Portal Milling Machine

FZ 100 M3 ABC FZ 42 VH 6 FZ 38 VH 30 FZ 37 VH 20 FZ 33 VH 12 FZ 32 VH 1 F. Zimmermann GmbH Portal Milling Machines Goethestraße 23 27 73770 Denkendorf, Germany Phone +49 711 934935-0 Fax +49 711 934935-300 info@f-zimmermann.com www.f-zimmermann.com FZ 30 / FZ 35 FZ 25 Apollo 11 09.2011

fz33 Portal Milling Machine The Port l to success

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OF A NEW gener tion Always ready for take-off, whenever it s needed. Difficult tasks in transportation, supply and rescue are mastered effortlessly by ultra-modern, high-tech helicopters. Their safety and precision, flexibility and efficiency are closely linked to the Portal Milling Machine FZ 33, the machine on which their cabins are manufactured. A new generation of portal milling machines shows its strengths: with its generous Z-axis the FZ 33 is mainly used in the aircraft industry, automotive industry and boatbuilding. Learn more about the new modular machine concept behind this Portal Milling Machine on the following pages. Contents Applications Advantages Technical details Milling heads Technical data CNC Portal Milling Machine FZ 33 Zimmermann 3

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The Portal Milling Machine FZ 33 with the future know-how The Portal Milling Machine FZ 33 is Zimmermann s latest engineering achievement. The FZ 33 is ready to perform demanding tasks in all areas of the automobile and aircraft industry. The standardized and modular development process permits fast and cost-effective tailoring to the customer s requirements. It is synonymous with versatility, high accuracy and efficiency. This model range satisfies the sector-specific requirements of many industries: In pattern and mold making for machining models with a vast variety of sizes and contours. In the manufacture of design models where large Z-axes are required, e. g. for machining 1:1 models. In aircraft production for machining structural parts of aluminum, laminating forms, jigs and fixtures, composite materials for interior and exterior. In boatbuilding for the manufacture of deck structures, laminating forms etc. In the area of alternative energy as a solution for different applications. The FZ 33 is designed for fast, complete five-sided machining* of aluminum and composite materials, and for finishing steel and cast using high-acceleration simultaneous operation. It is noteworthy especially for the following features: Work areas with up to 40 000 mm on the X-axis, 6 000 mm on the Y-axis and 3 000 mm on the Z-axis. Harmonious and powerful motions with rack drives on all linear axes. Very high accuracy and surface finish quality. Maximum economy Titanium Cast alloys Composites Plastics Expanded Steel Light alloys polystyrene Wood *Machining performance for these materials depends on the cutting parameters recommended by the tool manufacturer. Aircraft industry Boatbuilding CNC Portal Milling Machine FZ 33 Zimmermann 5

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The advantages of a remarkable design Z-axis up to 3 000 mm On the X-axis, mass-optimized, structurally-stiff overhaed gantry for high dynamics and precision Dust-proof bellows, especially important for dust-critical materials, optionally pressurized Encapsulated toolchanger outside the work area with pick-up or chain magazine Newly developed, 2-axis milling heads VH 20 and VH 30 Fixed sidewalls filled with DemTec reinforced concrete Heavy, fixed, cast machine table with sheet-metal covers all round The gantry design, with fixed machine bed, and an upper driven portal that travels in the X-direction, offers decisive advantages for the manufacture of tooling, molds and models, and in the aerospace and automotive industry. The cast machine bed is securely anchored to the foundation, so the workpiece does not move. Machining is independent of the weight of the workpiece. The moving mass is made up of the structurally-stiff portal, the cross-slide, the Z-axis ram, and the milling head. The constant mass ratio implies unchanging dynamic behavior; this is a prerequisite for machining workpieces with optimum surface finish and accuracy. The combination of high stability and stiffness, constant moving masses, and highly dynamic drives enables the high precision machining of materials* such as cast and steel, aluminum, Zamak, composites, and plastics. You, as the user, benefit from the fact that reworking is reduced to a minimum. Integral protective enclosure, optional work area covers Highlights High dynamics and precision Z-axis up to 3 000 mm Very low moving mass Innovative milling head technology with compact design *Machining performance for these materials depends on the cutting parameters recommended by the tool manufacturer. CNC Portal Milling Machine FZ 33 Zimmermann 7

The intelligence is in the detail Modularity The FZ 33 Portal Milling Machine with overhead gantry is based on a modular machine concept, on which various versions with different strokes, drive technologies and equipment levels can be realized. Measuring systems The three linear axes, X, Y and Z, have direct length measuring systems with Heidenhain glass scales (for axes over 3.0 m long steel measuring tapes are employed). The measuring systems are pressurized to protect them against dirt. Safety and reliability The sidewalls are an integral part of the machine s enclosure. The slideways, drives and measuring systems for the Y- and Z-axes are covered by dust-proof bellows to protect them against dirt. As standard the X-axis is equipped with lamella covers. The sidewalls optionally can be supplied with windows. For loading, at the front, there are sliding doors, or alternatively folding doors. The rear is closed off either by a fully encapsulated toolchanger, or by an additional sliding door. Drives Regardless of the control system supplier, all axes are equipped with Siemens Simodrive digital drives. On all linear axes power transmission is performed by means of modern gear-rack drives; the X- and Y-axes have four (or respectively two) electronically pre-loaded servomotors to eliminate backlash, while the Z-axis has a water-cooled servomotor with holding brake. The control system gantry function ensures that the two X-axis drives are perfectly synchronized. The powerful drive is especially suitable for high chip removal rates. R A C K & P I N I O N Rack and pinion The highly dynamic rack and pinion drives offer an extraordinarily well-balanced ratio between cost and performance. Any practical axis length can be provided and the system suits the widest possible spectrum of applications. Full power is available even while moving with lower feed rates no turbo-lag. Control systems Basically the FZ 33 can be combined with control systems and types from several different manufacturers. Modern control systems offer functions such as look ahead, jerk limitation, spline interpolation, and 5-axis machining. Numerous software options are available for many additional tasks. 8

