Complete Precision Machining of Large, Complex Parts

The high performance Hyperturn 200 milling-turning center from EMCO Maier Corporation (Novi, MI) is designed for complete precision machining of large work pieces up to 1,000 mm in turning diameter and for lengths up to 6,000 mm, with workpiece weight of 1,500 kg in the chuck and up to 6,000 kg between chuck and tailstock. The powerful main spindle is designed for heavy cutting with a max torque of 6,410 Nm and 84 kW. This machine can process large, complex workpieces in general machining, aerospace, shipbuilding, power engineering and the production of shafts for diesel engines. Its moving column is built in a “Box-in-Box” ram construction, assuring optimum rigidity and stability for machining with a high level of accuracy. The B-axis is equipped with a torque motor and integrated into the ram design. The cross slides consist of a welded steel construction with high torsional and bending stiffness, a crucial factor for the quality of the turning and milling.

The machine features a turning spindle with 84 kW, 6,400 Nm torque, milling spindle with 80 kW at 700 Nm. The machine can be equipped with two different milling spindles. The basic machine is equipped with a high torque milling spindle (430/630 Nm) at 6,500 rpm and, optionally, a high speed milling spindle (10,000 rpm / 230/340 Nm) is available as an alternative for the special machining of light metal alloys, aluminum, etc. The robust and flexible tailstock can be expanded with a high quality counter spindle with the same specifications as the main spindle. The basic machine provides 50 tool positions at the front, with an optional 100 and 200 positions, available either with an HSK 100 or Capto C8 connector. Other customer-specific adjustments are in the number of NC steady rests that can be used, 5-axis simultaneous machining, automatic tool presets and workpiece measurement sensors, a boring bar pick-up system, etc.

The HT 200 is equipped with a Siemens 840D sl that includes Shop-Turn. Users can use the CPS Pilot system for the 1:1 virtual machine, as well as 100 percent simulation of machining with collision detection.

EMCO also offers the large Powermill machining center from Mecof that provides users with precision, high dynamics, operational flexibility, and cost effectiveness in a massive traveling gantry 5-axis milling center. With its moving bridge structure, Powermill permits the loading of large, heavy workpieces on the stationary work table from overhead or from either end of the machine, making it ideal for handling aerospace components. Its simple overall design makes easy positioning, set up, and clamping possible for huge workpieces of practically unlimited weight. Users may specify travel in X/Y/Z: basically unlimited longitudinal X-axis travel and from 4 m, 5 m, 6 m and even 7 m of Y-axis stroke, with vertical ram stroke from 1.5 m to 2.5 m, plus several milling head options. Automatic head exchange systems are available to create a suitable solution for a wide range of large parts.

Double CNC platforms on each column use vertical adjustment, a 120-pocket or more tool changer, laser checking of tool and workpiece to assure precise setup, high pressure tool cooling system, volumetric compensation and more. Axes feed rate is 30 m/min. The mechanical universal milling head provides 6,000 rpm, 38 kW (S1), 1,000 Nm (S1), or users can choose a milling head with a straight head or with high-speed motorized spindles, or indexed or full 5-axis contouring milling heads to suite the material being machined and the geometric shape. These Mecof machines are popular for aerospace machining because they are designed for accurate production of assembly and lay-up tooling, long structural parts such as stringers, larger bulkheads and aircraft engine components such as discs and casings (through the application of rotary turning tables in front of or under the machine axes). The box-in-box structure assures machine structure rigidity, supporting high precision work over long axis travels. The massive structure, combined with agility, allows for flexible, productive machining of many different types of parts.

EMCO Maier Corporation, 46850 Magellan Drive, Unit 160 Novi, MI 48377-2448, 248-313-2700, Fax: 248-313-2701, www.emco-world.com.