Embed Size (px)
Citation preview
AMADA MACHINE TOOLS EUROPE
PRODUCT OVERVIEWMILLING TECHNOLOGY
THV DUPLEX MILLING MACHINESPMH PLATE MILLING MACHINES
2 / 3
AMADA MACHINE TOOLS
Headquarters in Japan (Isehara)
The AMADA Group is one of the leading international machine tool manufacturers with more than 6,000 employees throughout the world and a turnover of approx. 2 billion euros.
AMADA technologies are trend-setting production solutions to obtain a high level of economic efficiency and productivity while ensuring maximum environmental compatibility. One of the main objectives for the years to come is the large-scale expansion of the group‘s machine tool technology. To achieve this goal, Amada has already established a new organization back in 2009, AMADA Machine Tools Europe. As a Total Solution Provider, this company is guided by the individual customer needs. The same philosophy is already used in the development of new machines to meet the ever increasing demands of a Total Solution Provider.
AMADA environmental awareness
AMADA has developed a long-term environmental plan „AMADA Green Action“ to the ongoing promotion and preservation of the environment. In the development of new products, reduction of energy and resources are taken into account. New production facilities, such as the new plant in Toki, will be built according to these guidelines and operate under strict compliance with the conservation of resources.
New production site in Toki, Japan
On a total area of 156,000 sqm, a state-of-the-art manufacturing plant including an R&D Centre was built in Toki, Japan. Here, AMADA is manufacturing high-tech turning, grinding and sawing machines. The plant has been designed based on stringent ecological demands and is intended to realize the „Zero Emission“ concept. Using state-of-the-art and environmentally sound energy conservation, high-precision grinding and turning machines are produced here for the global market. The Technical Centre being part of the plant will be used as a communication platform.
AMADA GROUP
High-tech Development Centre near Mount Fuji: Fujinomiya Works New production site in Toki, Japan
AMADA Machine Tools Europe – European Headquarters in Haan, GermanyTechnical Centre in France Technical Centre in Italy
In order to further the development, based on more than 70 years of AMADA‘s experience in the manufacture of high precision machine tools and to strengthen AMADA‘s position in the important European market and in a sustained manner. AMADA Machine Tools Europe GmbH was established in 2009 to unite several established brands (including WASINO). The change of name is intended to promote global development and to consolidate the brand AMADA.
AMADA Machine Tools Germany: the European Headquarters
In order to enable advancement, AMADA Machine Tools invests in high-tech locations for development and production. In 2010, the Technical Centre in Haan, near Düsseldorf was opened.
AMADA Machine Tools France
The Technical Centre for AMADA machine tools and AMADA sheet metal processing branches is located in close proximity to Paris.
AMADA Machine Tools Italy
In May 2010, the Technical Centre in Vigolzone, Piacenza was opened as the base for the AMADA machine tools and AMADA sheet metal processing branches.
AMADA Machine Tools today
More than 1,000 employees world-wide Production of grinding, turning, milling and sawing machines More than 100,000 installed machines world-wide
AMADA MACHINE TOOLS EUROPE
New production site in Toki, Japan
4 / 5
DUPLEX MILLING MACHINES
THV SERIES
Material stop FANUC control unit – THV seriesWorking area of the THV-150
THV-150
Proven concept in series
For quite a long time, the concept of the THV duplex milling machine offered as a series machine has proven itself in the Asian market. The production advantages offered by the THV are utilized by companies in the tool steel industry, by manufacturers of supply parts for engineering and by companies working in the energy, transportation, automotive and aerospace sectors.
Economic duplex milling for higher cost effectiveness
The high-productivity THV-series duplex milling machines enables fully automatic plate machining in one material set-up. Resulting in high angular accuracy and parallelism of the finished workpiece and a considerable reduction of the cycle time.
Compared to conventional one-head milling machines, duplex milling with the THV series machines offers e.g. the following benefits:
shorter handling times low error rate due to automatic material width calibration Automatic indexing of the workpiece achieves high accuracy userfriendly operation
THV-430
The THV-430 has been designed for high-quality machining of plates measuring up to 430 x 430 mm and with a maximum height of 190 mm (option). In most applications, further machining is not required due to the extremely high surface finish of the machined parts.
Userfriendly operation
Easy to operate using interactive control. For setting up the automatic manufacturing process, only input of initial dimension,
finished dimension and material grade are required. NC and cutting skills are not needed.
