Milling Heads. High Performance Milling Technology

Transcription

1 Milling Heads High Performance Milling Technology

2 2 Milling heads

3 The Heart of the Milling Machine What is the difference between a simple 3-axis milling machine and a high-end, 5-axis milling machine for simultaneous machining? Exactly: the milling head. The heart of modern milling technology deserves special attention. For every machining operation the performance, the materials which can be machined, the removal rate and the surface finish all depend on the choice of the right milling head. In addition, factors such as possible milling strategies, simultaneous machining and the size of the workpiece are all directly linked to the milling head. An exciting subject and one which Zimmermann pays a lot of attention to. For it is the strong, reliable heart which ultimately determines the true value of a milling machine. All these criteria must naturally be weighed up against the investment costs and the long term return on investment. Head and heart in one: a Zimmermann milling head has the power and performance it needs to be the heart of the portal milling machine. But as befits any fine head it is also full of intelligence and good ideas. 3

4 Zimmermann Milling Heads at a Glance VH 6 VH 5 VH 4 Extremely capable milling head with flexible MuST spindle changing concept Fast, dynamic high-tech milling head with low weight and NC controlled dust extraction Extremely rigid gearhead for heavy duty machining at high torques T ORQUE MOTOR 4 Milling heads Orientation guide to the common areas of application of the various Milling head / Spindle combinations Material Titanium Steel, castings (rough machining) Steel, castings (finish machining) Aluminium (high volume) Aluminium (finishing) Composite materials (carbon and glass fibre) Plastic, Resine, wood Polystyrene, foam, plasticine Areas of application Mould and pattern making Models and prototypes Design, styling and cubing Production, mechanical machining Aerospace (aluminium) Aerospace (titanium) Aerospace (composites) Optimally suited Well suited Less suited Description Techn. data Page Page

5 VH 3 VH 2 VH 1 The allrounder for a wide range of applications in all areas Lighter milling head for especially large working areas Compact milling head for lightweight materials and large working areas W ORM& WHEEL HARMONIC VH 6 VH 5 VH 4 VH 3 VH 2 VH 1 Roughing 44 kw 2 Nm 1 min -1 Universal 5 kw 95 Nm 24 min -1 Finishing 2 kw 27 Nm 35 min -1 Universal 52 kw 45 Nm 24 min -1 Gear 35 kw 8 Nm 56min -1 Universal 6 kw 95 Nm 22 min -1 Universal 4 kw 48 Nm 25 min -1 Universal 45 kw 67 Nm 25 min -1 Universal 15 kw 12 Nm 22 min

6 VH 6 the Extreme Head We are proud to present the milling head to you which basically shouldn't exist: extremely strong, extremely fast, extremely accurate, extremely flexible and at the same time extremely economical. Pure force For really tough milling operations you need pure power and an enormous torque. The drives completely based on zero-backlash torque motors ensure maximum dynamic behaviour and agility. To assure this force transmission while at the same time keeping the head dimensions relatively small, the torque drive is provided with a reduction gear. This results in a slimmer head with a small interference contour in the lower area which is the only one of its kind on the market. Through the high drive torques, the rotary axes are perfectly suited for use as simultaneous axes or, closed loop controlled, they can be used for maintaining position. Maximum volumes The responsiveness, agility and speed of the digital drive, coupled with the enormous driving force of the milling head and the right choice of spindle, lead to chip removal volumes in all materials, such as have never been seen before. Greatest flexibility A milling head for 5-side machining of any materials, from roughing to superfinishing and that under extremely economic conditions in one setup. This flexibility is achieved using the innovative Multiple Spindle Technology (MuST ) from Zimmermann. To read more about this, see page 13. Fields of application The unique combination of force, dynamics and flexibility makes the VH 6 ideally suitable for all fields of application where maximum performance is required. The VH 6 is specially designed for High Performance Cutting (HPC) of particularly hard and tough materials such as titanium, steel or cast iron. Its versatility makes it outstandingly economical and user friendly. Features Torque drives Reduction gear Machines FZ 5, FZ 42 T ORQUE MOTOR Automatic Spindle Changing System MuST Torque A- and C-axes 1 35 Nm 3 standard spindles with up to 5 kw / 2 Nm or 35 min -1 Hydraulic clamping of both axes with 3 Nm Coolant / MQL externally and through the tool Direct optical measuring system 6 Milling heads

