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High Performance 5-Axis Machining CenterECOSPEED, ECOSPEED FDörries Scharmann
06.2
009
- 1.
000
E -
09-9
08b
Products:
Dörries Vertical Turning Machines Vertical Machining Centers
Droop+Rein Portal Machining Centers High Speed Machining Centers
Scharmann Horizontal Machining Centers Boring Mills
Mecof Horizontal and Vertical High Speed Milling Centers
Berthiez Vertical Turning Machines Vertical Grinding Machines
DS Aircraft Machining Centers
Service
Headquarters:
Dörries Scharmann Technologie GmbHHugo-Junkers-Straße 12-32D-41236 Mönchengladbach-RheydtTel. +49/2166/454-0Fax +49/2166/454-300www.ds-technologie.deinformation@ds-technologie.de
Sites, Subsidiaries and Service Centers:
Dörries Scharmann Technologie GmbHProduct line Droop+ReinHofkamp 2, D-33719 BielefeldTel. +49/521/5804-0, Fax +49/521/178006
Dörries Scharmann Technologie Service Center GmbH & Co. KGAm Sülzenbrückener Weg 14, D-99334 IchtershausenTel. +49/36202/77980, Fax +49/36202/779829
Dörries Scharmann Technologie GmbHService Center SouthWannetal 47b, D-88131 LindauTel. +49/2166/454-700, Fax +49/2166/454-701
Dörries Scharmann Technologie GmbHBeijing OfficeRoom 704, Kun Tai Building, No. 10 Chao Wai Da Jie, Chaoyang District, 100020 Beijing, PR ChinaTel. +86/10/65995556, Fax +86/10/65995559
Dörries Scharmann Technologie GmbHMoscow Officeul. Tverskaya 16/2, Building 1, 7. Floor, RUS-125009 MoscowTel. +7/495/737-4981, Fax +7/495/737-6588
DS Technology (USA), Inc.7861 Palace Drive, Cincinnati, OH 45249, USATel. +1/513/247-2590, Fax +1/513/247-2599
DS Technology (UK) Ltd.43/45 Phoenix Park, Avenue Close, Nechells, Birmingham B7 4NU, United KingdomTel. +44/121/3593637, Fax +44/121/3591868
Berthiez SAS5, rue Barrouin, F-42029 St. Etienne Cédex 1Tel. +33/4/77923992, Fax +33/4/77923993 www.berthiez.fr, sales@berthiez.fr
Mecof SrlVia Molino 2, I-15070 Belforte Monferrato, ALTel. +39/0143/8201, Fax +39/0143/823088 www.mecof.it, info@mecof.it
is it your business?
…digital standard?
Wing and body components for c iv i l and mil itary aircraft
2 3
The ultimate goal of the industry is to pro-
duce ever more increasing lighter weight
structural parts with increasing inherent
strength. Previous methods of joining a
number of profiled parts together, has largely
been replaced by machining larger structures
from aluminium billets. Thinner wall sections
and more complex contours in five axis pro-
vide for this possibility to decrease weight
and increase strength.
It is inevitable that as designers make more
use of the modern 3D CAD tools 5 axis
applications will increase.
To achieve this goal the only real solution
can be provided by high speed machining
where the distortion forces of the tool on
the component are largely eliminated.
This in turn means that a much higher accu-
racy and higher surface quality is demanded
not only from the linear axis but also from
the rotary axis.
To meet these demands the machine’s linear
axis, has to provide a highly dynamic extre-
mely stiff construction.
In the case of complex contours and radii
this can not be provided by the conventional
rotary drives of Fork or Swivel heads.
How close can you get to the …
The typical gantry type profiler as designed
in the 1970’s has largely remained unchan-
ged until today. The high mass of the bridge
or cross rail renders it totally unsuitable for
any high speed process.
I f you are using these solutions
then its l ikely you are not very c lose at
al l .
The Fork Head with its open design concept
lacks the stiffness required coupled with
rotational bearings, a relatively long swivel
length and mechanical geometric alignment
makes it unsuitable for real accurate high
speed application.
The Swivel Head with its closed design is a
much more stiff solution and goes some way
in the trend of high speed machining but still
suffers from some of the previously menti-
oned difficulties, it is however, also suited
for the machining of titanium and steel.
20 years and 180 rotary axis type heads shows us that
these head types are not a high speed
solution.
