TECHNICAL SPECIFICATION EMCOTURN E 45 · technical specification emcoturn e 45 with sinumerik 828d or fanuc serie 0i tf or ... 3-axes cnc-lathe with counter spindle, driven tools,

EMCO GmbH. 1.05.2018 Salzburger Straße 80 A-5400 Hallein-Taxach AUSTRIA

TECHNICAL SPECIFICATION

EEMMCCOOTTUURRNN EE 4455 with

SINUMERIK 828D or

FANUC serie 0i TF

or

HEIDENHAIN CNC PILOT 640

CNC-TURNING CENTER FOR BAR WORK OR CHUCK WORK

EMCO EMCOTURN E45 1.05.2018 Page 2 of 85

Overview of the modular concept:

EMCOTURNE45

E45 – Siemens for stationary tools

incl. tailstock

(S4ES01)

E45 – Fanuc for stationary tools

incl. tailstock

(S4EF11)

E45 M – Fanuc incl. driven tools,

C-axis and tailstock (S4EF12)

E45 M – Siemens incl. driven tools,

C-axis and tailstock (S4ES02)

E45 MY – Siemens incl. driven tools, C-axis, Y-axis and

tailstock (S4ES03)

E45 MY – Fanuc incl. driven tools, C-axis, Y-axis and

tailstock (S4EF13)

E45 SM – Siemens Incl. counter spindle, driven tools, C-axis

(S4ES20)

E45 SMY – Siemens Incl. counter spindle, driven tools, C-axis,

Y-axis (S4ES21)

E45 SM – Fanuc Incl. counter spindle, driven tools, C-axis

(S4EF20)

E45 SMY – Fanuc Incl. counter spindle, driven tools, C-axis,

Y-axis (S4EF21)

E45 – Heidenhain for stationary tools

incl. tailstock

(S4EH01)

E45 M – Heidenhainincl. driven tools,

C-axis and tailstock (S4EH02)

E45 MY – Heidenhainincl. driven tools, C-axis, Y-axis and

tailstock (S4EH03)

E45 SM – HeidenhainIncl. counter spindle, driven tools, C-axis

(S4EH20)

E45 SMY–HeidenhainIncl. counter spindle, driven tools, C-axis,

Y-axis (S4EH21)


Content:

EMCOTURN E45 - SIEMENS ____________________________________________ 4

EMCOTURN E45 M - SIEMENS __________________________________________ 5

EMCOTURN E45 MY - SIEMENS _________________________________________ 6

EMCOTURN E45 SM - SIEMENS _________________________________________ 7

EMCOTURN E45 SMY- SIEMENS ________________________________________ 8

EMCOTURN E45 - FANUC ______________________________________________ 9

EMCOTURN E45 M - FANUC ___________________________________________ 10

EMCOTURN E45 MY - FANUC __________________________________________ 11

EMCOTURN E45 SM - FANUC __________________________________________ 12

EMCOTURN E45 SMY - FANUC ________________________________________ 13

EMCOTURN E45 - HEIDENHAIN ________________________________________ 14

EMCOTURN E45 M - HEIDENHAIN ______________________________________ 15

EMCOTURN E45 MY-HEIDENHAIN ______________________________________ 16

EMCOTURN E45 SM - HEIDENHAIN _____________________________________ 17

EMCOTURN E45 SMY- HEIDENHAIN ____________________________________ 18

MAIN MACHINE OPTIONS _____________________________________________ 19

CONTROL LANGUAGES: _____________________________________________ 20

CONTROL OPTIONS - SINUMERIK 828D _________________________________ 22

CONTROL OPTIONS – FANUC 0i-TF ____________________________________ 26

MACHINE INSTALLATION KIT _________________________________________ 31

ACCESSORIES FOR BAR MACHINING: __________________________________ 33

EMCO SHORT BAR LOADER: __________________________________________ 34

FURTHER MACHINE ACCESSORIES ____________________________________ 42

AUTOMATION (Only for machines w/ Siemens) ___________________________ 47

UNLOADING THROUGH THE COUNTER SPINDLE _________________________ 49

CLAMPING CHUCKS: STANDARD SPINDLE (A2-5) ________________________ 50

CLAMPING CHUCKS: BigBore 52 SPINDLE (A2-5) _________________________ 55

CLAMPING CHUCKS: COUNTER SPINDLE A2-4 __________________________ 58

TOOL HOLDER VDI30-AXIAL (DIN69880): ________________________________ 60

TOOL HOLDER VDI25-RADIAL (DIN69880): ______________________________ 64

PACKING FOR MACHINE: _____________________________________________ 74

TECHNICAL DATA ___________________________________________________ 75


S4ES01 EMCOTURN E45 - SIEMENS

2-AXES CNC-LATHE WITH TAILSTOCK High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit SINUMERIK 828D including ShopTurn conversational programming system. Main spindle:

Spindle nose A2-5 (DIN 55026) Max. bar capacity: ø45 mm Max. drive power: 13 kW Spindle speed range: 0-6300 rpm

Tooling system:

12-station axial style tool turret VDI30, incl. bi-directional logic for up to 12 stationary tools.

Tailstock:

Hydraulic forced, free programmable, rigid construction without quill, max. force 6000 N for life-center MT 4.

Includes: Through-hole clamping cylinder including

draw tube Control Sinumerik 828D / OPERATE

conversational programming USB-interface Ethernet interface TFT color display 3D graphical simulation etc.

Machine lamp Coolant system incl. coolant pump (3,5bar) Hydraulic unit Interface for chip conveyor Documentation CE certificate

ATTENTON: please consider a longer delivery time!


S4ES02 EMCOTURN E45 M - SIEMENS

2-AXES CNC-LATHE WITH TAILSTOCK, DRIVEN TOOLS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit SINUMERIK 828D including ShopTurn conversational programming system. Main spindle:


Tooling system:

12-station axial style tool turret VDI30, incl. bi-directional logic for up to 6 driven tools

o Max. power: 4 kW o Max. torque: 16 Nm o Speed range: 0-5000 rpm o C-axis on the main spindle

Tailstock:


Includes: Through-hole clamping cylinder including draw

tube Mechanical spindle brake (main spindle) Control Sinumerik 828D / OPERATE




S4ES03 EMCOTURN E45 MY - SIEMENS

3-AXES CNC-LATHE WITH TAILSTOCK, DRIVEN TOOLS, Y-AXIS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit SINUMERIK 828D including ShopTurn conversational programming system. Main spindle:


Tooling system:



Y- axis:

Travel range: +40 / -30mm Tailstock:


Includes: Through-hole clamping cylinder including draw

tube Mechanical spindle brake (main spindle) Control Sinumerik 828D / OPERATE




S4ES20 EMCOTURN E45 SM - SIEMENS

2-AXES CNC-LATHE WITH COUNTER SPINDLE, DRIVEN TOOLS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit SINUMERIK 828D including ShopTurn conversational programming system.

