In the medical technology marketsegment, the manufacturing ofimplants represents an area char-acterised by the expectations ofefficient production but whichnevertheless must satisfy the spe-cial constraints of a medical envi-ronment.

Ralf Löttgen

Autonomy and Process CapacityThe HSM 400U ProdMed in its

standard configuration and the derived version for the productionof dental implants, as well as the UCP 600 Vario ProdMed, each have integrated and econom-ic solutions for tooling and compo-nent automation. This not only involves the physical change, butalso monitoring and evaluation oftools and components by measure-ments and the inspection of break-age, including documentation ofthe results.

In combination with the moni-toring functions of the control sys-tem as well as the “smart machine”modules included in the scope

of delivery for monitoring spindlevibrations (Extended APS), the automatic calibration of machinegeometry (ITC-5X) that can becalled in the NC program, plus theoption to transmit specific machineand process statuses to GSM tele-phones (RNS), the ProdMed ver-sions make a significant contribu-tion towards reliable and traceableresults in production.

Reduction in Piece TimesThrough a variety of completed

projects, it has been shown that forfrequently used tool diameters,high-speed technology with spin-dle speeds of more than 15'000 to30'000 rpm – even higher in excep-tional cases – can be used even forsemifinishing and finishing workon titanium alloys, and providesconsiderable potential for the re-duction of machining times. Edge

build-up and adhesion problemswith titanium alloys occur almostexclusively during roughing oper-ations, so that in general, low spin-dle speeds and higher axial and lat-eral infeeds are used accordingly.In such applications, the wide per-formance range of modern motorspindles can be used optimally,with comparatively high torques atlow rotation speeds and, depend-ing on the spindle type, at maxi-mum speeds from 20'000 up to54'000 rpm. With regard to ma-chining aspects, the system’s highflexibility makes a significant contribution for shorter part times whilst improving the level ofdetail and surface quality at thesame time.

Required Characteristics of theMaterials to be machined

Contrary to titanium machin-ing, it is hardly worth applying high-speed technology for alloys that aredifficult to machine, regardless ofthe machining situation. Depend-ing on the amount of material to beremoved and the part's geometry,

considerable emphasis should beplaced on the spindle output, i.e.the UCP 600 Vario ProdMed – spe-cialized for the operation of set,clamped axes and with spindlespeeds of 20'000 rpm – is recom-mended for machining work that is characterized by a high level of material removal, whereas an agile HSM 400U ProdMed, also using simultaneous 5-axis machin-ing with spindle speeds of 30’000 rpm, is preferable for morecomplex machining operationswith low demands on material removal.

Likewise, chip disposal andcooling lubricant treatment are ofparticular significance, especiallyin the case of titanium machining.Therefore, and depending on theexpected chip volumes, the threeProdMed models feature adapteddesigns based on bandpass filtertechnology that permits smoothproduction operation.

Integration into the Environmentand Processes

Of particular importance is thesmooth integration of new, de-mand-driven production resourcesinto the technical production envi-ronment, and also into the medicalenvironment in the case of medicaltechnology. In this case, variouscompany-specific aspects also playa role. Apart from characteristicsthat are taken for granted, such asreduced space requirement, relia-bility, ergonomics, integration intoIT networks, etc., the traceabilityof the machining results, the doc-umentation of the NC programused, and similar aspects assumeparticular significance. For thispurpose, automatic logbook en-tries or those created on command,status displays or measurementresults can be used and assessedindividually.

Frequently, the productionproblem on the machine is only partof a far more complex situation. For

example, an entire process can begin with the capture of three-dimensional geometry data on ascanner, and must end with a partthat satisfies quality requirements.This is where the development ofefficient and effective processchains, in cooperation with the rel-evant partners from the area of pro-duction technology, is of para-mount importance. If required, andin addition to the ProdMed ma-chines customized to satisfy theneeds of medical technology, serv-ices are also offered, which are in-tended to assist the developmentand implementation of successfuloverall processes in conjunctionwith the client's expertise. This includes advice on CAD/CAM issues, questions regarding toolselection or technological aspects,as well as contact with partners inthe process chain who are alreadyable to offer solutions to relevantproblems.

Thus, the Mikron ProdMed machines, including possible serv-ices in connection with the de-velopment of integral productionprocesses, reflect an offer that isfocussed on the needs of medicaltechnology.

Page 2-3: The HSM 400U at IWC in Schaffhausen/CH

Page 11: The HSM 400 at Hung Ming Ho in China

Page 6-7: Great enthusiasm forthe HPM 1000U/1100

Page 14-15: Large parts withthe HPM 1850U at Bühler/DE

Page 12-13: Medical Technology,the UCP 600 Vario und MEDARTIS

Specialist journal fromMikron Agie Charmilles AGfor the Milling Technology

Issue 16

Machining Centers for Medical Technology

www.mikron-ac.com

HSM 400U ProdMed, HSM 400U ProdMed Dental and UCP 600 Vario ProdMed

Please take notice of the articleon the pages 12-13.The company MEDARTIS/CHmanufactures medical productswith a UCP 600 Vario.

Distinctive originals in chrono-metry are the undisputable specialty of the North-easternSwiss watch manufacturer IWCSchaffhausen: The famous "DaVinci" with permanent calendar isa part just as the "Grande Compli-cation", the super antimagnetic"Ingenieur" or the "Aquatimer Automatic 2000", which will with-stand pressures to 2000 meterswater depth.

Jürgen Maurer

The fact that an American Engineer from Boston, FlorentineAriosto Jones set up the "Interna-tional Watch Co." in Schaffhausenin 1868 was no accident. The nameand the existence accounts themanufacturing location on theRhein - far away from the watch-centers of Western Switzerland -to this American. He found a new-ly constructed hydro-electric pow-er plant as the drive for his machines. - Ideal conditions for his passion, building perfect me-chanical clocks for the Americanmarket. He also found watchmak-ers in Schaffhausen who's careerswere backed by long tradition. Evidence of this was found in the

Schaffhausen public records office,dated 29 January, 1583 in entriesof trades artificer, the gunsmith,watch makers and winder makerson the city council. These entriesprove that the watchmaker tradesexisted in Schaffhausen at that time. The beginnings ofSchaffhauser clock-making art goback even further, back to 1409when a Monk from the nearbyRheinau Monastery built the strik-ing clock in the St. Johann church.

Originals of chronometry werecreated soon after the companywas formed, such as the Pallwe-ber pocket watch with a digital display, which is a much sought after collector's piece. As one ofthe first watch manufacturers, IWCrecognized the huge potential ofthe ever more popular wristwatchat the end of the 19th century, which was the reason for develop-ing a completely new factory. Onthe other hand however, the origi-nal inner workings of the pocketwatch were also used in the wrist-watches, as the market in the 30's demanded large precisionwristwatches. This led to the Portugese line - still a trendsetterfor wristwatches today in "King-size" format.

