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Large, long or odd shaped parts present various challenges; self-contained Suhner Multi-Master flex shaft machining units provide solutions
Bulky part machining can often become very difficult to integrate into a manufacturing process, when attempting to perform multiple operations on conventional CNC machines. Limited space or axis travel, one-sided spindle or tool accessibility are common restrictions when trying to design and fit multiple tool requirements onto a rigid machine concept. In addition, cycle time demands and accessibility issues from all sides and angles can make a single tool, 3-axis CNC machine option a losing proposition.
One new solution involves compact and self-contained single tool Multi-Master flex shaft machining units from SUHNER. These units are modular in design, which means they can be positioned in any direction around a workpiece. In most cases, all operations can be performed in one cycle, thereby reducing the overall machining cycle time to a minimum. Since all tooling modules work simultaneously, the cycle time is basically determined by the longest single machining operation and not the addition of all the tools working together. There are virtually no limitations to part size and the number of tools that are engaged at the same time, with this arrangement.gid machine concept. In addition, cycle time demands and accessibility issues from all sides and angles can make a single tool, 3-axis CNC machine option a losing proposition.
SUHNER offers a complete spindle program with optional feed systems…pneumatic, hydraulic and CNC…available in a quill feed or slide and spindle design. In combination with modern tooling technology, SUHNER Multi-Master machining units can achieve a high degree of performance and accuracy, when incorporated into a machine design.
Solid carbide tools permit cutting speeds up to 300 m/min in aluminum, at feed rates of 0.5 mm/rev. These rates result in very short cycle times and extended tool life.
Pictured transfer machine (Fig.1) illustrates a drilling station for an aluminum profile with 11 drilling operations. The actual machine time is 8 seconds for a roof rack railing. The machine is used in 3 shifts and produces a finished part in less than 20 seconds.
Depending on tool diameter, some of the drilling station units operate at 12,000 rpm.
A special purpose machine is shown in Fig. 2. This machine provides 33 holes in an automotive fiberglass- reinforced plastic part in less than 2.5 seconds. Years of experience and research with special tools and materials result in exeptional hole quality.
For all chipmaking operations including drilling, tapping, milling, reaming, flow drilling, boring, turning, inside and outside grooving etc. with internal or external coolant supply, SUHNER offers a comprehensive machining unit program for machine builders and end users alike.
SUHNER INDUSTRIAL PRODUCTS, CORP.
Hwy 411 S./Suhner Drive
P.O. Box 1234
Rome, GA 30162
Attention: Lee Coleman, Automation Division
Turning-milling centers with coordinated drive and CNC engineering achieve superior accuracy and repeatability
The complete machining of turbine blades requires striking a balance between powerful roughing and ultra-precise finishing, a task for which the modern five-axis turning-milling centers are ideal, when robust machine construction is combined with high-quality drive and control engineering. Experience is the solid basis on which the Hamuel Maschinenbau GmbH & Co. KG, Meeder, Germany, can offer a great deal: with 85 years of machine tool manufacturing, 35 years of CNC machining, 25 years of five-axis simultaneous machining and over 10 years in the construction of five-axis turning-milling centers. CEO Dr. Markus Stanik knows that experience by itself cannot be any yardstick for the quality of machine tools, noting, “It certainly helps us, together with the right partner companies, to design and build the machines so that our customers can be successful in the marketplace.” This machine builder and its many customers have developed correspondingly positive accomplishments together. Today, Hamuel stands on three standards:
The latter, as evidenced by Hamuel’s HSTM (high-speed turning-milling) series, has been marketed since 1999 and makes a decisive contribution to the sales and success of the company. Leading turbine manufacturers from the aerospace and power-generating industries have been particularly impressed by the dynamic response, capability and precision of these machines. Even the smallest faults are unacceptable on turbine blades
The HSTM that runs on the Sinumerik 840D sl CNC controllers is used mainly to manufacture turbine blades and blisks (turbine disks) deployed in stationary steam and gas turbines as well as in mobile turbines for aircraft jet engines and large turbochargers. These products always consist of high-strength materials, such as titanium or high-alloyed steels. Form deviations are taboo in such applications, because even the smallest error would significantly reduce the efficiency of the turbines. Correspondingly high and comprehensive are the requirements placed on the machine tools. Hamuel sales manager, Dipl.-Ing. Jochen Schaede, explains: “Our customers normally manufacture large turbine blades longer than approximately 1000 mm from forging blanks. In contrast, shorter workpieces are milled from a solid piece of material with a stock-removal ratio of approximately 80 percent. This makes it obvious that our machines must not only rough-cut very productively but also finish with high precision.” Whereas productivity takes precedence for rough-cutting, accuracy is more important for the subsequent finishing of the spatial free-form surfaces. “With regard to accuracy, our high-performance machining centers achieve a precision in the micrometer range coupled with excellent surface quality,” added Schaede.