Main spindle: Spindle nose A2-5 (DIN 55026) Max. bar capacity ø45 mm Max. drive power: 13 kW Spindle speed range: 0-6300 rpm

Counter spindle: Spindle nose A2-4 (DIN 55026) Max. drive power: 10 kW Spindle speed range: 0-6300 rpm

Tool turret: 12-station tool turret VDI25 radial with

bi-directional indexing logic for driven tools - Max. drive power: 4 kW - Max. torque: 16 Nm - Max. speed range: 6000 rpm

Includes: Through-hole clamping cylinder incl. draw

tube C-axis for main and counter spindle Mechanical spindle brakes CNC control Sinumerik 828D with HMI-

Operate SHOPTURN conversational

programming USB-interface Ethernet interface TFT color display 3D graphical simulation etc.

Machine lamp coolant system

- 1 pump @ 3,5 bar for the turret - 1 pump @ 3,5 bar to keep the working area clean

Parts ejector and coolant through the counter-spindle

Hydraulic unit Interface for chip conveyor Documentation, CE certificate


S4ES21 EMCOTURN E45 SMY- SIEMENS

3-AXES CNC-LATHE WITH COUNTER SPINDLE, DRIVEN TOOLS, Y-AXIS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit SINUMERIK 828D including ShopTurn conversational programming system.

Spindle nose A2-5 (DIN 55026) Max. bar capacity ø45 mm Max. drive power: 13 kW Spindle speed range: 0-6300 rpm




Y- axis: Travel range: +40/-30mm


tube C-axis for main and counter spindle Mechanical spindle brakes CNC control Sinumerik 828D with HMI-

Operate SHOPTURN conversational

programming USB-interface Ethernet interface TFT color display 3D graphical simulation etc.






S4EF11 EMCOTURN E45 - FANUC

2-AXES CNC-LATHE WITH TAILSTOCK High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. Advanced CNC control system FANUC 0i-TF incl. Manual Guide i conversational programming system. Main spindle:


Tooling system:


Tailstock: Hydraulic forced, free programmable,

rigid construction without quill, max. force 6000 N for life-center MT 4.


draw tube Control Fanuc 0i-TF

Manual Guide i conversational programming

USB-interface Ethernet interface TFT color display 15” 3D graphical simulation RS 232 interface etc.




S4EF12 EMCOTURN E45 M - FANUC

2-AXES CNC-LATHE WITH TAILSTOCK, DRIVEN TOOLS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. Advanced CNC control system FANUC 0i-TF incl. Manual Guide i conversational programming system. Main spindle:


Tooling system: 12-station axial style tool turret VDI30,

incl. bi-directional logic for up to 6 driven tools


Tailstock:



draw tube Mechanical spindle brake (main spindle) Control Fanuc 0i-TF





S4EF13 EMCOTURN E45 MY - FANUC

3-AXES CNC-LATHE WITH TAILSTOCK, DRIVEN TOOLS, Y-AXIS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. Advanced CNC control system FANUC 0i-TF incl. Manual Guide i conversational programming system. Main spindle:


Tooling system: 12-station axial style tool turret VDI30,

incl. bi-directional logic for up to 6 driven tools


Y- axis: Travel range: +40 / -30 mm

Tailstock: Hydraulic forced, free programmable,

rigid construction without quill, max. force 6000 N for life-center MT 4.


draw tube Mechanical spindle brake (main spindle) Control Fanuc 0i-TF





S4EF20 EMCOTURN E45 SM - FANUC

2-AXES CNC-LATHE WITH COUNTER SPINDLE, DRIVEN TOOLS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control FANUC 0i TF incl. Manual Guide conversational programming system.


Counter spindle: Spindle nose A2-4 (DIN 55026) Max. drive power: 7,5 kW Spindle speed range: 0-6300 rpm



Includes:

Through-hole clamping cylinder incl. draw tube

C-axis for main and counter spindle Mechanical spindle brakes CNC control FANUC 0iTF

MANUAL GUIDE i conversational programming

USB-interface + RS232 Ethernet interface TFT color display 15” 3D graphical simulation etc.






S4EF21 EMCOTURN E45 SMY - FANUC

3-AXES CNC-LATHE WITH COUNTER SPINDLE, DRIVEN TOOLS, Y-AXIS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control FANUC 0i TF incl. Manual Guide conversational programming system. Main spindle:


Counter spindle: Spindle nose A2-4 (DIN 55026) Max. drive power: 7,5 kW Spindle speed range: 0-6300 rpm





tube C-axis for main and counter spindle Mechanical spindle brakes CNC control FANUC 0iTF

MANUAL GUIDE i conversational programming

USB-interface + RS232 Ethernet interface TFT color display 15” 3D graphical simulation etc.






S4EH01 EMCOTURN E45 - HEIDENHAIN

2-AXES CNC-LATHE WITH TAILSTOCK High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit HEIDENHAIN CNC PILOT 640 including conversational programming system. Main spindle:


Tooling system:


Tailstock:


Includes:

Through-hole clamping cylinder including draw tube

Mechanical spindle brake (main spindle) Control Heidenhain CNC PILOT 640

Conversational programming USB-interface Ethernet interface TFT touch screen 15,6” 3D graphical simulation etc.

Machine lamp Coolant system incl. coolant pump (3,5bar) Hydraulic unit Interface for chip conveyor Documentation

CE certificate



S4EH02 EMCOTURN E45 M - HEIDENHAIN

2-AXES CNC-LATHE WITH TAILSTOCK, DRIVEN TOOLS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit HEIDENHAIN CNC PILOT 640 including conversational programming system. Main spindle:


Tooling system:



Tailstock:


Includes:




Machine lamp Coolant system incl. coolant pump (3,5bar) Hydraulic unit Interface for chip conveyor Documentation

CE certificate


S4EH03 EMCOTURN E45 MY-HEIDENHAIN

3-AXES CNC-LATHE WITH TAILSTOCK, DRIVEN TOOLS, Y-AXIS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit HEIDENHAIN CNC PILOT 640 including conversational programming system. Main spindle:


Tooling system:


Max. power: 4 kW Max. torque: 16 Nm Speed range: 0-5000 rpm C-axis on the main spindle

Y- axis:

Travel range: +40 / -30mm Tailstock:


Includes:






S4EH20 EMCOTURN E45 SM - HEIDENHAIN

2-AXES CNC-LATHE WITH COUNTER SPINDLE, DRIVEN TOOLS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit HEIDENHAIN CNC PILOT 640 including conversational programming system.






tube C-axis for main and counter spindle Mechanical spindle brakes Control Heidenhain CNC PILOT 640







S4EH21 EMCOTURN E45 SMY- HEIDENHAIN

3-AXES CNC-LATHE WITH COUNTER SPINDLE, DRIVEN TOOLS, Y-AXIS AND C-AXIS High efficient universal lathe with rigid and precise pre-loaded linear roller-type guide ways. State-of-the-art control unit HEIDENHAIN CNC PILOT 640 including conversational programming system.







tube C-axis for main and counter spindle Mechanical spindle brakes Control Heidenhain CNC PILOT 640







MAIN MACHINE OPTIONS

010 263 PRICE DEDUCTION / E45 WITHOUT TAILSTOCK

Price deduction for machine without tailstock. The tailstock The tailstock out of the basic machine is dropped and a cover is attached instead.