VH 20 and VH 30 newly developed 2-axis Milling Heads The VH 20 and VH 30 Milling Heads set new standards. They combine high torque with transitional rotation speeds of up to 360 /s around the A- and C-axes. These two new milling heads have been developed to extend the application spectrum of Zimmermann TORQUE M O T O R Portal Milling Machines. The A-axis drive employs dual torque motors with electronic backlash elimination. The C-axis has a direct torque drive. This enables rapid and, in conjunction with a high-resolution measurement system, high precision positioning. With their symmetrical and compact design, which tapers towards the tool, the VH 20 and VH 30 Milling Heads have a low interference contour and can be combined with spindles from various manufacturers. Milling head VH 20 Milling head VH 30 Highlights of the VH 20 and VH 30 High torque in the rotary axes in simultaneous operation Holding torque 3 000 Nm on the swiveling axes included Positioning accuracy of 12" or better, repeatability of 8" or better (DIN 3441) Supply of coolant minimum quantity lubrication (MQL), cooling air external or through the tool possible Compact design makes setting up and machining complex workpieces easier Applications of VH20 VH30 Length of Z-axis in mm 3000 2500 1500 1000 Clay VH20 NEU Crossover VH20/VH30 Alternative milling heads depending on application Plastics VH20 and VH30 Composites Aluminum VH30 Steel Cast alloys Material strength CNC Portal Milling Machine FZ 33 Zimmermann 9

FZ 33 Technical Data Machine FZ 33 Working ranges X-axis 2000 40000 mm ➀ Y-axis 2000 6000 mm ➀ ➁ Z-axis 1250 3000 mm ➀ ➂ Table size Length 2000 40000 mm Width 2000 4000 mm Height 250 mm Table load max. 15 000 kg/m 2 T-slots (longitudinal) 18 H12 Pitch of T-slots 250 mm Feed drives Feed rate on X-, Y-, and Z-axes up to 60 000 mm/min. Acceleration on linear axes ➃ up to 5 m/s 2 Accuracy ➃ Positioning accuracy on X-axis 0.030 mm Positioning accuracy on Y- and Z-axes 0.020 mm Repeatability on X-axis 0.015 mm Repeatability on Y- and Z-axes 0.010 mm Milling head VH 20 VH 30 Swiveling range A-axis ± 110 or + 125 /-95 C-axis up to ± 360 Performance Torque, A-axis Torque, C-axis Holding torque (clamped) Feedrate about A-, C-axis min. 1200 Nm 1047 Nm opt. 1279 Nm 3000 Nm 360 /s Accuracy ➃ Positioning accuracy A-, C-axes 12" = 0.0033 Repeatability A-, C-axes 8" = 0.0022 ➀ Other dimensions on request ➁ Y-axis up to 6 000 mm in combination with VH 12 and VH 1 possible ➂ Z-axis up to 3 000 mm in combination with VH 12 and VH 1 possible ➃ According to VDI 230-2 /DGQ3441, based on basic machine, depending on the length ➄ Permanent grease lubrication with automatic replenishment system (opt. oil-air lubrication) We reserve the right to make technical changes Milling spindle VH 20 VH 30 Power S1 max. (100 % duty cycle) 45 kw 60 kw Torque S1 max. (100 % duty cycle) 67 Nm 95 Nm Speed max. 25 000 rpm 22 000 rpm Constant power 6400 6000 25 000 rpm 22 000 rpm Tool holder HSK 63 A HSK 63 A Swivel axis spindle nose 326 mm 301 mm Tool clamping spring clamp spring clamp Tool release hydraulic hydraulic Lubrication permanent permanent grease lub. ➄ grease lub. ➄ Coolant supply Both external Both external Minimum-quantity lubrication and through and through Air blowing the tool the tool VH 20 Milling spindle torque diagram Universal spindle 45kW Torque Md Power P Md [Nm] P [kw] 100 70 60 75 45kW 50 67Nm 40 50 30 20 25 17.2Nm 10 10 0 0 4000 6400 12000 16000 20000 25000 n [rpm] VH 30 Milling spindle torque diagram Universal spindle 60kW Torque Md Power P Md [Nm] 100 75 50 25 10 95Nm 60kW 26Nm 0 4000 8000 12000 16000 22000 P [kw] 70 60 50 40 30 20 10 0 n [rpm] 10

Equipment options FZ 33 Simultaneous A-axis Simultaneous C-axis A-, C-axis clamping Control cabinet air conditioning Minimum quantity lubrication Coolant system (internal / external) Toolchanger 15, 30,50, 80 positions and more Measuring probe Tool measurement Chip conveyors Extraction systems Partitioned work area Work area cover 5-sided housing Standard Option Dimensions X-axis 2 000 40 000 mm Height 5350 9200 mm Z-axis 1 250 3 000 mm ➂ Y-axis 2 000 6 000 mm ➁ Table length 2 000 40 000 mm Table width 2 000 6 000 mm Width 6150 10150 mm Length 5250 48250 mm All dimensions given are examples for the FZ 33 in the minimum or maximum sizes realized to date. CNC Portal Milling Machine FZ 33 Zimmermann 11