CNC control for userfriendly operation
The THV is equipped with the E.C.O.S operating system. It simplifies the operation of the machine to such an extent that even untrained staff can work with the machines of the THV series in an easy and controlled manner.
Chamfering Machining steps External measuring table
6 / 7
DUPLEX MILLING MACHINES
THV SERIES
THV-800
Material support of the THV-800 ø250 mm milling head of the THV-800
Innovative, patent-registered material clamping
The material is clamped by a hydraulic clamping system. The workpiece fixture and the appropriate material supports can be easily changed. The correct workpiece fixture for the material size to be machined is displayed after entering the the material data. A keyway on the fixture ensures the correct selection.
Picture without standard guard
Patent-registered material clamping – side machining
THV-1000
Material stopPatent-registered material clamping – chamfering
Easy workpiece handling by means of automatic positioning and measuring devices
Correct loading of the workpiece into the working area is simplified by one front and one lateral stop plate. After the material size has been entered, the workpiece is automatically fed. Before machining is started, a touch probe automatically checks the workpiece width.
Picture without standard guard
8 / 9
DUPLEX MILLING MACHINES
THV SERIES
THV-1200
High angular accuracy and parallelism achieved by duplex milling heads
Before the machining process, the workpiece has to be centered on the rotary table. In doing so, the duplex mill can machine the two opposite sides of the material simultaneously. The „Automatic Centering System“ ensures smooth two-side machining and guarantees a high angular accuracy and parallelism of the workpiece. The cutting conditions are stored in the control unit. However, they can also be replaced by customized values.
Picture without standard guard
The THV-T series has been developed to enable the customer to cover the whole product range with one machine – both for precision-plate and bar stock machining. For both applications an automatic material stop system simplifies the set-up of the machine.
Bar stock machining (T series)
For the machining of bar stock with a length of up to 3000 mm, two additional work tables are used to support the material. Four material fixtures are automatically used. Just as in plate machining, the bar stock is aligned by means of a 1080 mm long stop plate which automatically adapts to the actual dimension during machine set-up. The bridge for the upper material clamping can be adjusted from a central control station. Thus, machine set-up is quick and easy.
THV-1200 (30-T)
Lateral viewMaterial fixture for bar stock – front view Material support with patent-registered indexing unit
Picture without standard guard
10 / 11
ADVANTAGES OF DUPLEX MILLING
THV SERIES
THV-430
Conventional milling machine
20 min
15 min
10 min
5 min
0 min
[Milling time] approx. 5 times faster!
SHORTER CYCLE TIMES – EXAMPLE: THV-430
Duplex milling machine THV-430
Conventional milling machine
Operating steps 1 4
Milling time approx. 4 min approx. 20 min
Total time [incl. preparation and set-up] approx. 10 min up to 45 min*
Machine parameters THV-430 (2 x 11 kW)
Material C45
Mill diameter (mm) ø 160
Cutting inserts (number) 8
Spindle speed (rpm) 300
Feedrate (mm/min) 480
Cutting width (mm) 150
Cutting depth (mm) 2.0
* Set-up time for the conventional milling machine includes the time required for data entry, material set-up changes and precise calibration. This depends on the skills of the operator.
Conventional milling machine Duplex milling machine
Operating cost Productivity & ease of operation Accuracy
MAXIMUM EFFICIENCY
Angular accuracy Parallelism
Duplex milling machines offer both high performance and maximum precision.
Accuracy Allowable tolerance (mm) Achieved value (mm)*
Parallelism A-CLess than 0.02 mm over a
measuring length of 300 mm0.006 mm
Angular accuracy of the sides in relation to each other (faces A · B · C · D)
Less than 0.02 mm over a measuring length of 300 mm
0.007 mm
Angular accuracy of the sides in relation to face E
Less than 0.03 mm over a measuring length of 100 mm
0.010 mm
* Values have been achieved by using the THV-430.
MAXIMUM PRECISION
12 / 13
TECHNOLOGY AND SCOPE OF DELIVERY
THV SERIES
Workpiece positioning (patent-registered)
Automatically positioned stops simplify workpiece set-up. All the operator has to do is load the workpiece, push it against the stops and clamp it.
Workpiece calibration (patent-registered)
Automatic examination of the entered workpiece dimensions and calculation of the workpiece center. Then the milling heads automatically move to the optimum position. This function is called „Automatic Centering System“.
Without automatic centering, only one side might be machined.
The „Automatic Centering System“ enables the two milling heads to always have the same distance to the workpiece and thus to mill with the same cutting depth.