IWC was on the scene as thewatches were used as the pioneersof flight were learning to fly - andstill has an extensive collection ofprofessional Pilot's watches, whichare equipped with a special protec-tive magnetic field. In the nineteenfifties, IWC wasn't only at the headof the race for automatic self-wind-ing watches but they developed anunsurpassed self-winding systemwith the Pellaton winding system,

which even today works exclusive-ly in their automatic manufactur-ing plants.

During the major turbulencesof the Swiss watch-making indus-try at the end of the seventies,Watches were engineered for men in Schaffhausen under theleadership of their revered PatronGünter Blümlein - against the push toward electronics - mechan-ical, innovative and of superiortechnology.

This self-conception led to thetongue in cheek advertising slogan:"IWC – since 1868. And as long asthere are still men." Since themen's watch has of course longsince become a woman's concernas well.

The technical perfection, thetraining of their engineers, the prevention of manufacturing massproducts: All of this correspondswith the old axiom of the IWC, tomake watches for few but of thehighest quality. This is the reasonthat the watches with thoroughmaintenance last for decades. Thisis also why they are collectorpieces, which fetch collector'sprices around the world. Distin-guished pulses for the mechanicalwatch come from IWC. 450 em-ployees manufacture the covetedpieces in Schaffhausen. IWC hasbelonged to Richemont SA sincethe year 2000.

2 High-speed machining HSMtoday Nr. 16

Dear Readers,

In this edition of HSMtoday, weonce again introduce you tocompanies who use our high-speed and high-frequency machining centers, clearly illustrating the fact that therange of application for our machining centers is highlyvaried. Mikron offers eachuser the machine best suitedto him from the broad spec-trum of machining, from theVCE Pro line vertical machin-ing centers to the universalhigh-performance machiningcenters of the UCP line. Withits HPM line of products (highly productive chip re-moval), Mikron launches ma-chining centers on the marketwith a working range of up to 1850 mm for the first time.

The HSM line of 5-axishigh speed machining centershas been continuously im-proved in recent years. Mikronhas put great effort into all its machines in order to optimizeautomation.New arrivals include the HSM 400U ProdMed, HSM 400U ProdMed Dentaland the UCP 600 Vario ProdMed, machines specially developedfor medical technology. Eachmachine features integratedand economic solutions fortooling and component au-tomation. With every new in-novation and further develop-ment, an important objectiveis to increase the competitiveedge of your company – be-cause your success is oursuccess.

Editorial

Jens ThingBrand Manager Mikron

IWC Schaffhausen - Where quality meets innovation

IWC prefers milling machines from within their own country. For almost two years, watch cases have been manufactured forthe "Ingenieur" on a Mikron HSM 400U of Nidau/CH

The HSM 400U palette changer. 3 watch casings are mounted on thefixture constructed for them at IWC

3High-speed machiningHSMtoday Nr. 16

Mikron and the “Ingenieur”

An HSM 400U from Mikron hasbeen working in the IWC millingshop in Schaffhausen for almost 2 years now. This milling center is mainly for producing the "Ingenieur" casings.

But first, more on this classicwatch from IWC. The name hasbeen the vision and the programfor 50 years. It stands for robust-ness, precision and technicalprogress. Its development was

the definite start to the automaticmechanisms in Schaffhausen. Thefirst time the “Ingenieur” appearedon the market, carrying the technical lightning symbol on the number plate - for electricity -was dated 1954/55. "Ingenieur” also means: Protection from ex-treme magnetic fields with an IWC-typical soft-iron casing interior.

An entire family of athletic,more attractive and especiallytough watches were derived from the watch-makers solitaire(www.iwc.ch).

The HSM 400U, which has awindow location in the IWC millingshop, is a processing center in aclass of its own, is very dynamicand the precision of all 5 axes isexceptional. When questioned asto why a Mikron machine was pur-chased, Hubert Uebelhör, the re-sponsible programmer and config-uration technician, explained thatthe name and the good machinesof the Swiss manufacturer are wellknown. The large 5-axes mobility,which is required for the partsspectrum of IWC, the pivoting an-gle and the simultaneous opera-tion abilities were important to him.The solid construction of the ma-chine and the acceleration were al-so very convincing. The iTNC 530controller by Heidenhain with itsuser-friendly interface is also sig-nificant for IWC.

As already mentioned, thewatch casing of the "Ingenieur" ismilled on the HSM 400U and it is done using full material, eitherof stainless steel or titanium. The winding mechanism is alsoproduced with this machine toachieve the best possible fittingprecision.

Since the HSM 400U is set upwith a palette and tool changer byMikron and the inexpensive palettesystem by 3R for automatic oper-ation, the assembled equipment

does not have to be unscrewed,they can be "parked" on thepalettes. This reduces set-up timesto very nearly zero. IWC watch casings can be produced overnightand on the weekend without an operator.

According to Hubert Uebelhör,the HSM 400U is generally veryuser-friendly and easy to operate.It is also very reliable and dimen-sionally stable. The HSM 400Umeets all of the demands of a mod-ern 5-axes processing center.

Particularly noteworthy is thedependable cooperation with theCompetence Centre in Nidau. If Hubert Uebelhör requires specialinformation or must have answers to processing questions that areout of the ordinary concerning the

machine, he can rely on the exten-sive knowledge of the Nidau Appli-cation Engineers.

The experiences with the spin-dle are by all means positive andthe temperature compensation(cycle 307) functions excellently,added Hubert Uebelhör. Cycle 307("smart machine" Module ITC-5X)is a calibration cycle, which enablesthe deviations in the pivoting rota-tional axis by determining the newpivot point of the C axis. These deviations occur on processing centers because of the heating ofthe pivoting rotational axes.

With HSK shrinking tools, suchas are used at IWC, the spindleworks like a charm. The exception-al rotational values produce a muchhigher life-span of the tools com-pared with the ISO cone with col-let grips and an improved surfacequality on the work piece.

2nd HSM 400U already on order!Based on the great experience

and the excellent milling results

with the HSM 400U by Mikron, IWChas ordered another machine.

In summarizing, the HSM ma-chines by Mikron meet the higheststandards concerning speed, precision and surface quality. Its demand-oriented design, the high quality components, the digital drive technology and one of the most modern controllers,these machines are designed formaximum efficiency, economic value and functionality.

www.mikron-ac.com

The Ingenieur Automatic AMG in Titanium casing. A statement for the common value, combining the IWCand the Mercedes AMG as the mark of Engineers with their lean toward perfection

Hubert Uebelhör,over 20 years of CNC experience

There is enough space in the tool changer of the HSM 400U for 68 tools

4 HSMtoday Nr. 16Highly productive 5-axes machining

Due to the impressive machiningcapabilities of the HPM 1850U,Mikron is now also using some ofthe technology used in these machines in the new HPM 1150Uand HPM 1350U. The HPM ma-chines are based on the provenmodels of the UCP Series.

Stefan Fahrni

The new HPM 1150U and HPM 1350U 5-axis simultaneousmachining centers can be used forheavy cutting work or highly pre-cise machining processes. Thissuccessful design with the designof the fourth axis as a circularmilling attachment and the fifth ax-is as a swiveling head means thatvery bulky work pieces can be machined. The HPM 1150U / 1350Uuniversal machining centers makean impact thanks to their out-standing performance as imple-mented in the aviation industry, the manufacture of moulds and inparts production as well as in many other fields of application.