Factory installed only! S4Y 020 SURCHARGE EMCOTURN 45 BigBore

Max. bar capacity 2 inch (ø50,8mm) instead of ø45mm. Spindle nose (DIN 55026): A2-5 Max. spindle speed: 5000 rpm Max. torque: 100 Nm Max. power: 13 kW Max. chuck size: ø175 mm

Factory installed only! S4Z 430 SURCHARGE RADIAL-TOOL-TURRET

VDI25 / E45M / E45MY

Radial-turret is replacing the standard axial-turret in the EMCOTURN E45 M/MY tailstock-version S4ES02 / S4ES03 und S4EF02 / S4EF03. 12-station tool turret VDI25 radial with bi-directional indexing logic for driven tools - Max. drive power: 4 kW - Max. torque: 16 Nm - Max. speed range: 6000 rpm

Factory installed only!


CONTROL LANGUAGES: Standard-Languages:

DE6 400 Control language / GERMAN

Standard version includes two languages switchable from German to English. Additional languages available as per surcharge.

EN6 400 Control language / ENGLISH

Standard version includes two languages switchable from German to English. Additional languages available as per surcharge.

TA6 400 Control language / ITALIAN

Standard version includes two languages switchable from German to English. Additional languages available as per surcharge. We reserve the right, that not all the displayed text is incorporated in the special language at the control.

Additional languages for extra costs:

FR6 400 Control language / FRENCH

Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control.

SP6 400 Control language / SPANISH


SE6 400 Control language / SCHWEDISH Additional control language, switchable to

English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control.

CZ6 400 Control language / CZECH


DK6 400 Control language / DANISH



NL6 400 Control language / DUTCH


FI6 400 Control language / FINNISH


HU6 400 Control language / HUNGARIAN


PL6 400 Control language / POLISH


PT6 400 Control language / PORTUGUESE


RU6 400 Control language / RUSSIAN


TR6 400 Control language / TURKISH


CN6 400 Control language / CHINESE-SIMPLE



CONTROL OPTIONS - SINUMERIK 828D

X3Z 600 ELECTRONIC HANDWHEEL

Portable electronic hand-wheel for SIEMENS or FANUC controls. Offers a convenient manual operation of the machine also with open machine door. ATTENTION: For machines with swing loader, this hand-wheel is replaced by the operating and display element Siemens HT2.

Retrofit able through EMCO technician! X3Z 270 PC-KEYBOARD WITH USB-INTERFACE

PC-keyboard for comfortable programing at the Sinumerik control. American key assignment - QWERTY

X3Z 430 MEMORY EXTENSION – SIEMENS 828D

Programs can be stored on a Compact-Flash Card with a memory capacity of 4GB.

Retrofit able through EMCO technician! X3Z 260 EMCO TOOL LOAD MONITORING 828D

This system is used to check the tool load during the machining. If the current load exceeds the set values for tool breakage, tool wear or tool missing, the machine will shut-off immediately.

Retrofit able through EMCO technician ! X3Z 670 GEAR HOBBING – 828D/840D-SL

Siemens software option „electronic gear shaft“ used for gear hobbing (gear machining). Enables an oriented synchronization of the leading spindle to the following spindle due to definition of the respective coupling factors. The achievable gear quality depends on the drive-train of the machine (main spindle drive system and milling spindle drive chain).



X3Z 720 ALTERNATE SPINDLE SPEED / 840D-sl

When machining workpieces, vibrations can occur which can be reduced by permanent speed changes. With the simple input of 3 parameters in an input mask thus increased process reliability can be achieved.

Retrofitable through EMCO technician! X3Z 750 TAILSTOCK-FUNCTION FOR COUNTER

SPINDLE / 840D-sl

This cycle allows the use of the counter spindle with mounted live-center to support the workpiece. So shaft parts can also be supported and machined in machines without a tailstock but with the help of the counter spindle being used. The max. feed force is limited to 50% of the max. axis force.

Retrofitable through EMCO technician! X3Z 690 SHOPTURN EXTENSION PACKAGE

Consisting of: Rest material removing cycle Monitoring function for simulation

Retrofit able through EMCO technician! X3Z 460 CAD-READER FOR SINUMERIK

Functions by the CAD Reader: Import DXF files Hide graphics layers Automatic contour trace Optional workpiece zero per contour/drill

point Several contours/drill points can be selected

simultaneously Create and convert contours or drill patterns

for ShopMill, ShopTurn, SINUMERIK Operate

Display existing contours/drill points in geometry processor/cycles support.

Available for HMI OPERATE 4.7 and higher!

Retrofit able through EMCO technician!


X3Z 301 EMCO NETSERVICE / SIEMENS

Activation of the Netservice Function at the machine control and connection to a server. The period of use is limited to 12 months, but extendable by additional 12 months. Advantage: Online-Diagnoses, Online-Updates, Internet based, etc. Simple as a web-mail and safe as online-banking!

Retrofitable through EMCO technician! X3Z 450 EASY MESSAGE FOR SINUMERIK 828D

Easy Message allows you to get process information (e.g. tool wear) out of the CNC control to your mobile phone via SMS. Just insert a SIM-card of your choice, set a user profile, select the information you want to get to your mobile phone and keep up to date. (SIM card not included)

Retrofitable through EMCO technician! X3Z 395 ENERGY CONTROL FOR 828D

A simple to use energy control page enables the operator to switch-off auxiliary drives or the complete machine to stand-by mode after the production has stopped. The additional >Control-Energy< function makes it possible to analyze the electric energy consumption of each servo or of the hole machine.

Factory installed only! S4Z 23S GLASS SCALE IN X-AXIS-828D/840Dsl

Absolute, direct measuring system (HEIDENHAIN) for the X-axis including sealing air.

Factory installed only! S4Z 24S GLASS SCALE IN Y-AXIS-828D/840Dsl

Absolute, direct measuring system (HEIDENHAIN) for the Y-axis including sealing air.

Factory installed only! S4Z 25S GLASS SCALE IN Z-AXIS-828D/840Dsl

Absolute, direct measuring system (HEIDENHAIN) for the Z-axis including sealing air.



S4Z 213D 3D-MACHINE DATA / E45 (S)MY

3D machine model inclusive work area in STP-format. The 3D machine model data will be delivered on USB-STICK. Copyright EMCO. Passing on to third parties is not permitted in any case!


CONTROL OPTIONS – FANUC 0i-TF

X3Z 600 ELECTRONIC HANDWHEEL

Portable electronic hand-wheel for SIEMENS or FANUC controls. Offers a convenient manual operation of the machine also with open machine door.

Retrofit able through EMCO technician! X3Z 095 MEMORY/PROGRAMM STORAGE

EXTENSION – FANUC 0i

The memory for part programs will be increased from 512 KB to 2 MB and the program storage will be increased from 400 to 1000 part programs.

Retrofit able through EMCO technician! X3Z 335 MEMORY EXTENSION – FANUC 0i/31i

Programs can be stored on a Compact Flash card with a memory of 2 GB.

X3Z 150 EMCO TOOL LOAD MONITORING-

FANUC 31i/0iTF

This system is used to check the tool load during the machining. If the current load exceeds the set values for tool breakage, tool wear or tool missing, the machine will shut-off immediately.

