PR HT65 Powermill ENG

a company of the Kuhn Group

Press Information, August 2013

HYPERTURN 65 Powermill – for greater productivity in complete

machining operations for complex workpieces

More clearance, more power, more possibilities: with a spindle distance of 1300 mm, a

powerful counter spindle which also allows 4-axis machining, a B-axis with a direct drive for

complex 5-axis simultaneous milling operations, an additional Y-axis for the lower turret, and

all proven, high-quality features of the Hyperturn series, the Hyperturn 65 Powermill is a

powerful addition to every machine range.

HALLEIN – The HYPERTURN series was conceived to gain considerable increases in

productivity during series production. Complex as well as costly turning, drilling, milling

and gear cutting operations can be carried out in only one work process. Additional

clampings and the temporary storage of parts are no longer necessary and workpiece

precision is greatly improved. Total production time, fixture and personnel costs, as well as

floor space requirements can be drastically reduced by choosing to work with the

HYPERTURN.

With a spindle distance of 1300 mm, the Hyperturn 65 Powermill has significantly more

clearance for simultaneous machining works on the main and counter spindles than

comparable models. With 29 kW and 250 Nm the counter spindle now has enough power to

machine the workpiece simultaneously with two tools. This "4 axis machining" is a further

aspect to improve productivity. A further benefit is the milling spindle, which with 29 kW,

79 Nm and 12,000 rpm, stands for high productivity in the complete machining of complex

workpieces. The B-axis direct drive gives the Hyperturn 65 PM good dynamics and contour

capabilities with 5-axis simultaneous machining, alongside shorter ancillary times spent

changing tools. The additional Y-axis on the lower turret makes extensive milling work

possible at the same time as machining with the milling spindle.

20, 40 or 80-piece tool magazines with HSK-T63 give the user more possibilities for

complete machining operations of complex workpieces, with simultaneously low set-up times


for individual parts manufacturing and high stability for turning and milling works. The frontal

arrangement is easy to set up and ergonomic.

As an alternative to the VDI30 or VDI40 12-position tool turret, EMCO offers a

new generation of turret with BMT interface and direct drive. Higher stability and precision,

and performance data similar to a milling machine, enable the complete machining of

turning/milling workpieces.

The machine versions with a milling spindle and turret including milling drive (SMBY/SMBY2)

have a cross slide underneath with a 12-position radial turret for 12 driven tools working up

to speeds of 5000 rpm.

The automatic bar machining and/or delivery of unit loads via a robot solution or the

EMCO gantry loader offer excellent potential for increased efficiency in automation.

In addition to mechanical and electrical performance values, control systems and software

are increasingly determining the productive efficiency of machine tools. Emco has therefore

fitted the Hyperturn 65 with the SINUMERIK 840D-sl control unit from Siemens. The new

user interface enables an intuitive and significantly easier programming of the machine.

Utilizing the machine to its full capacity as far as possible is a crucial aspect for increasing

productivity - the EMCO CPS Pilot can generate time and cost savings during machining as

the software enables customers to plan, program, simulate, and optimize production runs on

their PCs using a 3D model of the machine. The combination of the HYPERTURN with the

new EMCO CPS Pilot results in extremely positive multiplier effects: the perfect interplay

between CPS Pilot and the HYPERTURN means significant cost and time savings can

be achieved (see also the press release on EMCO CPS Pilot).

The HYPERTURN 65 Powermill is particularly interesting for the serial production of

workpieces, for example in the automotive industry, the fields of mechanical engineering and

materials handling, but also for the aircraft industry.


Technical details / Concept of the HYPERTURN

Mechanical engineering:

The machine base is the core of the machine. The extremely rigid and compact

welded-steel construction is filled with a special vibration-damping material. Reinforcing

materials provide additional rigidity in zones that are subject to intense stress. The high drive

power of the main, counter or milling spindle can thus be fully converted without any

limitations. The result: improved surface quality, more precise manufacturing tolerances, and

longer tool life.

Main spindle and drive technology:

The high drive power of the spindles, combined with optimal torque curve, ensures

economic efficiency in cutting steel, as well as high-speed cutting of aluminum. Highly

dynamic Integrated Spindle Motors (ISM), mounted with large precision bearings, allow for

a wide range of speeds with exceptional running truth. A symmetrical headstock, in

combination with temperature sensors at the bearings and integrated liquid cooling, ensures

thermostability.

All linear movements take place in preloaded, highly precise roller slides. This results in

significant advantages concerning feed rates, zero backlash, service life, lubricant

consumption and positioning accuracy.

Thanks to the unique sealing system at the guide shoe working in extremely dirty

environments no longer poses any problem. As an additional safeguard cover plate strips

made of spring steel are clipped onto the guide rails to attain a closed sealing surface.

C axis:

Technically speaking every spindle is also an axis. It can be brought into any position and

positioned with defined feed motion, making it easy to produce complex contours at the

periphery or front surface. The software required to program these movements (cylinder

interpolation and/or transmit) is already included in the delivery. Synchronized thread cutting

and polygonal turning are part of the machine’s basic equipment.