7 VH 5 Pure High Tech The new VH 5 milling head represents the current technical state-of-the-art in high speed machining. Dynamics The combination of relatively low weight and torque drives enables a maximum dynamics. High speed unlimited The fastest head in the Zimmermann range. Equipped entirely with torque drives, this head / machine combination achieves astonishing overall machining times. On the one hand the direct machining time benefits from the high head speeds, on the other hand very low non-productive times can be achieved with the VH 5 during approach and withdrawal, repositioning, etc. Intelligent extraction system The VH 5 is equipped with a unique, integrated extraction system. The system is based on internal extraction. The particular highlight is a suction hood controlled by its own NC-axis. This enables efficient extraction even with the most complicated contours. This is a great advantage particularly for critical materials where chips and dust are concerned such as carbon fibre. Fields of application The VH 5 milling head is particularly suitable when milling strategies often used on the machine require extreme movements of the head within a short space of time, as in simultaneous machining. Here it can use its advantages of speed to the full. It is ideal for enormous chip removal rates, typically in solid aluminium or carbon fibre materials. The fully direct driven head is also an extremely good match for the linear FZ 38 machine where, in combination with the extremely dynamic X-, Y- and Z-axes, it is able to achieve high overall speeds. The NC controlled extraction hood for internal chip removal during machining of complex contours. Features Torque drives Torque A-axis 65 Nm and C-axis 7 Nm Weight only 53 kg 1 standard spindle with up to 52 kw / 45 Nm or 24 min -1 NC axis for dust extraction Clamping of the A- and C-axes Rotational speed A- and C-axes of 36 / s Coolant / MQL externally and through the tool Direct optical measuring system Machines T ORQUE MOTOR FZ 5 Duo, FZ 42, FZ 38, FZ 37 7

8 VH 4 The Mechanical A huge spindle torque and the high clamping forces for the rotary axes are what distinguish this special milling and drilling head. The torque giant Thanks to its robust construction, the gear spindle of the VH 4 can achieve an unbelievable torque of 8 Nm. Thus the machine is predestined for machining the hardest and toughest materials. Very large tool diameters can be used with the VH 4 head. Absolute precision Despite its brute force, the VH 4 is amazingly precise. Its enormous torque at low speeds makes the VH 4 particularly suitable for classical rough machining and subsequent milling operations as well as drilling and thread cutting at low speeds. Features W ORM& WHEEL Huge spindle torque of 8 Nm at low rotational speeds 4 4 min -1 Torque A- and C-axes 8 Nm Clamping of both axes with a clamping force of 2 Nm Ideal for optional use with angle heads, etc. Coolant / MQL externally and through the tool Direct optical measuring system Machines FZ 5, FZ 5 Duo Furthermore, hard and tough materials such as titanium do not support high rotational speeds even during finish machining and can thus be machined to a very high quality finish directly with the VH 4 head. Fields of application Wherever rough machining of the hardest and toughest materials such as high alloy steels, cast iron or titanium is required. Large tools and heavy attachement such as angular heads are also the domain of the VH 4. The FZ 5 Duo is a particularly clever solution equipped with two VH 4 milling heads or a second fork head with HF spindle from the Zimmermann modular range for rough and finish machining in one setup. 8 Milling heads