Retrofit able through EMCO technician! X3Z 380 ENERGY CONTROL FOR FANUC 31i/0iTF

A simple to use energy control page enables the operator to switch-off auxiliary drives or the complete machine to stand-by mode after the production has stopped. The additional >Control-Energy< function makes it possible to analyze the electric energy consumption of each servo or of the hole machine.



X3Z 085 GEAR HOBBING – FANUC 31i/0iTF

Fanuc software option „electronic gear shaft“ used for gear hobbing (gear machining). Enables an oriented synchronization of the leading spindle to the following spindle due to definition of the respective coupling factors. The achievable gear quality depends on the drive-train of the machine (main spindle drive system and milling spindle drive chain).

Factory installed only! S4Z 23F GLASS SCALE IN X-AXIS-FANUC


Factory installed only! S4Z 21F GLASS SCALE IN Y-AXIS-FANUC


Factory installed only! S4Z 22F GLASS SCALE IN Z-AXIS-FANUC




CONTROL OPTIONS – HEIDENHAIN

X3Z 640 ELECTRONIC HANDWHEEL/ HEIDENHAIN

Portable electronic hand-wheel for machines with HEIDENHAIN control. Offers a convenient manual operation of the machine also with open machine door.

Retrofit able through EMCO technician! X3Z 470 DXF-CONVERTER FOR HEIDENHAIN

The DXF converter can be used to import contours in DXF format. DXF contours can be rough or finished parts, contour curves and milling contours. They must exist as two-dimensional elements in a separate layer without dimension lines, peripheral edges, etc.

Retrofit able through EMCO technician! X3Z 480 TURN PLUS FOR HEIDENHAIN

With the powerful, automatic programming TURN PLUS, you can get from the drawing to the finished workpiece in the quickest possible way. After you have entered the raw and finished part contour graphically or read in via DXF import, you only need to select material and clamping devices. Everything else is done automatically by the TURN PLUS: • Analysis of the contours • Planning the work strategy • Selection of tool and cutting data • Generation of NC blocks

Retrofit able through EMCO technician! X3Z 250 LOAD MONITORING FOR HEIDENHAIN

Detect tool wear and tool breakage during machining. Load Monitoring monitors the spindle and drive utilization of the machine and compares this with the load values of a reference machining. The CNC PILOT 640 can graphically display the load values in a separate window. If limit values are exceeded, either a substitute tool is changed or processing is stopped.



X3Z 677 GEAR HOBBING – HEIDENHAIN 640

HEIDENHAIN software option used for gear hobbing (gear machining). Enables an oriented synchronization of the leading spindle to the following spindle due to definition of the respective coupling factors. The achievable gear quality depends on the drive-train of the machine (main spindle drive system and milling spindle drive chain).

Factory installed only! S4Z 23H GLASS SCALE IN X-AXIS / HH640


Factory installed only! S4Z 24H GLASS SCALE IN Y-AXIS / HH640


Factory installed only! S4Z 25H GLASS SCALE IN Z-AXIS / HH640


Factory installed only! S4Z 650 TOOL PRESETTER – E45 / HH640

The tool presetter can be mounted inside the machine into a precision fixture when needed. This allows to measure the tools at the turret inside the machine very accurate. After use the arm can be stored in a storage location inside the machine housing. Adjustment gauge VDI30 included! Advantage: Quick change over Precise tool setting Cost effective



S4Z 660 TOOL PRESETTER – E45S/MT45 / HH640

`

The tool presetter can be mounted inside the machine into a precision fixture when needed. This allows to measure the tools at the turret inside the machine very accurate. After use the arm can be stored in a storage location inside the machine housing. Advantage: Quick change over Precise tool setting Adjustment gauge VDI25 (S3Z110) to be ordered separately !!

Factory installed only !! S3Z 110 ADJUSTMENT GAUGE VDI 25 - RADIAL

Gauge to adjust the tool presetter S3Z610 and S4Z610 in the machine.


MACHINE INSTALLATION KIT

S6Z 460 MACHINE INSTALLATION KIT

Consisting of: 4x vibration absorbing, height adjustable

levelling elements 4x angle plates to fasten the machine to

the floor 4x anchor bolts to lag the machine to the

floor

ESPRIT PROGRAMMING SYSTEM:

224 560 EMCO-ESPRIT PACKAGE / E-SERIES / TURNING

ESPRIT reads data from the following native formats: ACIS, DXF, IGES, Inventor (*.ipt, *.iam), Parasolid (X_T, X_B), Solid Edge (*.par, *.psm,*.asm), SolidWorks (*.sldprt, *.sldasm), VDA; Feature transfer from Inventor, Solid Edge and SolidWorks Optional data readers are available for: CATIA, Pro/ENGINEER, SIEMENS NX, STEP, STL.

RRP LIST PRICE: 8.100,- EURO ATTENTION: SPECIAL PRICE ACCORDING TO OFFER ONLY IN CONNECTION WITH NEW MACHINE PURCHASE! The most powerful CAD/CAM programming software for turning, milling and drilling. In only a few steps you can create the CNC-program from a CAD drawing. A 3D dynamic solid simulation shows the work piece, tools and also the chuck. The machining process is shown in real-time and collisions are detected to provide a proven process to the machine. The package supports programming of:

1 spindle 1 tool turret C-axis Driven tools

The package includes: ESPRIT Basis License, ESPRIT SolidTurn Traditional, ESPRIT SolidMillTurn Traditional, EMCO E-series standard postprocessor for Siemens or

Fanuc Customer data for licensing: Company: Address: Tel.: Fax.: Contact person: E-Mail: Customer P.O.-No.:

010 250 BASIC TRAINING FOR ESPRIT CAD/CAM

3 days basic training for ESPRIT CAD/CAM software. Max. number of persons: 3 persons Location: EMCO in Hallein/Austria (Training at the customers facility on request!)


224 500 EMCO-ESPRIT PACKAGE / E+MT-SERIE (MY)


RRP LIST PRICE: 9.900,- EURO ATTENTION: SPECIAL PRICE ACCORDING TO OFFER ONLY IN CONNECTION WITH NEW MACHINE PURCHASE! The most powerful CAD/CAM programming software for turning, milling and drilling. In only a few steps you can create the CNC-program from a CAD drawing. 3D dynamic solid simulation shows the work piece, chucks, tools and the working area of the machine. It eliminates the need for expensive dry runs on the NC machine and prevents machine crashes. The package supports programming of:

1 spindle 1 tool turret 1 steady-rest (not synchronized) C-axis Y-axis Driven tools

The package includes: ESPRIT Basis License, ESPRIT SolidTurn Traditional, ESPRIT SolidMillTurn Advanced, EMCO MAXXTURN standard postprocessor for Siemens or

Fanuc EMCOTURN / MAXXTURN machine-model simulation Incl. ToolShapes

Customer data for licensing: Company: Address: Tel.: Fax.: Contact Person: E-Mail: Customer P.O.-No.:

224 570 EMCO-ESPRIT PACKAGE / E+MT-SERIE WITH SUB SPINDLE (S/SM/SMY)


RRP LIST PRICE: 12.400,- EURO ATTENTION: SPECIAL PRICE ACCORDING TO OFFER ONLY IN CONNECTION WITH NEW MACHINE PURCHASE! The most powerful CAD/CAM programming software for turning, milling and drilling. In only a few steps you can create the CNC-program from a CAD drawing. 3D dynamic solid simulation shows the work piece, chucks, tools and the working area of the machine. It eliminates the need for expensive dry runs on the NC machine and prevents machine crashes. The package supports programming of:

2 spindle 1 tool turret 1 steady-rest (not synchronized) C-axis Y-axis Driven tools

The package includes: ESPRIT Basis License, ESPRIT SolidTurn Traditional, ESPRIT SolidTurn Multi Spindle ESPRIT SolidMillTurn Advanced, EMCO MAXXTURN standard postprocessor for Siemens or

Fanuc EMCOTURN / MAXXTURN machine-model simulation Incl. ToolShapes

Customer data for licensing: Company: Address: Tel.: Fax.: Contact Person: E-Mail:


Customer P.O.-No.:

ACCESSORIES FOR BAR MACHINING:

S4Z 710 PARTS CATCHER

Standard parts catcher system to unload the components from the main or counter spindle into a standard part box or to the conveyor belt (optional). Max. finished part length: 120mm Max. finished part diameter: 45 (51) mm Max. finished part weight: 2kg

Factory installed only !! X1Z 140 EMCO BAR LOADER INTERFACE FOR

SECOND-PARTY BAR LOADERS

Bar loader interface to connect non EMCO bar loader systems. The programming is done via M-functions. The signal exchange from Machine to bar loader goes through 24-pin HARDING-plug. The bar loader manufacturer must adopt the wiring and signals according to EMCO´s standard pinning! NEW: Safety signals are carried out with two channels!

Factory installed only !! R9Z 030 MACHINE STATUS LAMP/LED

The machine status lamp is divided in 3 color ranges: Red ... Alarm Green ... Automatic mode White ... Material handling

Retrofit able through EMCO technician ! R6Z 220 PLASTIC INSERT PUSHING SIZE 45

to be machine customised according to bar diameter. (Ø45,4-0,1 x 68,5+0,1 - 10 pieces required)

S4Z 270 PLASTIC INSERT PUSHING SIZE 52

to be machined customised according to bar diameter. (Ø51,4 -0,1 x 74 +0,1 – 9 pieces required)

S4Z 300 FINISHED PART CONVEYOR

Finished part conveyor belt to protect the parts from crashing into each other inclusive coolant recirculation and chip tray. It replaces the standard finished part box and is controlled via M-function. Effective surface for storage: 340 x 750mm


Factory installed only !!

EMCO SHORT BAR LOADER:

S3Z 930 EMCO SL1200 FOR E45/E65/MT45/HT65-PM INCL. EMCO INTERFACE

Short bar loading magazine for automatic loading of short bar stock with a diameter from 8 to 95 mm and a length up to 1200mm. The loading magazine is very compact and space-saving and also very simple to be used. Including EMCO Interface!!

TECHNICAL DATA: Bar length: 150 – 1200 mm Bar diameter: 8 – 95 mm Max. feed rate: 60 m/min Time for bar feed: approx. 3 sec Time for bar change: approx. 15 sec Bar storage surface: 560 x 1210 mm Storage capacity: 10 bars with ø 55 mm or 70 bars with ø 8 mm Bar in-feed side: Backside Power supply: 24 Volt DC (Interface) Air main supply: 6 bar Length: 1700 mm Width: 1250 mm Pusher rod/spindle height: 1090-1380 mm Weight: approx. 500 kg Safety features: according to CE Includes:

Push rod ø 15 mm Push rod ø 8 mm Fastening material Slide system to move the loader longitudinal

(approx. 400 mm) Documentation

Advantages:

Small foot print Simple to operate Simple and quick set-up change Possibility to load billets Easy adjustment of the diameter High-Speed function EMCO Design

Loading of hexagon and square bar stock not possible!!


L1Z010 DRAWERS FOR SL1200

In the two drawers, which are integrated in the bar loader frame, reduction bushings, hand tools or other utensils can be stored. The maximum load per drawer is 20 kg.




S3Z 452 SPINDLE EXTENSION FOR E45

To be able to load and support bar stock up to a length of 1100 mm through the spindle, this spindle extension is necessary. Includes 3 reduction bushings. The material must be supported very precisely with the reduction bushings to achieve a failure-free operation! Automated loading of bar stock up to ø45mm only with SL1200!

Retrofit able through EMCO technician! S3Z 521 SPINDLE EXTENSION FOR

E45-BIGBORE

To be able to load and support bar stock up to a length of 1100 mm through the spindle, this spindle extension is necessary. Includes 3 reduction bushings. The material must be supported very precisely with the reduction bushings to achieve a failure-free operation! Automated loading of bar stock up to ø51mm or 2” only with COMPACT LOAD or SL1200!

Retrofit able through EMCO technician! ZVZ341875 STANDARD PACKING SL1200

For easy pick-up with the forklift. Consisting of: pallet, rolamit-cover

ZVP547220 CLIMATE PACKING SL1200 for transportation over-sea.

Consisting of: pallet, dehumidifier, aluminium-cover and miscellaneous

ZVP302145 WOODENBOX SL1200 Additional protection for critical transportation

DE 1200 SL1200 Instruction Manual / GERMAN EN 1200 SL1200 Instruction Manual / ENGLISH TA 1200 SL1200 Instruction Manual / ITALIAN

FR 1200 SL1200 Instruction Manual / FRENCH

SP 1200 SL1200 Instruction Manual / SPANISH SE 1200 SL1200 Instruction Manual / SCHWEDISH CZ 1200 SL1200 Instruction Manual / CZECH

DK 1200 SL1200 Instruction Manual / DANISH

NL 1200 SL1200 Instruction Manual / DUTCH

FI 1200 SL1200 Instruction Manual / FINNISH

HU 1200 SL1200 Instruction Manual / HUNGARIAN PL 1200 SL1200 Instruction Manual / POLISH

PT 1200 SL1200 Instruction Manual / PORTUGUESE RU 1200 SL1200 Instruction Manual / RUSSIAN TR 1200 SL1200 Instruction Manual / TURKISH CN 1200 SL1200 Instruction Manual / CHINESE-SIMPLE


EMCO TOP LOAD 8 - 42 / 3200: S4Z 902 EMCO TOP LOAD 8-42/3200 INCLUSIVE

EMCO BAR LOADER INTERFACE- NEW

Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 42mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø35 mm

> 35 mm to the front SERVO controlled feeding system

Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: 1500 – 3200 mm Bar diameter: 8 – 42 mm Travelling speed: 0 - 30 m/min Storage capacity: approx. 235 mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 790mm Total height: 1300-1650mm Weight: approx. 1200 kg Safety devices: CE compliant Includes: Fastening material Slide system to move the loader longitudinal

(approx. 800mm) Conical centering sleeve 42 Clamping sleeve blank 42 (Polymer) 2x adapter (ø14/ø20mm)

Documentation

Retrofit able through EMCO technician ! 434 530 SEAWORTHY PACKING

TOP LOAD 8-42/3200 and 8-50/3200

The loader is packed with aluminium bandage, for transportation over-seas.