Direct driveThe HPM 1150U and HPM

1350U are now equipped with a direct drive swiveling head, whichassures yet faster and more

dynamic machining. An advantageof the direct drive is that the appli-cation window for five-axis ma-chining opens further. Milling thatin the past could only be performedby specialists is now much easierto handle.

Since a torque motor now drivesthe swiveling action, the gearboxis no longer needed, as well as thebelts and possible factors that mayaffect precision and service workthat goes along with that. The simultaneous swiveling head is also equipped with a hydraulicclamping device that makes it pos-sible to clamp the spindle in eachswiveling position. Optimal boringand machining procedures can nowbe carried from every position.

The advantages of the directdrive are especially evident whenthe possibility of simultaneousmilling can be fully utilized. Thebest example of this is an airplanepart on which curved surfaces mustbe produced in constantly chang-ing angles by hobbing. The moreprecise axis guides pay for them-selves during simultaneous ma-chining with direct drive in theround and swivel axes. Better sur-faces can be produced at even high-er feed rates.

Strong motor spindlesSpindles of the latest genera-

tion are used on the HPM 1850U,as well as on the HPM 1150U and HPM 1350U.

At 15000 rpm and 193 Nm, theyare among the strongest motorspindles on the market. In addition,all spindles are equipped with the necessary sensors to use the"Advanced Process System" (APSand APS extended) smart machinemodule.

The APS module is a monitor-ing system that opens up new opportunities for the user to observe and control the millingprocess on screen. This system wasespecially designed for high per-formance and high speed machin-ing. But it can also be used for other milling work. With the helpof an acceleration sensor integrat-ed in the spindle, vibrations duringthe milling process are recordedand displayed to the operator on the console. If necessary, theoperator can adjust the cut valuesto extend the service life of the tools and to prevent damage to the machine.

The emulsion treatment for thecooling through the spindle isequipped with the latest paperband filter technology. A safety

filter is installed with this unit to protect the rotary transmissionto the spindle.

In terms of optimal tool andwork piece measurement, the machining centers are alsoequipped with cutting-edge tech-nology. An OMP 60 sensor and the latest laser technology of theNC 4 Laser from Renishaw ensuresthat the HPM 1150 U and HPM 1350U are ready for precisionwork piece machining.

www.mikron-ac.com

HPM 1150U and 1350Unow with direct

drives for all roundand swivel axes

The HPM 1150U and 1350U product lineequipped with the latesttechnology was developedfrom the UCP 1150 andUCP 1350

An airplane part of aluminum illustrates the difference: 5-axis simultaneous machining centers with direct drive (photos above)

The direct drive and hydraulic clamping swiveling head makemachining of such quality possible today

5Universal machiningHSMtoday Nr. 16

Edi Hofstetter - Werkzeug- undMaschinenbau AG in Benken,Switzerland is a contemporaryfamily operation whose historygoes back to the year 1946. Theexperience gathered in the yearssince and their constant readinessfor continuous development hasmade the company what it is to-day. A VCE 1600 Pro from Mikronwas put into operation in January2005. It has been used ever sinceto machine components for tooland engineering applications, aswell as prototypes.

Jürgen Maurer

The company was founded byEdi Hofstetter in 1946. After train-ing as a machinist, Mr. Hofstetterleapt into self-employment at age 20. He was a noted handymanwith outstanding practical skills.He ultimately felt most at home inmetal machining. With a "nothingis impossible, everything is possi-ble" attitude, he took on even themost difficult projects.

Because of his great success,the plant in Benken was expendedin 1966 to include a residentialbuilding with a production hall. 20years later, a new production hallhad to be built with a higher ceiling to accommodate the newmachines. In 1993, the companychanged its corporate form to anAG (public limited company) and in1999, the siblings Ruth, Ulrich andJosef Hofstetter took over the company. In 2001, another produc-tion hall was erected directly nextto the existing buildings.

Edi Hofstetter - Werkzeug- undMaschinenbau AG is todayequipped with state-of-the-art machines. The proprietors arecompetent and the employees verywell trained which is clear fromtheir exacting work and services.They design complex three-dimen-sional components and then manufacture the components onthe machines especially built for that purpose. Work pieces of up to 20 tons can be machined in Benken.

Over 1000 m2 is utilized with 12 machines in two work-shops. Whether SMC compressionmoulds, assemblies, componentsor prototypes – thanks to the equip-ment, the personnel and the well-organized workflows, all jobs areperformed in a timely manner andwith exacting precision. ISO 9001certification is a given.

Ulrich Hofstetter, Head of Engineering, answers questionsabout his operation and the VCE 1600 Pro from Mikron:

Mr. Hofstetter, how did you hearabout the machine from Mikron?

In recent years, we have invest-ed in large, cumbersome ma-chines, but were lacking a fast machine. The original notion of asmall machine developed into theidea covering a broader range witha suitable machine. There was initially no mention of a Mikron because we thought it was too expensive. Even so, we solicited acomparison bid for a VCE 1200 Pro.The price/performance ratio sur-prised us.

What were your reasons for choosing the VCE 1600 Pro?

The knowledge of weight of ourwork pieces caused us to serious-ly consider the VCE 1600 Pro. Im-portant reasons were the tableload, the traverse paths, the Z tra-verse path in particular, the dynamics and the rational and veryprecise machining options of the

machine. The control system wasalso important to us. We absolute-ly wanted the Heidenhain iTNC 530,which we were already using inmany areas. We also had a choiceof spindles and the 540 I water tank.We decided on a 10,000 rpm spin-dle. The Konus BT 40 allows us touse available tools.

A visit to Steinkamp in Germanywhere we could view the machinein person ultimately convinced us.We already knew on our way backthat it would be the VCE 1600 Profrom Mikron.

What parts or type of components do you machine on the VCE 1600 Pro?

We machine all kinds of proto-

types, e.g. suction nozzles, compo-nents with deep ribs with a diam-eter of approximately 2 mm, adepth of 80 mm and a taper of 0.5°where even small tools are alsoneeded.

What materials do you prefer tomachine on the VCE 1600 Pro?

Primarily construction steel,

tempered steels and tool steel.Now and then also aluminum andbrass.

What industries are your customers in?

Because individual compo-nents make up approximately 60% of production, our customersnaturally come from a variety of industries, such as pressing plants,rail car manufacturers (forms for seat pans), as well as compa-nies in aircraft and machine construction.

What experiences have you andyour employees had with the VCE 1600 Pro, e.g. with stability,precision or process safety?

We have been very satisfiedwith the VCE 1600 Pro up to now.The machine fits into our produc-tion workflow with its size and a table load of up to 2.7 t. We have several options and it is easyto use for small or even large components.

The VCE 1600 Pro is also very dynamic in all axes.

Another performance characteris-tic is its precision. Milling in the 5 µm range is no problem at all.

How have your employees pro-gressed with the machine since?

Trouble free. Employees werebriefed by me and off they went un-der the principle "learn by doing".By the way, the manuals are goodand of course, you can glean some-thing from them. A big advantagewas certainly the control system,as already mentioned.