Y stopWorkpiece
Touch probe Z stop
Workpiece
Center Centermachined side
unmachined side
Center Center
same cutting depth
Without „Automatic Centering System“
With „Automatic Centering System“
HIGH-PRECISION AND HIGH-PRODUCTIVITY PLATE MILLING
Milling with the duplex milling machine
Process description:1. Workpiece clamping performed by the operator2. Automatic calibration and synchronous milling of the sides A-C3. Automatic indexing of the workpiece by 90°4. Automatic calibration and synchronous milling of the sides B-D5. Optional chamfering in automatic mode
Shorter downtime, higher machining precision, lower production cost
Mill
Mill
Mill
MillRotary table Rotary table Rotary tableRotary table
Workpiece fixture
Fixtures for all allowable workpiece sizes are supplied with the machine.
Hydraulic clamping system (patent-registered)
The hydraulic clamping unit can be adjusted in several step. It guarantees safe clamping throughout the machining process.
hydraulic workpiece fixture
Plan view
Hydraulic clamping system Workpiece fixture
14 / 15
PLATE MILLING MACHINE
PMH SERIES
PMH-1308
The sturdy-design AMADA PMH-1308 has a milling head with a diameter of 525 mm and can be used for machining dimensions of up to 1300 x 800 mm. Plates with a width of up to 500 mm can even be milled in one pass. This reduces the cycle times and ensures extremely high surface finishes.
Picture without standard guard
ø525 mm milling head Automatic measuring system Input screen of PMH-1308
1
2
SPECIAL MILLING HEAD TECHNOLOGY
Parallelism
Flatness
Surface finish* Material ST52 245 x 245 x 23 mm
Measuring point Measuring result*
Upper to lower surface 0.0192 mm
Type Size*
Ra 0.40 µm
Ry 2.87 µm
Rz 2.10 µm
Measuring point Measuring result*
1 0.0137 mm
2 0.0169 mm
Milling using the PMH-1308
The PMH-1308 has a 525 mm sized milling head, allowing plates with a width of up to 500 mm to be milled in one pass. Material surfaces obtained therefore have no transitions or steps.
Conventional milling with small milling heads
When milling plates using small milling heads, several milling processes are required. This may cause steps and strain in the material. For such machining, well-founded cutting experience and complex NC programming are required.
Tool measuring system Conventional machine with ø60-150 mm milling head PMH series with ø525 mm milling head
High machining quality
Nm kW
22,0
20,0
10,58,8
18,5
16001660 Nm
1396 Nm1400
1200
1000
800
600
400
200
500 100 150 200 250 min–1
60m
in–1
126
min
–1
0
50 % ED
22 kW (50 % ED)
16 / 17
TECHNOLOGY AND SCOPE OF DELIVERY
PMH SERIES
Large high-capacity milling head is able to offer more benefits than merely shorter cycle times
Apart from reduced cycle times, milling with the large milling head (Ø525 mm) has enormous benefits regarding workpiece quality:
no chatter marks whatsoever equally distributed thermal load excellent surface finish
As the machines of the PMH series have been especially designed to mill P plates, the milling head is positioned with a minimum inclination in relation to the workpiece.
Torque almost 3 times as high as on conventional milling machines
By default, the PMH-1308 is equipped with a high-capacity spindle with JIS No. 60 taper. On comparable conventional milling machines and machining centers, the spindle size corresponds to JIS No. 40 or JIS No. 50. A conventional milling machine with a driving power of 22.4 kW and a No. 50 spindle e.g. generates a torque of 600 Nm, whereas the PMH-1308 with the same power of 22.4 kW and a No. 60 spindle having a high-capacity gear unit is able to generate a torque of 1660 Nm.
Inclined milling head
Lateral view of face mill
Torque Output
No. 40 No. 50 No. 60
SPECIFICATIONS OF MILLING TECHNOLOGY
Specifications Workpiece dimensionsmax. (L x W x H)
Workpiece dimensionsmin. (L x W x H)
Workpiece weight max.