S4Z 912 EMCO TOP LOAD 8-42/3200 MULTI LEVEL

INCL. EMCO BAR LOADER INTERFACE- NEW

Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 42mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Extended bar storage Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø35 mm


Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: 2500 – 3200 mm Bar diameter: 8 – 42 mm Travelling speed: 0 - 30 m/min MULTI LEVEL bar storage: approx. 1000 mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 925mm Total height: 1300-1650mm Weight: approx. 1400 kg Safety devices: CE compliant Includes: MULTI LEVEL Material storage Fastening material Slide system to move the loader longitudinal


Documentation


TOP LOAD 8-42/3200 and 8-50/3200



EMCO TOP LOAD 8 - 50 / 3200 FOR BIG BORE MACHINE: S4Z 917 EMCO TOP LOAD 8-50/3200 INCLUSIVE

EMCO BAR LOADER INTERFACE- NEW

Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 50mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø45 mm


Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: 1500 – 3200 mm Bar diameter: 8 – 50 mm Travelling speed: 0 - 30 m/min Storage capacity: approx. 235 mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 790mm Total height: 1300-1650mm Weight: approx. 1200 kg Safety devices: CE compliant Includes: Fastening material Slide system to move the loader longitudinal


Documentation


TOP LOAD 8-42/3200 and 8-50/3200



S4Z 927 EMCO TOP LOAD 8-50/3200 MULTI LEVEL

INCL. EMCO BAR LOADER INTERFACE- NEW

Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 50mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Extended bar storage Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø45 mm


Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: 2500 – 3200 mm Bar diameter: 8 – 50 mm Travelling speed: 0 - 30 m/min MULTI LEVEL bar storage: approx. 1000 mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 925mm Total height: 1300-1650mm Weight: approx. 1400 kg Safety devices: CE compliant Includes: MULTI LEVEL Material storage Fastening material Slide system to move the loader longitudinal


Documentation Retrofit able through EMCO technician !

434 530 SEAWORTHY PACKING TOP LOAD 8-42/3200 and 8-50/3200



ACCESSORIES FOR EMCO TOP LOAD:

CLAMPING SLEEVE (STEEL)

This clamping sleeve is made out of hardened steel and needs to be ordered according to the bar stock diameter. Clamping range: Nominal diameter +/-0,25mm 446 006 – Clamping sleeve (steel) ø6mm 446 007 – Clamping sleeve (steel) ø7mm 446 008 – Clamping sleeve (steel) ø8mm 446 009 – Clamping sleeve (steel) ø9mm 446 010 – Clamping sleeve (steel) ø10mm 446 011 – Clamping sleeve (steel) ø11mm 446 012 – Clamping sleeve (steel) ø12mm 446 013 – Clamping sleeve (steel) ø13mm 446 014 – Clamping sleeve (steel) ø14mm 446 015 – Clamping sleeve (steel) ø15mm 446 016 – Clamping sleeve (steel) ø16mm 446 017 – Clamping sleeve (steel) ø17mm 446 018 – Clamping sleeve (steel) ø18mm 446 019 – Clamping sleeve (steel) ø19mm 446 020 – Clamping sleeve (steel) ø20mm 446 021 – Clamping sleeve (steel) ø21mm 446 022 – Clamping sleeve (steel) ø22mm 446 023 – Clamping sleeve (steel) ø23mm 446 024 – Clamping sleeve (steel) ø24mm 446 025 – Clamping sleeve (steel) ø25mm 446 026 – Clamping sleeve (steel) ø26mm 446 027 – Clamping sleeve (steel) ø27mm 446 028 – Clamping sleeve (steel) ø28mm 446 029 – Clamping sleeve (steel) ø29mm 446 030 – Clamping sleeve (steel) ø30mm 446 031 – Clamping sleeve (steel) ø31mm 446 032 – Clamping sleeve (steel) ø32mm 446 033 – Clamping sleeve (steel) ø33mm 446 034 – Clamping sleeve (steel) ø34mm 446 035 – Clamping sleeve (steel) ø35mm 446 036 – Clamping sleeve (steel) ø36mm 446 037 – Clamping sleeve (steel) ø37mm 446 038 – Clamping sleeve (steel) ø38mm 446 039 – Clamping sleeve (steel) ø39mm 446 040 – Clamping sleeve (steel) ø40mm 446 041 – Clamping sleeve (steel) ø41mm 446 042 – Clamping sleeve (steel) ø42mm 446 045 – Clamping sleeve (steel) ø45mm

434 550 CLAMPING SLEEVE BLANK (POLYMER)

– 42

Needs to be machined according to the used bar stock diameter. Outside diameter 42mm. Absorbs vibration in a good way!! Tip: first into a freezer, than machining!


FURTHER MACHINE ACCESSORIES

S4Z 620 TOOL PRESETTER – E45

The tool presetter can be mounted inside the machine into a precision fixture when needed. This allows to measure the tools at the turret inside the machine very accurate. After use the arm can be stored in a storage location inside the machine housing. Adjustment gauge VDI30 included! Advantage: Quick change over Precise tool setting Cost effective

Factory installed only! S4Z 610 TOOL PRESETTER – E45S/MT45

The tool presetter can be mounted inside the machine into a precision fixture when needed. This allows to measure the tools at the turret inside the machine very accurate. After use the arm can be stored in a storage location inside the machine housing. Advantage: Quick change over Precise tool setting Adjustment gauge VDI25 (S3Z110) to be ordered separately !!

Factory installed only !! S3Z 110 ADJUSTMENT GAUGE VDI 25 - RADIAL

Gauge to adjust the tool presetter S3Z610 and S4Z610 in the machine.

S4Z 140 COOLANT PISTOL / MULTIFLOW

To clean the machining area from chips with coolant (Note: never use air to clean the machine!)

Retrofit able through EMCO technician! 433 001 CHIP CONVEYOR E45 - 1200MM

Chain feeding system, dump-height 1200mm, suitable for:

Long steel shavings Snarl chips Wool chips Dry- and wet machining


ZVP 303 130 WOODEN BOX F. CHIP CONV. – 433000

Wooden box for chip conveyor (433000) as additional protection for critical transportation.

573 313 CHIP TIPCART- 400 LITER

Chip tipcart for emptying at ground level or with a fork truck. Safety chain at the backside. Welded sheet metal with reinforcement frame – watertight. 1 steerable roller and 2 fixed rollers made of rubber ø250mm. Incl. perforated steel plate and drain hole Color: RAL 9004 / black Filling volume approx. 400 Liter (H x W x D =1090 x 900 x 1330mm)

S4Z 640 FULL AUTOMATIC MACHINE DOOR-

MT45

Automatic servo driven machine door especially for manual loaded machines. Single key operation including door safety switch-bar. Time per stroke: approx. 2sec

Factory installed only! S3Z 010 OIL MIST SEPARATOR

Mechanical oil mist separator (RECOJET® -2) for separation of water –based aerosols such as cooling lubricant or spray mist. Air through put: 1000 qm/h Wattage: 250 Watt Connection diameter: ø160 mm (When using oil instead of water soluble, heavy smoke can be generated during the operation. In this case we recommend the use of an electrostatic separator. In case of low smoke generation, a filter attachment can be mounted on top of it.)

Retrofit able through EMCO technician! R9Z 025 FILTER ATTACHMENT FOR RECOJET-2

EUREVEN-F2011 filter top unit with moisture-repelling, synthetic filter material. Easy to clean. Suitable for low smoke generation. Can be easily mounted on top of the RECOJET 2 housing.