At Edi Hofstetter - Werkzeug-und Maschinenbau AG, every orderis seen as a challenge for the entire company. Our employees are used to facing challenging proj-ects head on. Ulrich Hofstetter andhis team still take the time tosearch for the optimal solutioneven for individual componentmanufacturing. This requires cre-ativity and a mountain of experi-ence in metal machining, some-thing readily available at the familycompany in Benken.

The VCE 1600 Pro from Mikronis mainly used for machiningindividual parts for tooling and engineering applications,as well as prototypes

Complex components,prototypes and a wholepile of swarf and chips

www.mikron-ac.com

6 Highly productive 5-axes machining HSMtoday Nr. 16

No other manufacture of state-of-the-art machining centers inthe HSM and HPM field has devel-oped such extremely successfulconcepts for cost-effective millingso consistently in the first fiveyears of the 21st century. Afterrolling out the HPM 1000U andHPM 1100, experts agree: Mikronhas done it again!

Urs Hänni

Single minded, persistent, longsighted and finally, thanks to a focus on the important, success-ful; these are some of the main characteristics you expect from companies. Of course, these samecompanies also expect similarcharacteristics from the manufac-turers of state-of-the-art machin-ing centers and in a related sensefrom the products, too.

Focusing on the importantMikron introduces the new HPM

series developed and tested over aperiod of two years and tested un-der production conditions, spot on.The five-axis HPM 1000U andthree-axis HPM 1100 adeptly meetthe requirements of today’s com-panies thanks to imaginative con-ceptual considerations. The mostimportant characteristics of thesemachining centers are unrestrict-ed accessibility of the machine atany time, the individual compo-nents perfectly coordinated to theperformance requirements in theHPM area, the unique robot sys-tem through the center of the ma-chine and the design of all compo-nents of the entire productioncenter on the three-shift operation.

HPM – High-performance millingFollowing HSM (High-Speed

Milling), Mikon has also now coined the term HPM (High-Per-formance Milling). HPM strategies,i.e. milling with the goal of achiev-ing the required performance overthe chip volume, not only place spe-cific requirements on the machineas a whole, but on each individualelement of the system.

The HPM 1000U and HPM 1100can clearly show that these de-mands can be met. Two spindlesare available. On the one hand, the20,000 rpm spindle and 198 Nm issuited for powerful machining oftough materials. On the other hand,the 28,000 rpm and 40 kW spindlehas all the properties to also cost-effectively machine parts withsmaller tools. The fully-simultane-ous circular swiveling table is available as a version for pallets or with a T-slots table top. In regards to power and dynamics, the linear

drive in the axes (two motors in theA axis, one motor in the C axis) offers complete security. The A axis can be locked in the settingsoperation. This improves the qual-ity of the work piece on the onehand and also prevents unneces-sary heat build-up on the table on the other. The temperature ofall power components mentioned

above including the switch cabinetare controlled by a regulated water cooling circuit.

3 shifts, 365 days a yearTo achieve the high rate of met-

al removal the entire year, the newmachines must be equipped withproduction-specific and reliableoptions, e.g. the cooling of the

HPM 1000U/HPM 1100Machining in

another dimension!

Overwhelming enthusiasm – Feedback fromEMO 2005 in Hanover, Germany clearly

shows that the new Mikron HPM series is thestandard in high-speed machining

The HPM 1100 machining center can handle a table load ofup to 2000 kg

The steep incline of the side panels ensures perfectchip discharge

machining process: Internal andexternal supply of coolant(IKZ/AKZ) is possible with coolingwater, air or oil mist. The pressureof the cooling water with IKZ (20 to 80 bar, 1200 I) can be variablyregulated from the operator con-sole. If additional cooling is need-ed while machining, an optionalcoolant system keeps the mediumat a constant temperature. In ad-dition, steam extraction for coolantsteam and oil mist is available forthe series. It was designed for high

efficiency and a long service life. Afully-automatic bellows seals theworkspace. The barrier can be au-tomatically unlocked when theswiveling table is manually loadedwith a crane and relocked once theloading is complete.

Of course, all smart machinemodules, e.g. ITC, APS or RNS canbe used to achieve a cost-effectivemilling process.

Pioneering robot systemThe real innovation with the

HPM 1,000U is the solution for au-tomatic loading. Work pieces of up to 800 kg are automaticallychanged from the palette maga-zine to the circular swiveling table.A hydraulic lift/rotation unit (pal-let changer) sets the preselectedpallets on the clamping devices ofthe circular swiveling table. Thepallet changer first executes a lin-ear movement through a paddlesealed from the working space. Atthe same time, the pallet is placedin the pallet magazine togetherwith the work piece to be machined,a process that takes less than 30 seconds.

The optional swiveling setupstation on the pallet magazinemakes loading the magazine withthe work pieces secured on the DINpallets easier. The setup stationand circular swiveling table havereliable fluid couplings. Of course,the compact tool changer that cankeep up to 215 tools on barely more than 1 m2 is part of the extremely compact design of the machine. This entirely new solution for automating heavy com-ponents offers unparalleled er-gonomic conditions at the work-station. Access to the working areaand pallet magazine is convenientand safe.

Your access – "Your access to themachine"

The robot system by the centeris part of the new "your access"concept from Mikron. Regardlessof which machine configuration youwant, access to all relevant com-ponents of the machining center isalways optimal. The "your access"concept shows its full effect withthe HPM 1000U. Whether as a ver-sion with a 40-unit tool changer oras a version with a double palletchanger in the center and a toolchanger, access to the machine isalways optimal.

Even connecting the palletmagazine or a flexible manufactur-ing system does not affect access.(see box) Past are the times whena pallet changer or pallet maga-zine stood in the way of the user infront of the working area.

The five-axes HPM 1000U andthe three-axes HPM 1000 meet therequirements placed on state-of-the-art machines. The most im-portant characteristics are unre-stricted accessibility of the ma-chine at any time, the individualelements perfectly coordinated tothe performance requirements inthe HPM area, the unique robot sys-tem by the center of the machineand the design of all componentsof the entire production center forextended shift operation.

7Highly productive 5-axes machining HSMtoday Nr. 16

www.mikron-ac.com

HPM 1100 und HPM 1000U

Work area HPM 1100 HPM 1000ULongitudinal X mm 1100 1000Cross Y mm 800 800Vertical Z mm 600 600

Feed rateRapid traverse rate X, Y, Z m/min 60 60Feed rate. X, Y, Z mm/min 0 - 20'000 0 - 20'000

Working spindleHigh-frequency spindle min-1 20,000 - HSK 63 20,000 / HSK 63Spindle power/Spindle torque 40% ED 66 kW / 198 Nm 66 kW / 198 NmHigh-frequency spindle min-1 28,000 - HSK 63 28,000 / HSK 63Spindle power/Spindle torque 40% ED 40 kW / 107 Nm 40 kW / 107 Nm

Work tableClamping surface mm 1200 x 900 -Max. table load kg 2000 -

Rotary tilting tableTilt range ° - +30/-110Rapid traverse rate C min-1 - 60Rapid traverse rate A min-1 - 30Clamping surface, autom. DIN-Pallet mm - 500x630Max. table load (central) kg - 800Clamping surface, manual Ø mm - 800

Tool changerCentral tool changer Tools 40 40Tool changer (tower) - 115/165/215

Pallet changerPallets - 5Dimension mm - 500 x 630

Mikron machining centers are wellknown für their ergonomic design. The new HPM 1100 und HPM 1000Uare unique when it comes to the access of the machine, no matter

which machine configuration the customer needs to produce its work pieces.