Swivel Head
Typical wing and
body components
from billet or plateFork Head
Required rotational speed of the C-Axis at a 6° angle
radius [mm]feed [m/min]
spee
d C-
Axis
[rp
m]
40
20
0 10080
6040
200
0
100
200
300
400
500
600
700
800
Fork and Swivel Head - Disadvantages:
Positioning velocity, Angular acceleration,
Weight, Stiffness, Accuracy, Swivel length,
Geometric alignment, Complexity, Slip Rings,
Rotary couplings
vertical beam
A new approach……for real
Production gains
5A new generation completely
optimised by FEA
applied force: Fx = 1kN
Deflection ∆x = 18 µm
Stiffness kxx = 55 N/µm
applied force: Fy = 1kN
Deflection ∆y = 20 µm
Stiffness kyy = 50 N/µm
applied force: Fz = 1kN
Deflection ∆z = 1 µm
Stiffness kzz = 250 N/µm
Optimisation of machine column
Task:
– Optimisation of wall thickness
regarding thickness and mass
– Easier assembly
Result:
– Stiffness increased 20 % with
same mass
Static deformation (x-direction)
Applied force: Fx = 10 kN
max. deformation: ∆x = 47.6 µm
Stiffness: Kxx = 210 N/µm
WHY THE NEED
nEfficiency is the most critical and important
driver in manufacturing industry today. As
business becomes evermore competitive and
cost conscious, the factor of efficiency will
become increasingly critical.
nECOSPEED was specifically designed,
exclusively for the purpose of high speed
machining of structural aircraft components
from aluminium alloy plate or billet type
materials.
nECOSPEED was specifically designed to use
conventional well proven machine tool
technology.
nECOSPEED uses components that are mainly
proprietary parts, which can be bought from
suppliers shelves.
nECOSPEED has a machine stiffness that
equals or betters standard machining centre
designs.
nECOSPEED has first class ‘’maintainability’’
features.
nECOSPEED with it’s Z-3 head being
configured through linear axes only, carries
none of the compromises and performance
weaknesses associated with rotary axes.
nECOSPEED is the most efficient machine
tool on the market today for producing alu-
minium aerospace type components.
nECOSPEED makes traditional Profiler almost
obsolete for this type of application. As time
passes, this efficiency and technological gap
will widen. In a few years time, companies
using traditional equipment in this field will
become uncompetitive.
nECOSPEED in terms of cost, represents an
economic solution. Although single unit
prices may be higher than a conventional
Profiler, less machines are required for a
given output. Fewer operating personnel are
also required to run the machines.
nECOSPEED provides previously unknown
surface qualities rendering deburring and
fettling to a minimum requirement.
nECOSPEED offers the production of multiple
parts or part sets from a single billet giving
considerable time savings.
nECOSPEED is capable of increasing its levels
of performance still further in the future, as
motor spindle development provides faster
and more powerful units these will be easily
incorporated into the existing design.
4The KEY - El imination of rotary axis
n Offers possible platform orientations up
to +/- 40° within a Z-stroke up to 370 mm
n Offers angular velocities and accelerations
of the platform of 15 U/min and 685°/s2
nPositioning speed of 80°/sec around the
tool tip is available in every space angle
n Has a low mass, which leads to lower
acceleration forces in X-and Y-directions
n Offers a max. Z-stroke of 670 mm
With the aforementioned in mind Dörries
Scharmann Technologie has developed a
3 axis head concept of extremely stiff design
that takes account of all of the previous
mentioned difficulties to meet the highly
accurate contouring and radii requirements
including the higher surface quality demands,
by eliminating the need for rotary motions.
Continuous motion through standard
elements
proven technology
Comfortable component handling, (horizontal loading,
vertical transfer and machining)
Layout showing rail guided vehicle, pallet
buffer stations and load/unload station
7High Performance 5 axis Machining Center ECOSPEED
6
no risk solution
Complete machine with covers showing
optimised chip evacuation with no traps.
Complete machine without covers
showing gantry axis drives.
Column group with extreme low mass
and highest stiffness incorporating all
drives for every axis.
Headstock with complete freedom of move-
ment without slip rings or rotary couplings.
Automatically exchangeable angle heads
(option).Pallet for component mounting prepared for
automatic vacuum connection (option).
Example layout of
two machine system
Static table group showing pallet
transfer drive, location and clamping
We are designing and manufacturing
customer specific machines and variants of
ECOSPEED.
If you have any additional requests please
contact us.
5 axis machining example
98
ECOSPEED FECOSPEED F was designed for machi-
ning smaller structural Aircraft parts.
Table sizes from 1,500 x 2,500 mm to
2,000 x 3,000 mm offer you a range
below ECOSPEED with the same tech-
nical advantages.
Configuration
n Stationary column, moveable table
group
n Horizontal motor spindle, vertical
component
n 5-axis machining capability by
Sprint Z3-head
n Rotatable load / unload station with
2 pallets horizontal loading – vertical
machining
n Stand alone machine extendable to
FMS
Advantages
n Dramatic productivity increase
n Highest chip removal rate
n Extreme high accuracy
n Highest acceleration / deceleration in
all axis
n Eliminate fettling, polishing, deburing
n Improved chip management (free chip
flow)
n Advantageous price / performance ratio
ECOSPEED F X-axis drives with master
slave concept
Electronically pre-loaded X-axis drive
n Double pinion, electronically
pre-loaded by 2 drives
Advantages
n backlash elimination
n High stiffness
n High positioning accuracy
n Easy maintenance by reduced number
of elements
ECOSPEED F pallet changer
(horizontal loading, vertical machining)
completely independent of machine
eliminating interference to work spindle
when loading components
Oil mist extraction data
capacity 2,400 m3/h
air exchange > 1/min
coolant contents in cleaned air 10 mg/m3
The angular milling head ensures
full 5 sided machining.