Retrofit able through customer!


S3Z 070 CONNECTION NOZZLE/VACUUM SYSTEM

Connection nozzle ø 160 mm to connect the machine to a centralized air vacuum system.

Retrofit able through EMCO technician! S4Z 160 AIR CONDITIONING SYSTEM – MT45

used for electrical cabinet especially if the machine is located in dusty, oily and hot areas. No air exchange between outside and inside

Retrofit able through EMCO technician ! R3Z 580 FOOT PEDAL

to actuate chuck or tailstock (one foot pedal needed for each)

Retrofit able through EMCO technician ! 573 310 LIFE CENTRE MT4

for tailstock version

S4Z 085 14 BAR HIGH PRESSURE COOLANT

PUMP 50Hz

An additional high pressure coolant pump with up to 14 bar is used to provide the coolant through the tool turret. An extra coolant pan, interface and software is included (50Hz).

Factory installed only !! S4Z 095 14 BAR HIGH PRESSURE COOLANT

PUMP 60Hz (USA)

An additional high pressure coolant pump with up to 14 bar is used to provide the coolant through the tool turret. An extra coolant pan, interface and software is included (60Hz).


MK 4 / MT 4


S4Y 300 SURCHARGE FOR PAPER BAND

FILTRATION UNIT FOR EMCOTURN E45 / BMF-BÜRENER

- Coolant tank capacity 600 Liter - Floor space LxWxH:1100x1100x800mm - Filter capacity: 150 l/min for water soluble - Average output purity: approx. 60- 40 µm - 1x screw spindle pump MTS20-40 Delivery pressure: 25 bar Flow rate approx. 24 l/min Power: 3 kW - 2x immersion pumps (flushing) SPK2-23/15 Delivery pressure: 4,3 bar Flow rate approx. 35 l/min Power: 0,75 kW - 1 roll of filter paper - Lifting pump MTA 90-180 A-W-A-B/50Hz - Electrical a. mechanical adoption - PLC adaption / painting: Graphite grey RAL7024 The chip conveyor must be offered separately. The standard coolant pumps of the basic machine are no longer there!

Factory installed only! R2Z 660 TEST MANDREL VDI 30 AXIAL

To check alignment of tool turret and reference point of the machine.

R2Z 670 TEST MANDREL-MAIN SPINDLE A2-5

Test mandrel (long) for main spindle A2-5 according to DIN 55026.

S4Z 630 TEST FLANGE A2-5

To check the alignment of the X and Y axes in relation to the spindle alignment.


R2Z 630 TEST MANDREL-COUNTER SPINDLE A2-4

Test mandrel (short) for counter spindle A2-4 according to DIN 55026.

R2Z 650 TEST MANDREL - VDI 25

Two test mandrels VDI 25 to check turret alignment and reference point of the machine. Consisting of: Test mandrel R2Z 640 010 Test mandrel R2Z 640 020

010 121 LASER MEASUREMENT AND PITCH

ERROR COMPENSATION

Measurement of the positioning tolerance to ISO 230 and VDI/DGQ 3441 made for all linear axis of the machine over the whole stroke including documentation for all measured axis. ATTENTION: This values can only be guaranteed under EMCO standardised environmental conditions. ONLY IN THE FACTORY



AUTOMATION (Only for machines w/ Siemens)

S4E M01 SWING LOADER EMCOTURN E45

Integrated loading and unloading system, programmable via Sinumerik 828D control. Two NC-servo axis guarantee a flexible and free programmable loading process. This process can be stored into the part program work-sheet. Change-over is only a matter of calling up a different work-piece. Raw parts can be stored in a gravity chute, chain-feeder or other solutions can be offered. Max. travelling speed: 60 m/min Max. swiveling speed: 180°/sec

Factory installed only!!

GRIPPER SOLUTIONS:

010 760 2-FINGER-GRIPPER W/ 180° OPENING

Pneumatically operated toggle lever gripper for loading of shafts. The parts are fed in horizontally in a chute or on a conveyor. Parts can be swallowed by the chuck or clamped between centres. The unloading is done by the parts catcher. Max. part size: approx. ø30 x 200 mm Max. part weight: approx. 2 kg

Factory installed only!! 010 765 2-FINGER- GRIPPER W/ 180° OPENING

MOUNTED ON AN INDEXING UNIT

Pneumatically operated toggle lever gripper for loading of shafts. The parts are fed in horizontally or vertically. Parts can be swallowed by the chuck or clamped between centres. This gripper enables to flip the part for the 2nd operation. The unloading is done by the parts catcher. Max. part size: approx. ø60 x 100 mm Max. part weight: approx. 2 kg



010 770 2-FINGER-PARALLEL GRIPPER W/

90° INDEXING UNIT

Pneumatically operated parallel gripper to pick-up raw parts from a conveyor system. This enables oriented loading of casting and forgings. The unloading is done by the parts catcher. Max. part size: approx. ø60 x 100 mm Max. part weight: approx. 2 kg


FEED-IN / FEED-OUT SYSTEMS:

010 780 CHAIN FEEDER SYSTEM

Conveyor system to store and feed-in raw parts. Effective length: 1300mm Effective width: 567mm (Chain module: 27,1mm). The raw parts are stored in part specific fixtures. These fixtures need to be offered and clarified by the Automation Department of EMCO in Hallein.

Factory installed only!! 010 785 DOUBLE CHAIN FEEDER SYSTEM

Two line chain feeder system to feed-in raw parts and to feed-out finished parts. Effective length: 1300mm Effective width: 567mm (Chain module: 27,1mm). The raw parts are stored in part specific fixtures. These fixtures need to be offered and clarified by the Automation Department of EMCO in Hallein.

Factory installed only!! On request! SINGLE/MULTIPLE FEED-IN CHUTE

This system is used to store and feed-in round components. The parts must roll down the chute to the pick-up position. Depending on the part length, the system can be extended to up to 10 chutes. Each single chute includes raw part sensor and pick-up logic to guarantee unmanned production. Effective width to use: 600mm



R9Z 030 MACHINE STATUS LAMP/LED

The machine status lamp is divided in 3 color ranges: Red ... Alarm Green ... Automatic mode White ... Material handling

Retrofit able through EMCO technician ! S4Z 710 PARTS CATCHER MAXXTURN 45

Standard parts catcher system to unload the components from the main or counter spindle into a standard part box or to the conveyor belt (optional). Max. finished part length: 120mm Max. finished part diameter: 45mm Max. finished part weight: 2kg

Factory installed only !! S4Z 300 FINISHED PART CONVEYOR

Finished part conveyor belt to protect the parts from crashing into each other inclusive coolant recirculation and chip tray. It replaces the standard finished part box and is controlled via M-function. Effective surface for storage: 340 x 750mm

Factory installed only!! ATTENTION: To ensure a quick and effective order-processing within the customers, our partners and EMCO, every automated project must go thru EMCO´s Automation department before order-acceptance. Therefore EMCO has setup a form „Catalogue of requirements – Special items description“ (VA03.0 099). This form must be filled and forwarded to department TSS. Raw part and finished part drawings including sample parts should be forwarded as well.