Basic machinewith central 40-unit tool changer

Basic machine withdouble palletchanger and toolchanger

Basic machine withpallet changer, 5-unit pallet magazineand tool changer

Combination of 3 basic machines, pallet changer and tool chang-er with a flexible manufacturing system

Flexible manufacturing system (FFS)

The pallet changer is handled through the portal directly, makingaccess to the machine effortless

The fully-simultaneous circular swiveling table is available as aversion for pallets (above) or with a T-slots table top

The large tool changer with up to 215 tools is near theoperator console

10 Universal machining HSMtoday Nr. 16

Considerably shorter machiningtimes and larger volumes are pos-sible with the new VCE Pro-X machining centers. Even difficultjobs, such as the production of thinwalled work pieces are now eveneasier.

Stefan Fahrni

For each production order,whether in parts production or tooland mould making, carefully calculated unit costs are becomingincreasingly more important. At the same time, the day-to-day business affects the demand forflexibility and processing time. Animportant element in this relation-ship is the selection of suitable production resources.

With the VCE 800 Pro-X and

VCE 1000 Pro-X, Mikron offers uni-versal machining centers thatguarantee maximum utility andcalculable investment costs.

Torque of nearly 100 NmThe new inline motor spindle

from Step-Tec achieves 15 kW (S5)and a torque of nearly 100 Nm.These characteristics allow the useof face milling up to 85 mm in di-ameter or boring tools up to 60 mmin diameter. For machining withsmaller tool diameters, a maxi-mum continuous speed of 16,000rpm is available. The machine hasan internal coolant feed for cost-effective use of suitable boringtools. The cooling units are alsopart of scope of delivery and areused for cooling through the toolachieving a pressure of 18 bar and

having all necessary filters. By in-tegrating the bandpass filter in themachine, no additional installationspace is needed.

Even plastics and filings are re-liably filtered out. Equipped assuch, the VCE Pro-X series is ide-ally equipped for all machining.

Thanks to cooling through thetool, the high spindle speeds and the corresponding feeds, the VCE Pro-X series is also ideal forcost-effective chip removal of aluminum.

Dynamic axesAn early realization when us-

ing high-speed spindles is the factthat high surface quality of the workpiece and cost-effective service lifeof the milling tools also require dy-namic axes. The VCE Pro-X with

process speeds of 36 m/min (X, Y)and 24 m/min (Z) account for theseaspects. This characteristic makescost-effective machining of three-dimensional cavities possible, e.g.forging dies, injection and die-castmoulds with little or medium com-plexity and the respective elec-trodes.

An optional divider further ex-

pands the area of application of theVCE Pro-X. The 4th axis is suitedfor the additional applications inthe positioning and for simultane-ous machining (S6).The machine's workbenches aredesigned to allow pneumaticclamping devices or pallet clamp-ing systems to be supplied withcompressed air.

The VCE Pro-X machines fromMikron are also used for tradition-al machining. With high feed rates,individual parts such as perforat-ed plates, which include a largenumber of traverse paths, can bemachined more economically. Thespindle torques also allow highswarf volumes, such as in the man-

ufacture of moulds and in the aviation industry but also thosearising in general mechanical ma-chining. In this market segment,the Mikron VCE Pro-X line offersunbeatable advantages.

www.mikron-ac.com

Universal machining centers, capably and completely equipped

VCE 800 Pro-X andVCE 1000 Pro-X

machining centers

By integrating the bandpass filter in the machine, no additionalinstallation space is needed

11High-speed machiningHSMtoday Nr. 16

The invention of the zipper cannotbe attributed to just one inventor.Inventors in various countries hadworked on the idea of a quick release fastener over decades. Today, the zipper is indispensablein the world of fashion. Numerousmanufacturers have brought theirgoods to market in the mean time.

Yandi Ma

Because the demand for zip-pers has steadily grown in the past,the entrepreneur Leung (photo below) made the decision in 1987to found a company to manufac-ture zippers. Hung Ming Ho Co Ltd.has since become one of the mostprogressive companies in China inthis industry, developing into amarket leader in just a few shortyears.

As an official zipper supplier toseveral internationally recognizedclothing brands, Hung Ming Ho CoLtd. represents a brand that guar-antees the quality of their products.Production of the zipper manufac-ture takes place in Southern China near the city of Nanhei, abouta 1-hour's drive from Guangzhou.

Machines from the AgieCharmilles GF have certainly alsocontributed to the big success ofHung Ming Ho Co Ltd. The machinepark includes 5 Mikron machines,4 machines from Agie and 5 ma-chines from Charmilles. Mr. Leungappreciates the AgieCharmilles GFas a solid and reliable partner.

First HSM 400 purchaseIn 2004, Mr. Leung purchased

his first Mikron HSM 400 with a42,000 rpm spindle. There were twoprimary reasons why he chose ma-chines from Mikron: the option ofhigh-speed machining and the factthat he was already very confidentin the customer service from AgieCharmilles China (HK) Ltd.

His decision to choose Mikronmachines has been profitable todate. The components milled using the HSM 400 are extremelyprecise as is required in the zipperindustry. In addition, the machin-ing times with the HSM 400 havebeen cut by 50%. Just six monthsafter installing the first HSM 400,Hung Ming Ho Co Ltd. purchasedtwo more HSM 400s configuredidentically.

"The wages for a well-trainedand experienced machine opera-tor are fairly high in our area.Thankfully, the training anddemonstration center from Mikronoffers training and other develop-ment opportunities. As a result, wehave also been able to hire less-experienced operators and havethem trained on Mikron machines.

Mikron technicians also visit us often, not only to see whether themachines are running well, but al-so to test milled components to seewhether they meet the requiredstandard. They give our employeesadvice, e.g. what concerns theCAD/CAM programming, explainmilling strategies or provide in-struction for selecting the righttools," explains Leung, BusinessManager.

Expansion planned The company plans to build

their own machines for the manu-facture of zippers in the future. The first step in this direction was the purchase of two MikronVCE 600 Pro machining centers atthe end of last year. Both machinesare equipped with a pallet system.The next step is then to purchasea 5-axis high-speed milling ma-chine HSM 600U equipped with a high-performance 36,000 rpmspindle with high torque.