9 VH 3 The Allrounder The linchpin of the Zimmermann milling head range. There is really hardly any job which cannot be done by this high performance head. An allrounder in the best sense of the word strong and cost-effective. Universal use If Zimmermann were only allowed one milling head then it would be the VH 3. This is an apt description of the VH 3. Extremely robustly built, the VH 3 can be used on all the heavier Zimmermann machines. The VH 3 has been designed specifically for modern 5-axis simultaneous machining. Strong holding torques for the A- and C-axes thereby guarantee safe and accurate continuous path control. Fast drives and very strong high performance spindles ensure high machining performance during modern HSC machining. Precision worm and wheel drives ensure accuracy and damping. Unlimited power Torque of up to 2 Nm is available in the rotary axes and the milling spindle has a power of 6 kw and 95 Nm more than enough for all machining tasks. A new design The VH 3 has been completely redesigned: Small interference contour for better access. Water-cooled worm and wheel drive for higher accuracy and elimination of thermal influences. Higher swivel speeds for shorter overall machining times. Clamping of rotary axes for more rigidity during rough machining. Automatic grease relubrication for long-life cycle and cost effectiveness. Fields of application Ideal when a wide range of machining applications needs to be covered by one head. Today rapidly changing tasks are common and difficult to plan in advance. The extremely versatile VH 3 is perfect in this situation. Features W ORM& WHEEL Precision worm and wheel drive (water-cooled) Standard spindle with 6 kw and 95 Nm Universal high-performance head Hydraulic clamping of the A- and C-axes Coolant / MQL externally and through the tool Optical direct measuring system Grease relubrication Machines FZ 5 Duo, FZ 38, FZ 37, FZ 35 9

10 VH 2 The Compact Head The enormous strength of VH 2 comes into its own wherever low interference contours or reduced moving masses are required. Maximum working ranges A special feature of Zimmermann portal milling machines is that due to their ideal structural stiffness they can cope with extremely large working ranges. Especially where the Z- and / or Y-axes are very long, the weight of the milling head has a key influence on milling accuracy. It is important above all to avoid torsion and bending forces in order to attain the best possible surface finish and contour accuracy. Where large sized working ranges are required but heavy materials are seldom machined, or high machining speeds are needed, Features W ORM& WHEEL Precision worm and wheel drive (water-cooled) 2 standard spindles with 45 kw and 67 Nm Universal high-performance head Hydraulic clamping of the A- and C-axes Coolant / MQL externally and through the tool Optical direct measuring system Grease relubrication Machines FZ 38, FZ 37, FZ 32, FZ 3 the use of the weight-optimised VH 2 is an obvious choice. Complicated contours Portal milling machines are being used to machine ever more complex workpieces with tight contours. This often calls for complex clamping fixtures which limit the access to the part's surface. The VH 2 with its compact size is often the ideal solution to work efficiently under these restricted conditions. Light machines The VH 2 is particularly suitable for medium volume machining of lightweight materials up to aluminium or for finish machining of steel. A new design Like the VH 3, the VH 2 has been completely redesigned: Small interference contour for better access. Water-cooled worm and wheel drive for higher accuracy and elimination of thermal influences. Higher swivel speeds for shorter overall machining times. Clamping of rotary axes for more rigidity during rough machining. Automatic grease relubrication for long-life cycle and cost effectiveness. Fields of application Basically the VH 2 is similar to the VH 3 as far as universality is concerned and it offers the same advantages with regard to order flexibility. However it is particularly suitable wherever high performance combined with low weight and / or small size is important. Very large working areas and particularly complex workpieces, e.g. in the design field or aircraft manufacture, are areas where the VH 2 can often provide the solution. 1 Milling heads