The "Powermill" turning/milling spindle:

The powerful milling spindle with HSK-T63 tool interface can be used for both turning and

drilling/milling work. The milling spindle can be continuously swiveled within a range of

+/- 120° and clamped anywhere. With a useful Y-travel of +120/-100 mm, even the most

complex of machining work can be carried out. This includes gear-cutting operations,

turning/milling work for crankpins, 5-axis machining, and much more. The tools can be

prepared according to the customer's requirements with a 20-piece pick-up magazine, or a

40 or 80-piece chain magazine.

Y-axis in the turret slide:

The Y axis was realized by two interpolating axes. That results in a distribution of the cutting

force in two levels and adds stability to heavy-duty turning and milling. This means the lower

turret with integrated milling drive can also be used for complex milling operations at all

12 positions, combined with a Y-axis with +/-50 mm travel.

Tailstock:

In the tailstock version the HYPERTURN is particularly suited for mass machining shaft

parts. The tailstock is completely NC controlled and can be positioned using a recirculating

ball spindle. This enables the movement interpolating with other axes, saving machining

time.

Work area:

The work area offers superb ergonomics, which results in very good accessibility to the

individual components. Generously designed free space provides for an optimum chip flow

even when machining critical materials. All guides are covered with sheets made of Niro to

prevent damages.

Machine enclosure – new design:

The flush front with a large viewing window is inspired by the well-known design of the

EMCO milling machines, the Linearmill 600 and MMV 2000.

The HYPERTURN 65 PM machine housing provides all-round protection against chips and

is 100 % coolant proof. A large safety glass window in the door provides a clear view of the


work area. The ergonomically designed operating panel can be slid horizontally as far as the

center of the machine door. The control panel can be swiveled 90° vertically and up to

10° horizontally.

Control unit:

Thanks to the SINUMERIK 840D-sl, the HYPERTURN is equipped with one of the most

advanced controls on the market. The drive and control package, which is entirely digital, is

able to handle up to 10 channels and 31 axes. Technology cycles simplify both turning, as

well as milling operations. By the means of coordinate transformations (TRANS, RED,

SCALE, MIRROR), any number of machining processes can be realized in the space.

Complex machining requirements can therefore be realized quickly and efficiently. The

superior quality of the Sinumerik 840D-sl is reflected in the high precision of each workpiece.

The full alphanumeric keyboard makes programming easier.


Technical Data:

HYPERTURN 65 Powermill

Max. bar capacity [mm] 65 (76.2)

Max. speed [rpm] Main spindle Counter spindle Milling spindle Driven tools

0 - 5000 (4000)

0 - 5000 0 - 12000 0 - 5000

Max. Drive power [kW] Main spindle at 100/40% duty cycle counter spindle at 100/40% duty cycle Milling spindle at 100/40% duty cycle Driven tools

21 / 29 21 / 29 29 / 22

6.7

Max. Traverse path [mm] Travel in X1/X2 Travel in Z1/Z2 Travel in Y1/Y2

405 / 260

1050 / 1050 220 / 100

Rapid speed X/Y/Z [m/min] 30 / 12 / 30

Tool storage capacity 20 (40 / 80)

Number of driven tools 12

Models:

HYPERTURN 65 PM - SYB: with main and counter spindles, milling spindle, B and Y

axes and 20-tool station magazine

HYPERTURN 65 PM - SMYB: with main and counter spindles, lower tool system

including milling drive, milling spindle, B and Y axes and 20-tool station magazine

HYPERTURN 65 PM - SMY2B: with main and counter spindle, lower tool system

including milling drive and Y axis, milling spindle, B and Y axes and 20-tool station

magazine


High performance turning and milling center

Controller: The Sinumerik 840D solution line controller on the HYPERTURN 65 PowerMill is located to the right of the working area and can be swivelled in a moving panel. This guarantees optimum

ergonomic conditions for setting up the machine and moving it into position.


Adequate space between the two spindles for simultaneous machining on the main and counter spindles.

The milling spindle, which has a drive output of 29 kW and a torque of up to 79 Nm, with a top speed of 12,000 rpm, allows the most complex of turned and milled parts to be manufactured. Gearing can

also be produced on both spindles.


About EMCO

The Salzburg machinery company EMCO is one of the leading manufacturers of machine tools in Europe. Its two commitments "Made in the Heart of Europe" and "Design to Cost" are the main factors in the success of the international company, which stands for functional design and the highest quality standards. EMCO currently employs some 630 staff at a total of 5 production facilities in Austria, Germany and Italy. Further information can be found online at www.emco-world.com Further information and requests for pictures:

EMCO Maier Ges.m.b.H. Contact: Christa Vergnes, e-mail: [email protected]

Salzburger Strasse 80, Postfach 131, 5400 Hallein-Taxach AUSTRIA

Tel.: +43-6245-891-0, Fax: +43-6245-86965 Internet: www.emco-world.com

http://www.emco-world.com/

http://www.emco.at/

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PR HT65 Powermill ENG