High Performance5 axis Machining Center ECOSPEED F
Uni directional moments, rapid traverse
Opposing moments pre-loaded area,
feed mode
Uni directional moments, rapid traverse
comparison
Siemens Sinumerik 840 D
1
75
24,000
50
272
34
10 11Performance analys is
Year of construction
Producer
Spindle power
Spindle speed
Feedrate
Acceleration
* year of Retrofit
FPV 2,500/25
Performance characteristics
1975 - 2000
(5-axis machining)
1987*
Droop + Rein
30
12
8
0.2
1998*
Droop + Rein
40
24
20
1.5
2000
DST
75
24
50
10.0
Control
No. of spindles
Power
Speed
max. Feed
time for 8 components
time for 1 component
Bosch CC
4
33
6,000
10
480
60
Time comparison
vertical beam (see page 2)
(kW)
rpm. * 1,000
m/min.
min.
min.
Technical data ECOSPEED
factsX-axis
Y-axis
Z-axis
Angle orientation
Z-stroke at ± 40°
Pallet size in X-axis
Pallet size in Y-axis
Tool magazine
Coolant
Chip evacuation
Process control
Oil mist extraction unit
CNC Control
Video
Acc./Dec. in X
Acc./Dec. in Y
Acc./Dec. in Z
Rapid traverse in X
Rapid traverse in Y
Rapid traverse in Z
High rotary positioning velocity
High rotary acceleration
Spindles
3,800 - 6,300 mm
2,500 mm
670 mm
± 40°
370 mm
3,500 - 6,000 mm
2,000 mm
38, 57, 93, 129 tools / HSK-A 63/80
Minimum Quantity Lubrication /
Flood and Through Tool Coolant
Hinged belt conveyor
Extraction volume 100,000 cm3/min
Component probing, Tool life
management, Tool length control,
Tool measuring, Tool coding,
Tool balancing / Pre-setting,
Post processor
Basic machine capacity 2,400 m3/h
Siemens SINUMERIK 840 D
Video monitoring inside machine housing
9.81 m/sec2
9.81 m/sec2
9.81 m/sec2
50 m/min
50 m/min
50 m/min
80°/sec
≥ 685°/sec2
(eg. 115 ms to full speed)
80 kW, 46 Nm, 30,000 rpm
120 kW, 83 Nm, 30,000 rpm
and more
3,300 - 15,800 mm
2,500 mm
670 mm
± 40°
370 mm
7,000 * 15,000 mm
1,500 * 2,500 mm
min. 125 tools / HSK-A 63/80
Minimum Quantity Lubrication /
Flood and Through Tool Coolant
Hinged belt conveyor
Extraction volume 100,000 cm3/min
Component probing, Tool life
management, Tool length control,
Tool measuring, Tool coding,
Tool balancing / Pre-setting,
Post processor
Basic machine capacity 2,400 m3/h
Siemens SINUMERIK 840 D
Video monitoring inside machine housing
9.81 m/sec2
9.81 m/sec2
9.81 m/sec2
65 m/min
50 m/min
50 m/min
80°/sec
≥ 685°/sec2
(eg. 115 ms to full speed)
80 kW, 46 Nm, 30,000 rpm
120 kW, 83 Nm, 30,000 rpm
and more
ECOSPEED FECOSPEED
1975
Droop + Rein
20
4
4
0.1
Unit FPA 2,500/24 FPA 3,000/33 ECOSPEED
(kW)
rpm. * 1,000
m/min.
m/s2
Unit Droop + Rein FBV 3,200 ECOSPEED
Performance characteristics 1975 - 2000
(Efficiency)Performance characteristics 1975 - 2000
(Technology Development)
FPV 2,500/251975
FPA 2,500/241987*
FPA1998*
ECOSPEED2000
800
700
600
500
400
300
200
100
0
FPV 2,500/251975
FPA 2,500/241987*
FPA1998*
ECOSPEED2000
80
70
60
50
40
30
20
10
0
Spindle Power (kW)Spindle Speed (rpm.*1,000)Feedrate (m/min)Acceleration (m/s2)
Material removal rate (dm3/h)Part production time (h), based on five different EUROFIGHTER parts
X-axis
Y-axis
Z-axis
A/B-axis
up to 3,000 mm
above 3,000 mm up to 8,000 mm
above 8,000 mm
2,500 mm
670 mm
+/- 40°
Positional accuracy according
VDI/DGQ 3441
Axis Working Area
10 µm
+ 1.5 µm/1,000 mm
+ 2.0 µm/1,000 mm
10 µm
8 µm
10 arc. sec.
P
5 µm
+ 0.5 µm/1,000 mm
+ 1.0 µm/1,000 mm
5 µm
4 µm
5 arc. sec.
Ps
Recommended