Key to this capability is the combination of compact machine construction together with perfectly matched drive and control engineering. The basis is the robust machine design with a one-piece machine base – either as welded construction cast with special concrete or latterly directly as polymer-concrete made from a single piece of material. The careful distribution of the masses ensures the best dynamic rigidity. The experience of the developers at Hamuel paired with the knowledge of the Siemens mechatronic experts make such results possible, as Jochen Schaede confirmed: “Thanks to various simulation tools, the Siemens engineers could provide us with very exact data to which we could add or remove masses. It was certainly advantageous that we could procure all components required for the dynamics from Siemens starting with the spindle, including the axis drives, and ending with the CNC. This means we needed only a few iteration loops in order to obtain a perfect dynamic rigidity in the machines.” It is also important that all components are arranged so that the horizontally clamped turbine blades and blisks can be machined optimally. This is also facilitated by the 45°-inclined orientation of the axes that ensures a favorable swarf removal further augmented by the permanent rinsing of the machine internal area. The accessibility has also been enhanced by this inclined axis orientation. Such designed and built HSTM machines equipped with precise direct drives from Siemens achieve a maximum positioning accuracy of 5 µm with traversal speeds exceeding 40 m/min in all linear axes. Indeed, the extremely fast rotary axes have a positioning accuracy of 3 µm. This allows the user to achieve maximum productivity, accuracy and surface finishes in the range of Ra = 0.8 µm, and so fully meet the industry requirements placed on the blade machining. CNC ensures optimized surface transitions at the inlet and outlet edges One of the biggest challenges for the turbine-blade manufacturing industry concerns the critical surface transitions (leading and trailing edges) of the turbine blades. To achieve a high quality, the milling paths described with curve interpolation points must have a constant machining speed. As a consequence, the leading and trailing edges demand extreme angular accelerations. The number of curve interpolation points to be described is correspondingly quite high.
The controller now faces the challenge to reliably process the generated NC steps that are supported by the fast block cycle times and the look-ahead function of the CNC. “Hardly any other controller can supply the drive information for all five axes in the required short time as reliably as the Sinumerik 840D sl controller,” confirmed Jochen Schaede, who added, “The new Advanced Surface motion control that includes among other things an optimized look-ahead function is also excellent. And I would also like to mention the five-axis high-speed turning-milling of free-form surfaces requires a continuous spatial reorientation of the geometry vectors.” This leads to the use of the Traori (transformation orientation) principle in the Sinumerik 840D sl. Hamuel’s customers can therefore achieve reproducible results with the best-possible surface finish, exact contour accuracy and with the maximum possible machining speed.
In addition to the primary properties of precision, productivity and reliability, Hamuel also appreciates other properties of the Siemens drive and control engineering – an example: the DRIVE-CLiQ interface. When this digital connection is used, all appropriately equipped drive components are detected automatically. Only a cable for the connection is required to achieve this result. Equivalent circuit diagram data for the motors and the characteristic values of the installed encoder systems are all stored. This avoids the need for manual data input during the commissioning and so makes this task more reliable and much faster, according to Hamuel engineers. Sales manager Schaede is also impressed with the “know-how” protection onboard the control. With the help of innovative software, his customers can protect all their programs and their application know-how, using individual passwords and so largely prevent unauthorized access. According to Hamuel, the Teleservice offered by Siemens has proven to be an important advantage for its machine users who often operate globally. It allows not only software problems to be rectified but also updates to be installed fast and reliably without needing to be present onsite. Manufacturing operations save time and money and they always remain up-to-date with the latest software releases, via this service. Powerful motor spindle with Hirth gearing
The capability of the turning-milling center also depends greatly on the 54-kW motor spindle made by Weiss Spindeltechnologie GmbH (a Siemens subsidiary). Equipped with a HSK A63 tool holder, it is able to provide the high torque required for roughing plus speeds as high as 16,000 rpm for finishing. This means an optimum cutting speed is always guaranteed. As a practical detail, the Hamuel engineers also emphasize the integrated Hirth gearing that makes it possible to clamp the spindle and relieve load on the bearings during the turning process. The machine sizes in the HSTM Series are oriented to the length of the workpieces to be produced in standard ranges from ≤ 500 mm (HSTM 300) to 1750 mm (HSTM 1500). On special request, Hamuel also builds larger machines. A project for machining blades as large as 2500 mm in length is currently running in the field. CEO Markus Stanik explains, “Thanks to our modular machine construction, we are able to satisfy special requests and build turning-milling centers in these dimensions.”
New developments already in the introductory phase are also evolving at Hamuel. For example, in the near future, a special gas will be able to be used to cool the tool in the HSTM machines. A machine base made of mineral casting is also now offered. One of the first machines of this type has already been presented at EMO. “This material not only exhibits excellent properties with regard to vibration suppression but we have also been able to reduce somewhat our dependency on steel suppliers,” noted Markus Stanik. For the machine user, this makes itself apparent directly in improved surface quality and a significantly longer tool service life. CNC gantry milling machines of the HSM (high-speed milling) series In addition to the component production and the construction of the HSTM series, the company’s HMS Series machines are another mainstay for Hamuel. These simultaneous five-axis machining centers are designed for high-speed cutting (HSC). They feature not only the modern Siemens drive and CNC control engineering, but also the optimized milling-head systems and the high-performance high-speed spindles, providing this capability. HSM machines allow high-performance roughing and ultra-precise finishing. With regard to the size of the HSM machines, the manufacturer adapts the designs specifically based on the customer requirements. As a component producer, Hamuel also has its own machines in constant use at its factory.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
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SIEMENS INDUSTRY, INC.
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Attention: John Meyer, Manager, Marketing Communication
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
About Hamuel Maschinenbau GmbH & Co. KG, Meeder, Germany
Hamuel was founded in 1927 and is now part of the Hamuel Reichenbacher company group. More than 2000 CNC machines from this enterprise group are currently in use globally for the machining of a wide range of materials. The focus of Hamuel Maschinenbau comprises three areas: the production of machine-tool components, CNC gantry milling machines (HSM) and five-axis CNC turning-milling centers (HSTM).Continue reading