ROTAMILL 22 Gantry Type Milling Center for 5/6 Axis Machining

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Garry Pearson
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1 ROTAMILL 22 Gantry Type Milling Center for 5/6 Axis Machining Edition 01/2016 High Performance with 6 Axes

machining centre in highly stable gantry

2 Machine construction 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. Turbine Gear wheel Tool and mould making Aerospace Energy technology Motor housing Swivel housing Injection Prototyping mould 2 3

Highlights at a glance Complete production in one setting for high productivity and flexibility Ergonomically

workpiece sizes and piece numbers High dynamic rotational axes (milling head, rotary table) with powerful highly

Optimal accessibility of the working space / easy loading Big vision panel for the inspection of the working area

for repeatability and high thermal stability All around safety system according to DIN/EN 12417 Up to 6 machining

3 Highlights at a glance 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 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 Up to 6 machining axes (X, Y, Z, A, C optional, rotary table) in combination with modern control systems are available for simultaneous machining. 4 5

High grade components: Feed axes X-/ Y-/ Z with high

in all axes, size 63 Multiple linear guides for high

8 guiding carriages, size 55 Control systems: Standard

solutionline Heidenhain precision guides (in X, Y, Z)

optional C-axis as 6th axis in the ram) for most

4 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 6 7

Turning/milling centres set standards for

As a 6 axis version it enables machining

5 Turning/milling centres set standards for economic, precise and customised solutions. The Rotamill machining centre incorporates a turning option together with high power milling 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 diameters up to 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. 8 9

Motor spindle pallet As main drives the high performance spindles made

long life service, and are steadily advanced.

spindles with 21 / 27 / 34 kw up to 60 kw high speed spindle with 24.

The new 42 kw turning/milling spindle with 250 Nm and HSK-T100

clamping device. Allround applications CS-27-180 Nom.

torque S6 (Nm): 170 Tool interface: HSK-A100* Heavy duty milling

power S1 (kw): 34 Max. speed (rpm): 12.000 Nom. power S1 (kw): 21 Max.

torque S6 (Nm): 220 Tool interface: HSK-A100* Max.

40 40 20 20 Turning/milling illi CST-42-180-S Highspeed-Applications

6 Motor spindle pallet As main drives the high performance spindles made by CyTec are used, that are characterised 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 rpm. The new 42 kw turning/milling spindle with 250 Nm and HSK-T100 interface 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. Allround applications CS Nom. power S1 (kw): 27 Max. speed (rpm): Max. torque S6 (Nm): 170 Tool interface: HSK-A100* Heavy duty milling CS S Highspeed applications CS A Nom. power S1 (kw): 34 Max. speed (rpm): Nom. power S1 (kw): 21 Max. speed (rpm): Max. torque S6 (Nm): 220 Tool interface: HSK-A100* Max. torque S6 (Nm): 130 Tool interface: HSK-A63* Turning/milling illi CST S Highspeed-Applications CS S S Nom. power S1 (kw): 42 Max. speed (rpm): Nom. power S1 (kw): 60 Max. speed (rpm): Max. torque S6 (Nm): 250 Tool interface: HSK-T100* Max. torque S6 (Nm): 109 Tool interface: HSK-A63* Power S1 Torque S1 *Other tool interfaces (e. g. Coromant Capto) available on customer demand. 10 Power S6 Torque S6 11

7 Machine data Travel range axes X / Y / Z / / mm Gantry height mm Axis dynamic Rapid traverse X / Y / Z 50m/min Acceleration 4 m/s 2 Working area spindle Vertical distance spindle nose - table top -184 up to mm Horizontal distance spindle nose - table center 125 up to mm Fork milling head A-axis Swivel angle +/- 110 Swivel speed 360 / s Torque Nm Clamping torque Nm Positioning accuracy +/- 2,5 Rotary table Face plate diameter Standard mm Table load max. (centric) kg Maximum speed 100 / 250 rpm Torque max Nm Clamping torque Nm Positioning accuracy +/- 2,5 Interference area Diameter mm Examples injection moulds: x 730 x 780 mm 1015 Interference diameter mm x x 410 mm 12 13

NC rotary table and NC milling head Automatic head exchange NC-Rotary table

different face plate diameters available on customers demand (Standard 1800

torque combined with extremely short positioning times Integrated clamp

g. for rough machining tasks High bearing rigidity by means of free from

encoders for optimised position control As an option, the rotary table can be

allows for an automatic head change (e. g.

For this purpose three pivotable pickup stations are equipped each with a

Thereby the operator can fulfill the demands for optimum relation of surface

8 NC rotary table and NC milling head Automatic head exchange 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 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. Option: Rotary table with pallet clamping system 14 15

Options for loading Max. workpiece size 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.