Power Machine weight Milling heads
THV-150 150 x 150 x 52 mm 7 x 7 x 7 mm 20 kg 2 x 5,5 kW 2200 kg Ø 63 mm
THV-430 (160) 435 x 435 x 150 mm 20 x 20 x 10 mm 230 kg 2 x 11 kW 6000 kg Ø 160 mm
THV-430 (200) 435 x 435 x 190 mm 20 x 20 x 10 mm 290 kg 2 x 11 kW 6500 kg Ø 200 mm
THV-800 810 x 810 x 230 mm 70 x 70 x 10 mm 1200 kg 2 x 11 kW 8500 kg Ø 250 mm
THV-800 (20-T)(plate) 800 x 800 x 230 mm 40 x 40 x 10 mm 1200 kg 2 x 11 kW 8500 kg Ø 250 mm
(Flat bar steel) 2000 x 800 x 230 mm 600 x 40 x 10 mm 3000 kg 2 x 11 kW 13000 kg Ø 250 mm
THV-1000 1020 x 1020 x 400 mm 120 x 120 x 10 mm 3500 kg 2 x 22 kW 20000 kg Ø 425 mm
THV-1200 1220 x 1220 x 400 mm 320 x 320 x 10 mm 4500 kg 2 x 22 kW 28500 kg Ø 425 mm
THV-1200 (30-T)(plate) 1200 x 1200 x 230 mm 250 x 250 x 10 mm 2500 kg 2 x 11 kW 20000 kg Ø 250 mm
(Flat bar steel) 3000 x 1200 x 230 mm 1200 x 80 x 10 mm 6000 kg 2 x 11 kW 23000 kg Ø 250 mm
Overview of options
External measuring table
Bar code 5° indexing tableExpanded
material magazineIncreased
spindle powerSpindle
cooling system
THV-150 x x
THV-430 x x x x x x
THV-800 x x x
THV-1000 x x
THV-1200 x x
THV-800 (20-T) x x x
THV-1200 (30-T) x x
* Subject to alterations
Specifications Workpiece dimensionsmax. (L x W x H)
Workpiece weight max.
Power Machine weight Milling heads
PMH-1308 1300 x 800 x 300 mm 3500 kg 22 kW 9000 kg Ø 525 mm
PMH-3015 3000 x 1500 x 350 mm 13000 kg 30 kW 22000 kg Ø 525 mm
PMH-4020 4200 x 2010 x 400 mm 15000 kg 30 kW 35000 kg Ø 525 mm
18 / 19
EXPERIENCE TECHNOLOGY IN ACTION
Technology by AMADA Machine Tools Europe GmbH
AMADA Machine Tools Europe considers itself to be the first contact for customers and prospects as regards technical matters. Experience grinding, turning, milling and sawing technologies in action, discuss your requirements with skilled engineers, look for ideas and benefit from solutions.
The latest machines, precision measuring equipment, and related accessories are available to work on the ideas and concepts and test them immediately.
The Technical Center is available for individual customer visits and themed events with customers and suppliers. It is the active communication platform for interaction between users, suppliers and developers.
TECHNOLOGY
AMADA Machine Tools Europe – Application
AMADA MACHINE TOOLS EUROPE supports the customer throughout the whole investment decision-making process. In our Technical Centre, we calculate the job times and we discuss the process analysis results with our customers. A separate room for precision measuring enables the results to be verified immediately.
APPLICATION ENGINEERING
AMADA Machine Tools Europe – Service
AMADA MACHINE TOOLS EUROPE provides tailor-made service support for the complete operating life of your turning, grinding, milling and sawing machines.
Our proficient service staff will help you to use your machine in the most efficient manner. Our comprehensive service network guarantees fast availability of a service technician and reduced idle times of your machine tool. Spare parts warehouses in Haan and Wertheim shorten the delivery times to the minimum.
With AMADA MACHINE TOOLS original spare parts, you will reach maximum reliability.
SERVICE
AMADA MACHINE TOOLS EUROPE
Germany
France
Italy
AMADA MACHINE TOOLS EUROPE GmbHAmada Allee 342781 HaanTel.: +49 (0) 2104 177 70Mail: [email protected]
AMADA MACHINE TOOLS EUROPE GmbH FranceZI PARIS Nord II, 96 Avenue de la Pyramide93290 Tremblay-en-FranceTel.: +33 (0) 149 903 094Mail: [email protected]
AMADA MACHINE TOOLS EUROPE GmbH ItalyVia Amada I., 1/329010 Pontenure (Piacenza)Tel.: +39 0523 872 311Mail: [email protected]
The cutting performance data in this catalogue is affected by material, tooling and cutting conditions. Technical changes reserved.
Russia AMADA OOODokukina Street 16, Building 3, 5FMoscow 129226Tel.: +7 495 518-99-03Mail: [email protected]
© AMADA MACHINE TOOLS EUROPE GmbH – 03/2013