11 VH 1 Perfectly Simple How light can a milling head be? That depends on the application! This extremely light milling head was developed especially for the FZ 25 and FZ 15 portal milling machines. Less is more The idea behind the development of the ultra light portal milling machines is quite simple: Why use very heavy and massive portal milling machines to machine lightweight materials like polyurethane? It makes no sense at all. Also the accuracy required for the typical applications of these machines is less than what would be technically possible. This is exactly the philosophy behind the VH 1 milling head. It is a true minimalist! Large volumes What is decisive when machining polystyrene, light plastics and high-resistance foam is usually the large volume of material to be removed. Thus a dynamic milling head is required which is specially suited to the lightweight construction of the machine. accuracy and have a high structural stiffness. With a systematic lightweight machine construction, a heavy milling head would have the disadvantage of causing bending and torsion of the portal. The VH 1 is the perfect choice. Thus especially with the FZ 25 extremely large working areas can now be achieved. Fields of application Parts made of polystyrene, blockboard or light plastics call for lightweight, cost-effective milling machines. This market segment is served by the FZ 25 and FZ 15 milling machines. The appropriate milling head is the VH 1. Working ranges Large models made of lightweight materials mostly call for large working ranges. Maybe the surface finish specified on such a specialist machine is not quite as high as on a heavy machine but it still needs to achieve the required Features HARMONIC Harmonic drive Weight only 14 kg incl. spindle Standard spindle with 15 kw / 12 Nm and 22 min -1 Machines FZ 25, FZ 15 11

12 Drive Technology One of the most important criteria for the quality of a milling head is the technology used to drive the A- and C-axes. Several different concepts each with different strengths and weaknesses compete in this segment. Zimmermann has mastered all the different drive techniques and is constantly on the look out for new trends in order to take advantage of the best innovations in the future. For each type of milling head and each application exactly the right drive is selected which is optimally suited for the work to be carried out. T ORQUE MOTOR W ORM& WHEEL HARMONIC Drive technology comparison Feed rate Acceleration Surface finish Energy requirement Safety by power failure Life expectancy Crash sensitivity Ease of maintenance Investment costs Repair costs Cost effectiveness Better Worse Torque drive Complete direct driven milling head for applications requiring the highest speeds and accelerations: A lot of repositioning and tool changes True, constant simultaneous machining on fast machines Advantages Extremely fast High axial acceleration Hardly any wear VH 6 and VH 5 milling heads Worm and wheel drive Well balanced drive system for high force transmission and accuracy. Suitable for almost all areas of application: Mixed simultaneous machining and 3-axis milling Advantages Good damping by mechanical worm and wheel drive for very good surface finish Good closed loop control High reduction for strong milling heads of small size Reasonable costs VH 4, VH 3 and VH 2 milling heads Harmonic drive Simple and light drive system which nonetheless has very little backlash: For lightweight materials and suitably designed machines Advantages Light and small Very little backlash Reasonable costs VH 1 milling head 12 Milling heads

13 The MuST Milling Head The VH 6 milling head is equipped with Zimmermann's innovative Multiple Spindle Technology (MuST ). This system offers several key advantages: Roughing and subsequent finish machining of heavy materials such as titanium, steel and cast iron can be carried out on a machine in one setup. This reduces setup time and thus also production costs. Investment in a second machine is unnecessary. Potential for doing additional tasks other than milling in the same setup. Changing the spindle instead of the milling head offers advan- tages in terms of repeatability, reliability (fewer interfaces) and cost. The high finish machining precision of the machine is not affected by the HSC technology used for rough machining. Modular system Stage 1: One spindle permanently mounted in the milling head (Standard). Stage 2: Semiautomatic spindle change (Optional). Stage 3: Fully automatic spindle change (Optional) enabling unmanned shifts. MuST Milling spindles Three MuST milling spindles of different specifications are available for all areas of application: Roughing spindle Specially designed for HSC machining of castings, steel and titanium. Universal spindle For all machining of aluminium, composite materials and for light rough machining of steel and castings. Finishing spindle High frequency spindle for fine contouring and highest quality surface finishes. High-End Milling Spindles Zimmermann milling heads are equipped with high performance standard milling spindles made by Weiss and Fischer. For almost all milling heads there is a choice of spindles available (for roughing, finishing as well as universal spindles). Naturally, for particular applications, other spindles can also be specified. As a standard our spindles are supplied with a unique monitoring system consisting of a vibration sensor, bearing temperature, motor temperature. The milling spindles supplied by Zimmermann are carefully tuned to the particular application, taking the milling machine, milling head and milling spindle into account. Universal spindle VH 3 Competitor's universal spindle 1 14 Nm 95,5 Nm Aluminium machining 6 kw When choosing a spindle, it is often less the pure spindle performance data than the sum of all the performance parameters in the relevant speed range for the particular application which is important. An example is the comparison of the universal spindle of the AC 3 milling head with a competitor's spindle aduring high volume machining of aluminium. At first sight, the competitor's spindle appears to have a higher torque. However, what is important is that the VH 3 spindle delivers its high torque over the whole of the speed range concerned. The performance data and diagrams of all Zimmermann milling spindles are shown on pages 14 to