The business manager of HungMing Ho Co Ltd. plans to acquirestill more machines from Mikronin the next five years for the plannedexpansion of his company.

www.mikron-ac.com

The HSM 400 fromMikron is also at homein the world of fashion

Zippers – they are needed everywhere. Boxer Laila Ali, daughter of Muhamad Ali, poses forHSMtoday in a fashion shop

The Chinese company Hung Ming Ho Co Ltd. relies

on European machines in theproduction of zippers

Photo: adidas

What do Mikron machines have todo with medical technology? Operative supply for bone breaksand other bone injuries with metal implants (osteosynthesis)is found more and more often now.The company MEDARTIS, with itsmain office in Basel Switzerlandproduces exactly those platesmade of titanium on machines byMikron.

Jürgen Maurer

In 1997, Dr. h.c. Thomas Strau-mann founded the MEDARTISGroup. It was a re-entry into Osteosynthesis for mouth, jaw andface surgery. His father alreadyworks in this branch at the Strau-mann AG Institute. In 1954, Prof.Dr. Reinhard Staumann, who is theGrandfather of Thomas Staumann,had already founded the Strau-mann AG Institute, which was then specialized in Metallurgy andPhysics for the watch industry. Hisson, Dr. h.c. Fritz Straumann im-plemented the synthesis of metal-lurgy, physics and medicine by uti-lizing the special metallurgical andphysical knowledge for developingmetallic implants for handlingbone breaks. MEDARTIS led thefurther development of metallur-gy and now has extensive know-how in the production of high qual-ity titanium implants. Philosophyand operation have been embossedthrough the pioneering work of the

Staumann Group in metallurgy, osteosynthesis and implantology.In 2004, the MEDARTIS Group ex-panded their product portfolio withorthopedics and hand surgery.Meanwhile, MEDARTIS has closeto 100 employees in its service.

The goal and the responsibilityof MEDARTIS is to provide the sur-geons and the OP personnel in themouth, jaw and facial surgery, theplastic hand surgery and the or-thopedic surgery with all innova-tive implants, instruments andservices that mean advancementin the osteosynthesis and therefore quality of life for the patients.In order to satisfy this high-setgoal, the intensive cooperation with surgeons, scientists, univer-sities and clinics are of the utmostimportance to MEDARTIS.

OsteosynthesisOsteosynthesis is the operative

provision for bone breaks and oth-er bone injuries with metal im-plants. The goal is to fix the frag-ments with one another in the mostnormal position possible. Unlike acast, osteosynthesis normally en-ables early movement or even load-ing on the fracture. The choice of whether a fracture should be handled with a cast, osteosyn-thesis or no treatment is made depending on localization, stress,misalignment of the fragments, results of movement loss and theoperation risks.

The production of plates with themachine by Mikron

In 2005 MEDARTIS had to ex-pand production. Mikron machineswere also utilized in the new facility in Bretzwil (Basel-Land,Switzerland), two UCP 600 Vario'sand an HSM 600U. Special platesare being produced for the so-called radius (underarm andhand) here. The prototypes for thisare also milled in Basel and on aUCP 600 Vario.

All product development startswith MEDARTIS keeping in closecontact with customers. Productconcepts for which the optimumapplication is planned togetherwith the surgeons are developedthis way. Detailed three-dimen-sional CAD construction drawingsand computer simulations make upthe basis of the first prototypes,which are then evaluated in clini-cal testing. The products are man-ufactured in-house and with the cooperation with external partnerson the most modern CNC systems.The highest level of quality testing according to international-ly recognized standards and guide-lines secure a constantly high prod-uct quality. During a visit, PeterWeisskopf, member of MEDARTISmanagement and responsible forproduction, showed us the newplant in Bretzwil. Upon entering,we had already determined unmis-takably that special things aremade here. Everything is veryclean, light, organized and almostclinical already. The work stationswith microscopes and other meas-urement and testing equipmentstood out. Medical products mustoften be tested thoroughly beforethey arrive on the market.

The Mikron machines stand atone end of the hall - two UCP 600Vario's and one HSM 600U. We areglad that MEDARTIS decided onMikron and again for the 5-axesprocessing centers. We wanted tofind out some of the backgroundthat the decision was based on. Peter Weisskopf gladly provided us with the information.

„We manufacture medical

12 Universal High Performance Cutting HSMtoday Nr. 16

The UCP 600 Vario by Mikron in

medical technology

The x-ray shows the exact position of the plate screwed in placeafter the operation

MEDARTIS® - Impressive technology and the Medic's art

Titanium plate as it is milled on both Mikron UCP 600 Vario's in theMEDARTIS plant in Bretzwil (Baselland/Switzerland)

For continued processing on titanium plates fastened on anapparatus

Bone models with various plates for fixing finger bonesmade by MEDARTIS

13HSMtoday Nr. 16 Universal High Performance Cutting

products here in Bretzwil. You canimagine that quality and the tech-nology used have the highest pri-ority, especially after realizing thatthe various implants are used forpeople. Naturally, we decided up-on a manufacturer that we knowbuilds high-quality machines. Thedecision for Mikron was of coursepreceded by comparisons with oth-er companies. The price/perform-ance ratio of the Mikron machinesconvinced us. The 5th axis is an investment in the future. TheHeidenhain controller is also im-portant to us and is proven in operation. It is also no problem to transfer programs from the HSM 600U to the UCP 600 Vario;this type of compatibility is a strongadvantage as well. One of our em-ployees, who had already had

some good experience with ma-chines by Mikron, also providedsome positive influence."

Automation is indispensableBoth the UCP 600 Vario and the

HSM 600U are set up with paletteand tool changers for automaticoperation, to guarantee 24 hour operation. „The automation was also an important aspect forprocuring the Mikron machines“,stressed Peter Weisskopf. „The machines have to run for 24 hoursand this is possible because of palletizing. “ The Mikron-offered"smart machine" module RNSworks better and cheaper than ifwe would have run the operationin shifts. “RNS makes it possibleto obtain information about the operation status of the Mikron

machining center as well as the milling process regardless of the location.” The operator can receive information about the operating status or program status of the machine via SMS to a mobile phone.

Precision parts are absolutelynecessary

Where precision and surfacequality is concerned, there are nocompromises at MEDARTIS. Sincethese parts are for use in medicalproducts, aesthetics are also important. Since the Mikron machines are known for their good milling results and for the exceptional surface quality of theparts they process, they meet the requirements of MEDARTISperfectly.

Peter Weisskopf confesses thata good machine also needs a capable operator however. That iswhy two employees spent sometime in the Nidau Mikron facility.They were trained on the Heiden-hain controller in the HSM Compe-tence Centre.

Peter Weisskopf continues:„We've made a good decision withthe Mikron machines. The two UCP 600 Vario's and the HSM 600Uare very versatile. They are de-pendable and are designed verywell for the automation. The partsthat are milled with them have aquality surface and are very pre-cise, exactly what we need."

Solution - the Vario System With its UCP 600 Vario, Mikron

has a convincing 5-axis solution forautomated production. As well asthe compact basic machine itself,the Vario system has: a multitudeof high-performance milling spin-dles; a scaleable, modular toolchanger system, the best knownpallet changer from other Mikronmachines; and the right disposalor cleaning solution for every chipand coolant situation. It is up to thecustomer to decide just how vari-

able their UCP 600 is to be. How-ever, one thing is guaranteed tostay the same: access to the machine and peripheral devices iswonderful.

