steel construction which reliably absorbs vibrations. A fully hydrostatic guidance system guarantees highest precision and protection from wear even when performing heavy-duty machining. Both the heavily ribbed column and the RAM are designed for extra stiffness, as well. Double hydrostatic guideways enclose the RAM completely, resulting in excellent damping of vibrations and reliable long-term stability. Multi-purpose machines increase efficiency The PCR 160 is the largest of 14 UnionChemnitz machines in operation at Magna Machine. UnionChemnitz draws on many years experience in manufacturing heavy-duty machine tools to develop versatile, customized horizontal boring mills. Another machine on the shop floor is the KCU 150, a planer-type boring mill with a spindle diameter of 5.9 (150 mm). It has an X-axis of 126 (3,200 mm), a Y-axis of 118 (3,000 mm) and a Z-axis of 59 (1,500 mm). Its performance is sufficient for turn-key manufacturing of triplex and quintuplex fracking blocks in one set-up. With an eye to the machine shop s overall efficiency, Scott Kramer wanted this boring mill to permit multiple machining operations, as well. UnionChemnitz equipped the KCU 150 with an integrated, CNC-controlled facing head to allow for boring, milling and turning. The boring spindle can be used without removing the facing head. The machine effortlessly switches between machining modes with the help of a 60-pocket tool changer. Contact Magna Machine Co Southland Rd Cincinnati, OH USA T: F: sales@magna-machine.com magna-machine.com The PCR 160 allows for boring, milling and turning of large components UnionChemnitz Communications / 06

7 Horizontal boring mill PCR 150 increases efficiency and machining quality in machine shop Boring, milling and turning with a single machine More than 60 horizontal boring mills (HBMs) by UnionChemnitz have been sold to North American customers in the past 15 years. One of its winning strengths: process integration. Customized HBMs far exceed the machining performance of conventional boring mills by combining boring, milling, turning and grinding operations in a single machine. One of these special boring mills, a HBM with a spindle diameter of 5.9 (150 mm) of the type PCR 150, has been equipped with two set-up systems to allow for a broad range of machining tasks. It features both a rotary and traversing table for boring and milling operations and a high-speed rotary table for vertical turning operations. The machine is capable of completely machining workpieces with a weight of up to 50 tons in a single set-up, saving time and money in the machine shop. UnionChemnitz is an expert in integrating special solutions for its customers. We are a market leader in manufacturing horizontal boring and milling machines that can machine workpieces with a length of up to 157 (40 m), a height of up to 39 (10 m) and a maximum weight of 250 tons, says Dr. Benedikt Sitte, President of the company. The experts at UnionChemnitz used their experience and know-how to customize a PCR 150 for the Austrian Ing. Kierein & Webel GmbH & Co KG (Kierein & Webel) to enhance the machine shop s machining capacity, flexibility and efficiency. The machine tool is designed for heavy-duty machining, precise finishing and effective five-side machining of large and heavy workpieces. High-speed rotary table for turning applications Two set-up systems for increased machining flexibility Flexibility is one of the most important qualities in a modern machine shop. In order to optimize machining time and expand the HBM s field of application at the same time, two set-up tables were integrated along the 512 (13-meter) X-axis. The first, a rotary and traversing table for boring and milling operations, has a traverse of 118 (3,000 mm) and a set-up area of 98 x 98 (2,500 x 2,500 mm) with a maximum workpiece weight of 40 tons. The second set-up system, a high-speed rotary table, allows for vertical turning operations. It has a load-bearing capacity of 50 tons and a maximum speed of 60 rpm. When performing vertical turning operations, the vertical milling unit is automatically mounted from a pick-up station integrated by UnionChemnitz. This arrangement allows for machining operations to be performed on one of the tables while another workpiece is set up on the other a huge time-saver. The HBM with a maximum power of 46 kw now covers boring, milling and turning operations on workpieces with a height of up to 138 (3,500 mm) to Kierein & Webel s complete satisfaction. To add further flexibility, the W-axis (boring spindle: 28 ; 700 mm) and Z-axis (RAM: 59 ; 1,500 mm) allow for machining deep within workpieces with a combined length of 87 (2,200 mm). The tools required for the various machining tasks are switched quickly and effortlessly with the help of an automatic 40-pocket tool changer. According to Karl Ebenlechner, COO and joint owner of Kierein & Webel, the customized PCR 150 has greatly improved his machine shop s efficiency. Ebenlechner: For the finish-machining of heavy compressor housings, which weigh 33 tons, we have to machine the crankshaft bearings to tolerances of two to three µ in diameter and alignment. You only achieve that with the help of a robust highprecision machine. Horizontal boring and milling machines by UnionChemnitz are renowned for their outstanding precision. The PCR 150 in operation at Kierein & Webel has been designed for the utmost precision down to the last detail. It was custom-built on an already existing foundation in the machine shop. The robustly designed machine bed with a backlash-free double pinion drive and gear rack, combined with the strongly ribbed steel column, guarantees extreme stiffness and thus excellent machining results, Dr. Benedikt Sitte explains. The X and Y-axes traverse in preloaded linear roller guideways and the Z-axis is hydrostatically guided, resulting in high accuracy and reliable protection from wear. Multiple droop compensation, a double precision spindle bearing with long life grease lubrication and thermal monitoring of the spindle bearings within the RAM further add to the PCR s precision. The result: a high-precision, multi-purpose machine that significantly increases efficiency and machining quality in the machine shop. Contact Besides flexibility, the machining tasks performed at Kierein & Webel require outstanding machining precision. Around 30 employees perform various machining tasks at the 70,000 ft 2 (6,500 m²) production facility located in the city of Vienna, including boring, CNC turning and milling, honing, circular grinding, toothing and tooth flank grinding. The day-to-day business includes very demanding machining challenges that are now efficiently managed by the PCR 150. An example by Karl Ing. Kierein & Webel Josef Österreicher-Gasse Vienna Austria T: +43 (1) F: +43 (1) office@kierein-webel.at kierein-webel.at The PCR 150 with a rotary and traversing table Even rotationally symmetric workpieces with a diameter of 118 (3,000 mm) can be machined in one set-up 07 / UnionChemnitz Communications

8 Powerful Precision the UnionChemnitz Product Portfolio P-Series The P-Series horizontal boring mills with a floor plate allow for powerful heavy-duty cutting during roughing operations and simultaneously provide utmost precision when performing finishing tasks. The machines of this series can be equipped with a RAM (PR-Series). K-Series The machine tool series for precise complete machining of heavy, prismatic workpieces. It can be equipped with a RAM and facing head as well as a comprehensive range of equipment. The planer type design is ideal for extremely precise machining tasks. T-Series The horizontal boring mills of the table type T-Series are specifically designed for the effective multi-side machining of medium-sized work pieces. A wide range of options and special equipment enables tailored adaptation to the customer s needs. MILLFORCE-Series The travelling column mills of the MILLFORCE-Series combine fast and exact positioning of the milling heads with excellent stability. Designed for the machining of medium-sized workpieces, they are characterized by outstanding flexibility in the machining of single parts and small or medium-sized series. UNION Werkzeugmaschinen GmbH Chemnitz Clemens-Winkler-Str Chemnitz/Germany T: +49 (0) F: +49 (0) unionchemnitz.com Contact in the USA UnionChemnitz 101 River Street Ford City, PA USA T: F: info.us@unionchemnitz.com Imprint UnionChemnitz Communications Issue: 2016//02 Responsible: HerkulesGroup Corporate Communication