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The Hyperturn 65 Powermill from EMCO Maier Corp. offers a large spindle clearance of 1300mm, a powerful counter spindle which also allows 4-axis machining, a B-axis with a direct drive for complex 5-axis simultaneous milling operations, and an additional Y-axis for the lower turret, making it ideal for machining complex parts.
The ergonomically designed machine is particularly well-suited to the serial production of workpieces, for example in the automotive industry, the fields of mechanical engineering and materials handling, but also for the aircraft industry.
Complex, costly turning, drilling, milling and gear cutting operations can be competed in one setup. Additional handling and part storage is eliminated and workpiece precision is greatly improved. Total production time, fixture and personnel costs, as well as floor space requirements can be drastically reduced with the HYPERTURN.
With 29 kW and 250 Nm the counter spindle now has enough power to machine the workpiece simultaneously with two tools, enabling 4 axis machining.
A further benefit is the milling spindle, which with 29 kW, 79 Nm torque and speeds to 12,000 rpm, promotes productivity in the complete machining of complex workpieces. The B-axis direct drive gives the Hyperturn 65 PM good dynamics and contour capabilities with 5-axis simultaneous machining, along with shorter tool change times. The additional Y-axis on the lower turret makes extensive milling work possible at the same time as machining with the milling spindle.
The milling spindle with HSK-T63 tool interface can be used for both turning and drilling/milling work. It can be continuously swiveled within a range of +/- 120° and clamped at any point. With a useful Y-travel of +120/-100mm, even the most complex of machining work can be carried out. This includes gear-cutting operations, turning/milling work for crankpins, 5-axis machining, and much more. The tools can be prepared according to the customer's requirements with a 20-piece pick-up magazine, or a 40- or 80-piece chain magazine.
The Y-axis is accomplished by two interpolating axes, resulting in a distribution of the cutting force in two levels and adds stability to heavy-duty turning and milling. This means the lower turret with integrated milling drive can also be used for complex milling operations at all 12 positions, combined with a Y-axis with +/-50mm travel.
Twenty, 40 or 80-piece tool magazines with HSK-T63 give the user more possibilities for complete machining operations of complex workpieces, with simultaneously low set-up times for individual parts manufacturing and high stability for turning and milling works. The frontal arrangement is easy to set up and ergonomic.
As an alternative to the VDI30 or VDI40 12-position tool turret, EMCO offers a new generation of turret with BMT interface and direct drive. Higher stability and precision, and performance data similar to a milling machine, enable the complete machining of turning/milling workpieces.
The machine versions with a milling spindle and turret including milling drive (SMBY/SMBY2) have a cross slide underneath with a 12-position radial turret for 12 driven tools working up to speeds of 5000 rpm.
The automatic bar machining and/or delivery of unit loads via a robot solution or the EMCO gantry loader offer excellent potential for increased efficiency in automation.
In addition to mechanical and electrical performance values, control systems and also affect machine tool productivity. The Hyperturn 65 is controlled by the Siemens SINUMERIK 840D-sl. The new user interface enables an intuitive and significantly easier programming of the machine.
Utilizing the machine to its full capacity as far as possible is a crucial aspect for increasing productivity. The EMCO CPS Pilot simulation software can generate time and cost savings during machining as this software enables customers to plan, program, simulate, and optimize production runs on their PCs using a 3D model of the machine.
In the tailstock version the HYPERTURN is particularly suited for mass machining shaft parts. The tailstock is completely NC controlled and can be positioned using a recirculating ball spindle. This enables the movement interpolating with other axes, saving machining time.
Related Glossary Terms
- clearance
clearance
Space provided behind a tool’s land or relief to prevent rubbing and subsequent premature deterioration of the tool. See land; relief.
- cutting force
cutting force
Engagement of a tool’s cutting edge with a workpiece generates a cutting force. Such a cutting force combines tangential, feed and radial forces, which can be measured by a dynamometer. Of the three cutting force components, tangential force is the greatest. Tangential force generates torque and accounts for more than 95 percent of the machining power. See dynamometer.
- fixture
fixture
Device, often made in-house, that holds a specific workpiece. See jig; modular fixturing.
- gang cutting ( milling)
gang cutting ( milling)
Machining with several cutters mounted on a single arbor, generally for simultaneous cutting.
- materials handling
materials handling
Methods, equipment and systems for conveying materials to various machines and processing areas and for transferring finished parts to assembly, packaging and shipping areas.
- milling
milling
Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.
- milling machine ( mill)
milling machine ( mill)
Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.
- numerical control ( NC)
numerical control ( NC)
Any controlled equipment that allows an operator to program its movement by entering a series of coded numbers and symbols. See CNC, computer numerical control; DNC, direct numerical control.
- turning
turning
Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.