The basis of the UCP 600 Variohas everything required to be usedsuccessfully in tool and mouldmaking, medical technology andthe entire machining process forframe components, etc.

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Loading the palette changer is comfortable because of the optimalworking height of the UCP 600 Vario

The Heidenhain iTNC 530 makes the UCP 600 Vario safe and easy to operate

The palette changer of the UCP 600 Vario offers room for 7 to10 palettes depending on the manufacturer

Machine model UCP 600 VarioWorking rangeLongitudinal X mm 600Cross Y mm 450Vertical Z mm 450Swivelling B ° -115 / +30Turning C ° n x 360High speed motor spindleMaximum speed min-1 12,000 / 20,000 / 42,000Spindle performence at 40% ED/S6 kW 15 / 16 / 14Toolholder ISO 40 / HSK A63 / HSK E40Feed driveFeed - rapid speed X/Y/Z m/min max. 22Tool changerMagazine positions quantity 30-220, (configuration

upon request)Rotary swivel tableTable dimension mm 450Max. workpiece weight (5-axis operation) kg 200Table versions table Ø 450 mm,

with starshaped or parallel .arrangement of the T-slots

Pallet versions 3R (Dynafix), Erowa (UPC), Mecatool (GPS) (others upon request)

Control CNC Heidenhain iTNC 530Construction kg 7700Pallet changer (Optional)Number of pallets Units 7 (Dynafix, UPC), 10 (GPS)Pallet surface mm x mm 3R (Dynafix) 280x280,

Erowa (UPC) 320x320. Mecatool (GPS) 240x240, (others upon request)

14 HSMtoday Nr. 16Highly productive 5-axes machining

Today's tools enable ever bettermachining performance. Theyhave smaller diameters but require greater feeds in return. Touse these advantages of modernmachining in parts productionwith up to 2 meter swings, Mikronbuilt the HPM 1850U.

Stefan Fahrni

The HPM 1850U is the machin-ing center for consistent imple-mentation of current machiningtechnology. It has been developedto ensure high performance com-bined with extremely high preci-sion in the manufacture of moulds,cast parts and in batch production.Due to its rigid structure it is suit-able for heavy roughing as well asaccurate finishing operations.

The HPM 1850U allows high accuracy 5-axis simultaneous machining. The machine bed is cast from a single piece. This elim-inates geometric deviations on the basis caused by year-longstresses in machining. The portalof the machine supports the Z-car-riages of new, weight saving materials. This is in accordancewith the high dynamics of the machine, approximately 300 kglighter than a comparable Z-car-riage of cast but has the samestrength and better vibrationdamping. The advantages are especially evident in fast Z-axismovements such as are requiredfor mould manufacturing.

The versatility of the HPM 1850U• High dynamics with directly

driven round and pivot axes• Selection between palette and

circular milling attachment• Stability in processing thanks to

hydraulic clamping on theround and pivoting axes

• 5-axes simultaneous machining• Spindles with 15,000 or 24,000

rpm, or 8,000 rpm with up to324 Nm with the HSK100

• Tool magazine with over 200tools

• Tools having swing diametersof up to 2 meters and 4 tons inweight

The HPM 1850U is especiallyliked by the operators because ofthe ideal accessibility. The machin-ing can be observed easily at anytime. Part loading is also very user-friendly. When using the machinewith a palette changer on bothloading stations, even a platformis not required. The palettes can belowered to a work-level that is com-fortable for the operator.

Flexible milling headThe HPM 1850U enables un-

dercutting a work piece without anytrouble when using 5-axes simul-taneous machining. The millinghead allows the tool spindle to piv-ot by 140° simultaneously. The piv-ot axis can also be clamped to ef-ficiently utilize the highest motorspindle speed. The clamp is madeso powerful that it needs no index-

ing. The spindle can therefore befastened at any angle position. Theswitching time from vertical to horizontal machining is less than1 second. This makes machiningpossible that could not have evenbeen imagined before. From roughmachining, 5-side complete ma-chining to 5-axes simultaneousmachining on turbine blades, theapplication of the new Mikron HPM 1850U are almost limitless.

Direct drive circular millingattachment

New challenges concerningmachining power require newpaths and new technology to im-plement them effectively. This iswhy a linear motor has been usedas the circular milling attachmentdrive on the HPM 1850U by Mikron.Swift acceleration and high speedsare only possible with this technol-ogy. The large clamping table withup to 1600 mm diameter and loadsof up to 4,000 kg can be moved ata rate of up to 30 rpm. Its enor-mous torque and achievable posi-tioning precision is impressive. Twocharacteristic values that are im-portant to Mikron in this machine.

High-performance motor spindleEither motor spindles with

15,000 rpm and 193 Nm torque or 24,000 rpm are used with theHPM 1850U. The tool interface isthe modern and widely used HSK63interface. For machining with longand large tools, the high-torque

High accuracy with up to 4 ton work

piece weight

The HPM 1850U is perfectly suited for large work piece machining

The HPM 1850U offers themost modern high-powermachining of work pieceswith up to 2 meter swingsand 4 ton weight

The HPM 1850U for 5-axis simultaneous machining

2 meter swing diameter and up to 4 ton weight

15Highly productive 5-axes machining HSMtoday Nr. 16

motor spindle with 324 Nm and8,000 rpm is recommended. Nat-urally, this motor spindle has anHSK 100 tool receptacle to trans-fer maximum rigidity to the tool.This provides the machine withenough power and reserves to han-dle even the most demanding taskswith no problems.

Pallet changer offers directaccess

Large machines are normallyencircled by a platform in order toenable the machine operator ac-cess to the machine for loading.Mikron is of the opinion that this isvery cumbersome to the operator.They have therefore done away withthe platform. The machine isequipped with a lifting apparatusthat brings the palette up to theheight of the work-table. The HPM 1850U is the only machine ofthis size with ground-level accessto both loading stations. Both load-ing stations are also equipped witha manual rotating mechanism. Thisis especially useful for clampinglarge work pieces at the rear as well. This makes loading and unloading clamping towers mucheasier.

Adaptive controlThe HPM 1850U is equipped

with the Heidenhain iTNC 530 con-troller. This controller can be eas-ily integrated into the most differ-ent of operational procedures. Nomatter whether producing individ-ual parts or in a series, simple orcomplicated parts or whether theproduction is to be done "on de-mand" or has been organized cen-trally, the iTNC 530 is the ideal con-troller for any field of application.

Software controls feed totally automatically

To fully utilize the high poweredmodern tools, the machine musthave ideal interaction between un-compromising mechanics and de-pendable software. This makes theHPM 1850U able, for example, with

the optional software "AdaptiveControl System" (ACS) to recordthe loads of the work pieces and toautomatically adapt feeds for roughcutting accordingly. This is alwaysbased on the programmed feed setto 100%. The controller uses themeasured load values on the toolto calculate the optimum feed forthe current cutting conditions andautomatically regulates upward ordownward accordingly. Since blankcontour deviations occur andtherefore can create varying toolholding capabilities (enlacement,clamping depth), tool wear, air cut-ting, measurement deviations andhardening, these contour differ-ences must be compensated forduring machining so that the opti-mum feed is guaranteed in everysituation. As high as possible, aslow as required. If the "AdaptiveControl System" (ACS) is used, theresult is shortened productiontimes with simultaneously im-proved machining security. Other"smart machine" modules such as"APS" and "APS extended" alsohelp to optimizing the machiningand in keeping the wear to the tooland the machine to a minimum byrecognizing vibrations.