14 Milling Heads Technical Data The Zimmermann milling head programme together with our wide spectrum of portal milling machines covers a very wide range of applications. The adjacent table shows the standard data of the milling heads and standard milling spindles. Naturally, in variance to these and depending on the particular application, other sizes, models and levels of performance can also supply. Please contact us! Milling head VH 6 Swivel ranges A-axis ± 1 C-axis ± 36 ( ) Performance Torque A-axis 1 35 Nm Torque C-axis 1 35 Nm Acceleration A-axis 7 / s 2 Acceleration C-axis 7 / s 2 Feed rate A-, C-axes 15 /s Accuracies 1 Positioning accuracy A-, C-axes 2 15 =,41 Repeatability A-, C-axes 2 1 =,27 Axis clamping Clamping A-axis hydraulic Clamping C-axis hydraulic Holding torque A- and C-axis 3 Nm Cooling Worm cooling Motor cooling A-axis Water cooling Motor cooling C-axis Water cooling-sandwich pr Dimensions and weights Dimensions incl. spindle (LxWxH) x 68 x 98 mm Milling head weight incl. spindle 1 46 kg Milling spindle Roughing spindle Power S1 max. (1% ED) 44 kw Torque S1 max. (1% ED) 2 Nm Rot. speed max. 1 min -1 Constant power 21 1min -1 Tool holder HSK 1 A, SK 5 opt. Swivel axis Spindle nose Tool clamping Tool release Lubrication Sensors Vibration sensor Temperature sensor / Spindle housing Temperature sensor / Bearing Coolant and lubrication media Coolant supply spindle front side Coolant supply through the tool MQL Spindle front side / max. pressure MQL through the tool Machine type (standard) 42 mm mit HSK1 A 45 mm mit SK 5 Spring clamping hydraulic Permanent grease lubric. FZ 5, FZ 42 2 bar 5 bar 5 bar 5 bar 14 Milling heads

15 T ORQUE MOTOR VH 5 VH 4 VH 3 ± 11 W ORM& T ORQUE WHEEL MOTOR ± 1 ± 11 ± 275 ± 275 W ORM& WHEEL ± 36 / ± 36 / 65 Nm 8 Nm 1 Nm 7 Nm 8 Nm 1 Nm 8 / s 2,1 /s 2 3 / s 2 8 / s 2,1 /s 2 3 / s 2 36 / s 25 / s 9 /s max., 6 /s perm. 16 =,44 1 =,27 15 =,41 12 =,33 8 =,22 1 =,27 hydraulic hydraulic hydraulic hydraulic hydraulic spring loaded 2 Nm 2 Nm 2 Nm inciple 475x 68 x 86 mm 475x 68 x 86mm 1 4 kg 1 36kg Universal spindle Finishing spindle 5 kw 2 kw 95 Nm 27 Nm 24 min min min min -1 HSK 63 A HSK 5 E 3 mm 3 mm 3 water cooled water cooled water cooled 35 x 56 x 66 mm 59 x 68 x 59 mm 46 x 56 x 74 mm ca. 6 kg 9 kg 62 kg Universal spindle Gear spindle Universal spindle 52 kw 35 kw (S 6 / 6% ED) 6 kw 45 Nm 8 Nm (S 6 / 6% ED) 95 Nm 24 min min min min min min -1 HSK 63 A SK 5 HSK 63 A 25 mm 27 mm 3 mm Spring clamping hydraulic Oil lubrication Spring clamping hydraulic Oil lubrication Spring clamping Spring clamping Spring clamping hydraulic hydraulic hydraulic Permanent grease lubric. Perm. grease / Oil circul. 4 Grease relubrication 2 bar 5 bar 5 bar 5 bar 2 bar 5 bar 5 bar 5 bar 4 bar 8 bar 8 bar 8 bar 5 bar 5 bar 5 bar 5 bar FZ 5, FZ 42 FZ 5, FZ 42 FZ 5 Duo, FZ 42, FZ 5, FZ 5 Duo FZ 5 Duo, FZ 38, FZ 38, FZ 37 FZ 37, FZ 35 15