Opening working area 188 Working area 2746 1656 1090 1359 841 X-Travel 2200 650 650 Y-Travel 1300 Portal width 1900 1 Ø1550 Ø1498 Ø1300 not possible in case of head exchange (2 heads) head exchange

9 Options for loading Max. workpiece size 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. Opening working area 188 Working area X-Travel Y-Travel 1300 Portal width Ø1550 Ø1498 Ø1300 not possible in case of head exchange (2 heads) head exchange station extended 3 125,5 2 Max. workpiece size ,5 (tool length 0) 715,5 (tool length 300) These data refer to a 21kW spindle with 110mm spindle nose Z The maximum workpiece size is 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 16 17

Control systems In terms of high power, efficiency and precision, the high end products of manufacturer Heidenhain are the best suited.

milling CMS Comprehensive machine protection through Brankamp collision monitoring Immediate detection of rapid force changes Minimises subsequent damage

the spindle nose detects thermal linear expansion Data are integrated in the CNC control to compensate linear deviation Resistant to dirt and heat Extended

axis machining EnergySaving Energy feedback during braking process High power LED lamps substitute conventional machine lights Extensive energy saving

programming Graphic programming High performance processor (1,8 GHZ) and regulator Significantly higher speed during program process for very good

0,5 ms Higher simulation speed and enhanced display through graphic test run MDynamics as optimal control for the tool and mould maker Minimised downtimes

10 Control systems In terms of high power, efficiency and precision, the high end products of manufacturer Heidenhain are the best suited. Heidenhain TNC 640 HSCI Option: Siemens 840D solutionline HSCI - HEIDENHAIN Serial Controller Interface Easiest interactive programming for turning and milling CMS Comprehensive machine protection through Brankamp collision monitoring Immediate detection of rapid force changes Minimises subsequent damage caused by programming, setup and operating errors Enhances the life span of the machine SGS Monitoring of the linear displacement of the spindle Sensor on the spindle nose detects thermal linear expansion Data are integrated in the CNC control to compensate linear deviation Resistant to dirt and heat Extended precision control Automatic checking and correction of axis accuracy in the space Easiest handling and programming by the operator Highest precision in 5 axis machining EnergySaving Energy feedback during braking process High power LED lamps substitute conventional machine lights Extensive energy saving functions According to requirements, de-activation of ancillary components 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 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 Higher performance during collision monitoring and 5 axis functions 18 19

Options/additional features Option extended tool magazine Differing from the standard magazine

device For the protection of the working area and of the operator, an effective suction system

By means of a linear drive the suction ring is positioned directly to the workpiece surface, so

Option extended Y travel Option minimal quantities of lubricant (MQL) X-travel 2200 1359 841

mm. So the machining of cubic workpieces with a lateral length of 1500 mm is possible.

maintenance effort for the coolant is dispensed Lower heat input into the workpiece 800 800

downtimes for loading and unloading of the workpieces workpiece preparation outside the machine

extended safety in the working area through unmanned operation Option turning/milling spindle

serration, that clamps the spindle shaft rigidly when required.

Option special heads For individual applications which are different from the normal machining

11 Options/additional features 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 suction device For the protection of the working area and of the operator, 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 positioned directly to the workpiece surface, so that all generated emissions are removed properly. Option extended Y travel Option minimal quantities of lubricant (MQL) X-travel Workpiece diagonal 2121 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. 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 Y-travel 1600 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 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. 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 manufacturing of models and prototypes skimming/turning heads grinding heads 20 21

Dimensions / Technical Data Clearance working area 1878 Travel range Axes X / Y / Z 2.200 / 1.300 / 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/s 2 Height min. 4319 Height max.

12 Dimensions / Technical Data Clearance working area 1878 Travel range Axes X / Y / Z / / mm Working area spindle Vertical distance spindle nose - table top -184 up to mm Horizontal distance spindle nose - table center 125 up to mm Gantry height mm Interference area Diameter mm Feed force X / Y / Z N Axis dynamic Rapid traverse X / Y / Z mm/min Acceleration 4 m/s 2 Height min Height max Fork milling head A-axis Swivel angle +/- 110 Swivel speed 360 / min Torque Nm Clamping torque Nm Positioning accuracy +/- 2,5 Motor spindles Technical data see page 9 Tool places HSK-A 63 / HSK A / 39 Rot. table Ø 1800 Tool magazine Tool weight max. HSK-A 63 / HSK A / 15 kg Tool length max. 300 mm Tool diameter HSK-A63 / HSK-A / 125 mm Face plate diameter Standard mm Option / mm Table load max. (centric) kg in milling mode, kg in turning mode 6774 Machine length 4501 Rotary table Maximum speed 100 rpm (optional 250 rpm) Positioning accuracy +/- 2,5 Clamping torque Nm Torque max 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 in Y direction Drag link or slat band conveyor Chip disposal Capacity of paper band filter device litres Coolant pressure CTS / ECS 60 / 20 bar Filter performance 400 litres/min Doors closed 2990 Doors open 4890 Place requirement X / Y / Z (each without coolant device) / / mm Machine width Setting-up data Machine weight kg Total power input 125 KVA 6547 Mains connection 3 x 400 V / 50 Hz Compressed air supply 6 bar 22 23

7 D-72124 Pliezhausen Telefon: +49 7127 929499-0

13 Production plant Service center EDEL Entwicklung und Vertriebs-GmbH Carl-Zeiss Str. 7 D Pliezhausen Telefon: Telefax: info@edelgmbh.de Internet: Edition 01/2016

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