The new 5-axes machining cen-tre HPM 1850U by Mikron opensnew paths to the modern and eco-nomical production of large partsup to 1.6 m3 parts volumes.

No matter whether the HPM 1850U is used in mould man-ufacture, in cast machining or inseries production, the high powerand precision is very impressive.Many users are positively surprisedthat such precise machining is possible considering the size of the HPM 1850U.

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The HPM 1850U allows high accuracy 5-axis simultaneous machiningThe exceptionally large sliding doors ensure optimal accessibility to the loading area

The pallets can be manually turned and locked in 8 positions

The HPM 1850U is ideal for series production with an optional palette changer. Automation allows extending productivity in the nightly and weekend hourswith no operator

16 “smart machine” HSMtoday Nr. 16

Just as a Formula 1 driver wouldnever be able to get the most outof his race car without electronicsupport, an operator of a machin-ing center needs support to max-imize the total available potentialof his milling machine for the ma-chining process; smart machinegives him this support.In addition, he is also able to sig-nificantly improve the service lifeof various machine components.

Alexandre Condrau

The ITC upgrade to 5-axis machines

ITC-5X is an additional moduleof the "intelligent thermal control"for machines with circular swivel-ing tables.

With steadily increasing ma-chine performance, it is no longerpossible to prevent thermal effectsthrough design measures alone.

Despite exact compensationbetween tool and work piece, theposition of the rotation axes savedin the control system can changedue to thermal drift, somethingparticularly evident when workingin tilted plains. This is where ITC-5X comes into play.

ITC-5X functionality:Using a caliper (option), a sim-

ple, automatic calibration cyclemeasures the spatial position of

the rotation. The measurement canbe taken on a reference pallet (option) or reference surfaces ofthe work table or the work piece.The position measured is automat-ically saved.

Benefits of ITC-5X:• Greater work piece precision

with pivoting and/or rotating machining (cycle 19, planefunctions, M128)

• Compensation for external in-fluences through recalibration

• Increased process safety for 5-axis machining

• Minimized downtimes (no man-ual measurements)

• Automatic recalibration duringunmanned operation

Spindle Protection System - SPS

Condition-oriented monitoringfor daily production

Conventional corrective main-tenance is only performed whendamage has already occurred. Thisleads to unexpected machine capacity reduction and high main-tenance costs.

A prerequisite for preventivemaintenance is, therefore, perfectknowledge of the condition of themachine and its components. Mon-itoring of the main spindle is thekey. Condition-oriented monitoring

makes spindle condition prognosispossible. SPS enables real-time in-spection and contributes to effec-tive servicing and efficient correc-tive maintenance.

The operating principle of SPSWear, age-related damage and

overloading are the main reasonsfor spindle failure. Insufficientbearing lubrication or extrusioncooling accelerates these symp-toms of fatigue. A real-time condi-tion monitor compares the currentstate with knowledge-based targetbehavior. Depending upon theevent, either an SPS warning or anSPS error message with a stop inproduction is triggered.

The benefits of SPS• Automated, self-monitoring of

spindle condition• Continuous maintenance of

spindle condition, thereby re-sulting in earlier identificationof spindle faults

• Optimal time planning of cor-rective maintenance measuresand, therefore, the avoidanceof long downtimes after a spin-dle failure

SIGMA - The management systemfor your process chain

SIGMA generates and managesorder, drawing and parts data in anintegrated way for milling and elec-tric discharge machining (EDM),custom-made to workshop speci-fications.

Furthermore, the managementsystem acquires and manageswork pieces and data at the prede-termined location. Data such as NCprograms and work piece correc-tions are processed for machiningby SIGMA and made available tovarious systems via a network.

Starting and monitoring of ma-chining is fully automatic. At thesame time, process data is record-ed and displayed.

The functionality – SIGMA growsas the need grows:

The SIGMA Cell ManagementSystem is responsible for the man-agement of a MIKRON milling cell.With the SIGMA Workshop Man-agement System, it is possible toadd one or more measuring de-vices and as many machining cen-ters as desired. The entire processchain can be controlled via thisMulti Machine Management.

Normally, SIGMA is installed on

the Mikron machine controller oron the measuring device comput-er. However, the use of an addi-tional terminal is recommended ifthe workload of the measuring device is heavy or the distance between machining station andmeasuring device is large.

Thanks to SIGMA's open archi-tecture, all Agie Charmilles ma-chines can be managed.

The SIGMA identification systemSIGMA can work with pallet

identification. Pallets can be sup-plied with ID chips which provideeach with a distinctive, permanent-ly stored identity. As soon as a pal-let is identified, all data stored inthe database for this pallet is madeavailable. An electronic ID system ensureshigh process safety: • Always the right machining

program • Always the right correction

values • Always the right magazine

position • Always the right machining

sequence

Support for the retrofitting of existing pallet changers with IDsystems.

Regarding multi-machine sys-tems, System 3R can provide fur-ther assistance with the projectplanning and installation of theSIGMA Workshop ManagementSystem.

The benefits of SIGMA• Unmanned, automatic job ma-

chining and further treatmentof process data

• Increased productivity• Job priority: Simple scheduling

and rescheduling• Scalability: Sigma adapts itself

to your needs• Concise operation and

process data display for variousmachines

• Single measurement of workpieces and pallets

• Automatic electrode manufac-ture control for cavity sinkingby EDM via the respective superior order

• Increased process safety

The "smart machine" modulescan be used on all Mikron machineswith current Heidenhain controls.Some of the modules already form

part of the standard configurationof machines. Others are availableas an option. Each “smart ma-chine” module fulfils a specificfunction. Like a modular system,the user can choose the modulesthat he finds most suitable for im-proving the milling process.

A list of available modules canbe viewed on the Mikron websiteunder Products, smart machine.

“smart machine” Modules

for optimizing themilling process

Mikron offers various modules under the term "smart machines" (software and hardware) to make the milling process simpler and easier to control for the operator

HSMtodayTM

Specialist journal from Mikron

Publisher:

Mikron Agie Charmilles AG Ipsachstrasse 16, CH-2560 Nidau Tel. +41 32 366 11 11, Fax +41 32 366 11 66,E-Mail: mikron@mikron-ac.com

Brand Manager: Jens Thing

Managing and Design Editor: Jürgen Maurer

Photo adaptation: Vik Furer

Circulation: 60,000

Published in German, French, English, Italian, Spanish and Chinese

Photos: adidas, IWC, MEDARTIS andMikron

Print: Stämpfli AG, CH-3001 Bern

Issue 16, 2006

© Mikron Agie Charmilles AG 2006

Impressum

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Agie Charmilles Group

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