16 VH 2 VH 1 W ORM& WHEEL ± 11 ± 115 ± 275 ± 213 HARMONIC ± 36 / 8 Nm 3 Nm 8 Nm 3 Nm 3 / s 2 12 /s 2 3 / s 2 15 /s 2 max. 9 / s, permanent 6 / s 5 / s 15 =,41 56 =,15 1 =,27 12 =,33 hydraulic spring loaded 1 6 Nm 3 Nm water cooled 46 x 52 x 67 mm 46 x 52 x 71 mm 2 x 49 x 56 mm 53 kg 55 kg ca. 14 kg Universal spindle Universal spindle Universal spindle 4 kw 45 kw 15 kw 48 Nm 67 Nm 12 Nm 25 min min min min min min -1 HSK 63 A HSK 63 A HSK 63 F 3 mm 34 mm 262 mm Spring clamping Spring clamping Spring clamping hydraulic hydraulic pneumatic Grease relubrication Grease relubrication Permanent grease lubric. 8 bar 8 bar 8 bar 8 bar 5 bar 5 bar 5 bar 5 bar FZ 3 FZ 38, FZ 37, FZ 32 FZ 25, FZ 15 1 According to VDI / DGQ Axis compensated 3 VH 4: Oil circulation cooling also used for cooling and lubricating the A- and C-axes 4 VH 4: Front bearing: Permanent grease lubrication, rear bearing: Oil circulation cooling 5 From the bottom edge of the vertical slide All dimensions and details are non-binding. We reserve the right to make technical changes. Other spindle types and manufacturers available on demand (e.g. Fischer) Standard Option 16

17 VH 6 Milling spindle performance diagrams Roughing spindle 44 kw Nm 44 kw Torque Md Power P Universal spindle 5 kw Torque Md Power P kw ,5 Nm 4 95, VH 3 Milling spindle performance diagrams Universal spindle 6 kw Torque Md Power P kw ,5 95,5 Nm Finishing spindle 2 kw Torque Md Power P kw Nm VH 5 Milling spindle performance diagrams Universal spindle 52 kw kw Torque Md Power P Nm VH 2 Milling spindle performance diagrams Universal spindle 4 kw Torque Md Power P kw Nm Universal spindle 45 kw kw Torque Md Power P Nm VH 4 Milling spindle performance diagrams Gear spindle 35 kw Nm Torque Md Power P kw VH 1 Milling spindle performance diagrams Universal spindle 15 kw Torque Md Power P kw Nm Milling heads

18 High Performance Milling Technology Styrofoam Milling Technology FZ 5 FZ 2 FZ 42 FZ 15 FZ 38 FZ 37 Zimmermann is synonymous with CNC portal milling machines on a big scale. Specialisation and our high rate of innovation has put our technology out in front worldwide. A uniquely wide and finely tuned programme, including a large number of different machines and milling heads, enables you to choose the perfect machine for every application, thus offering you the ideal solution with regard to quality and cost-effectiveness. FZ 35 FZ 32 FZ 3 FZ 25 BK F. Zimmermann GmbH Goethestraße D-7377 Denkendorf, Germany Phone +49 (7 11) Fax +49 (7 11) info@f-zimmermann.com Member of the DMTG Dalian Machine Tool Group Corp. 38 Anshan Road Dalian PRC Apollo