UNLOADING THROUGH THE COUNTER SPINDLE

Information PREPARATION TO UNLOAD SHAFTS THROUGH THE COUNTER SPINDLE

The standard machine can be modified to enable the unloading of long shafts through the counter spindle. Therefore, the solid clamping cylinder and part ejector gets replaced by a through hole clamping cylinder. Max. work piece diameter: ø32 mm


CLAMPING CHUCKS: STANDARD SPINDLE (A2-5)

575 003 POWER COLLET CHUCK 173E / A2-5

SMW- dead length collet chuck, complete with bayonet lock, for short taper A2-5 (DIN 55026), incl. mounting screws and draw tube adaptor, collets not included, Type KSZ-MB 40-A05 (nmax.:6000 rpm), clamping range: ø2-42 mm

Collets refer to >spec_collets_en.doc< 440 900 SPANNTOP-MODULAR COLLET CHUCK (A2-5)

HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø45 (ø52) mm, no internal part-stop possible; collet changer 440 925 necessary, (nmax.: 7000 rpm), incl. draw adapter

440 911 SPANNTOP-MINI-COMBI COLLET CHUCK (A2-5)

HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø45 (ø52) mm, incl. internal part-stop, collet changer 440 925 necessary, (nmax.: 7000 rpm), incl. draw adapter

440 921 SPANNTOP-MINI-COMBI AXFIX COLLET CHUCK

(A2-5)

HAINBUCH collet chuck (dead-length style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø45 (ø52) mm, incl. internal part-stop, collet changer 440 925 necessary, (nmax.: 7000 rpm), incl. draw adapter Advantage: No axial collet stroke and therefore no unfavorable tension between both spindles during take over!


010 600 COLLET SK 52 BZI - ROUND

HAINBUCH Collet SK 52 BZI for round bar stock, total clamping range ø 5-52mm; 0,5mm steps, To clamp on raw or finished surfaces with serrated or smooth clamping surface. Please define the clamping diameter and whether the clamping surface should be serrated or smooth!

010 605 COLLET SK 52 BZI - HEXAGON

HAINBUCH Collet SK 52 BZI for hexagon bar stock, total clamping range 7-45mm in 1mm steps, Please define the hexagon size to be clamped on.

010 610 COLLET SK 52 BZI - SQUARE

HAINBUCH Collet SK 52 BZI for square bar stock, total clamping range 8-36mm in 1mm steps, Please define the square size to be clamped on.

440 925 MANUAL COLLET CHANGER BZI 52

To change HAINBUCH collets BZI 42/52 (Hainbuch: MQ 42/52).

574 670 3 JAW CHUCK KFD-HS 160/3 - A2-5

RÖHM power-chuck KFD-HSø160/3 hydraulic operated, for high spindle speed and with large through-hole (ø46), incl. 1 set of hardened reversible jaws with a serration of 1/16“x 90°, to mount on spindle nose size A2-5, (nmax.:8000rpm)


574 700 3- JAW CHUCK KFD-HE 170 - A2-5

RÖHM power-chuck KFD-HE 170, hydraulic operated, with through hole (ø43), incl. set of soft jaws with a serration of 1/16“x 90° and draw tube adapt for EMCOTURN E45, for spindle nose size A2-5 (nmax. 6300rpm) smallest clamping diameter: 20mm

574 675 SET OF 3 HARD JAWS

Set of reversible hard jaws for 574700 and 574670 with a serration of 1/16“x 90°

R3Y 230 SET OF 3 SOFT JAWS

Set of soft jaws for 574700 and 574670 with a serration of 1/16“x 90°

586620 3- JAW-CHUCK BH-D 165/3 A2-5

SMW-AUTOBLOK® power chuck with through hole type BH-D 165-46-A05 (hydraulically operated). Through hole ø46mm, Incl. 1 set of soft jaws with a serration of 1/16“x 90°. To mount on spindle nose A2-5 / M52x1,5 (DIN55026) (nmax.: 6000 rpm)

SMW Id-No: 45009433 586621 SET OF 3 SOFT JAWS

Set of soft jaws WBSA-D165 with a serration of 1/16“x 90° for power chuck SMW BH-D 165 and BB-D 175. Hole spacing: 16,5 mm Groove width: 14 mm

SMW Id-No: 12071680 586622 SET OF 3 HARD JAWS

Set of hard reversible jaws MHB-D130 for power chuck SMW BH-D 165 and BB-D 175. Hole spacing: 16,5 mm Groove width: 14 mm

SMW Id-No: 12081636


574 680 3-JAW-CHUCK KNCS-N 170/3 A2-5

SMW-AUTOBLOK® power chuck with quick change jaw system type KNCS-N-170-43-3-A05 (hydraulically operated). Through hole diameter 43mm, Incl. 1 set of hardened monobloc-step jaws ground when mounted on chuck, to mount on spindle nose A2-5 (DIN55026) (nmax.:6300 rpm)

574 685 SET OF 3 HARDENED BASE JAWS

Set of 3 hardened base jaws type GBK 160 for power chuck with quick change jaw system Type KNCS-N-170-43-3-A05 (574680)

574 690 SET OF 3 SOFT TOP JAWS

Set of 3 soft top jaws type WAK 160-10 for power chuck with quick change jaw system Type KNCS-N-170-43-3-A05 (574680)

571310 3-JAW-CHUCK KNCS-NB 210/3 / A2-5

WITH WIDE MASTER JAWS

SMW-AUTOBLOK® power chuck with quick change jaw system KNCS-NB-210-52-A05 (hydraulically operated). Through hole diameter 52 mm. Incl. 1 set of hardened base jaws GBKB 210 and hardened, reversible top jaws GUA 200, to mount on spindle nose A2-5 / M52x1,5 (DIN55026) with rotating thread ring incl. mounting key (nmax.: 5000 rpm)

SMW Id-No: 162555 571311 SET OF 3 HARD BASE JAWS

Set of hard base jaws type GBKB 210 for power chuck with quick change jaws SMW type KNCS-NB-210 and KNCS-NB-225

SMW Id-No: 138494


571270 SET OF 3 SOFT TOP JAWS

Set of soft top jaws type WAK 200-10 for power chuck with quick change jaws SMW type KNCS-N-210 and KNCS-NB-210/225

SMW Id-No: 012492

574 630 GREASE GUN SMW INCL. 2 ADAPTORS

Grease gun including: - Nosepiece for cone headed grease nipple - Nosepiece for funnel grease nipple - 500 g cartridge of special grease K05 Suitable for RÖHM and SMW power chuckes.


CLAMPING CHUCKS: BigBore 52 SPINDLE (A2-5)

440 940 SPANNTOP®-NOVA -MODULAR COLLET CHUCK (A2-5) BIG BORE

HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø52 mm, no internal part-stop possible; collet changer 440 925 necessary, (nmax.: 7000 rpm), incl. draw adapter

440 951 SPANNTOP-MINI-COMBI COLLET CHUCK

(A2-5) BIG BORE

HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø52 mm, incl. internal part-stop, collet changer 440 925 necessary, (nmax.: 7000 rpm), incl. draw adapter

440 961 SPANNTOP-MINI-COMBI AXFIX COLLET

CHUCK (A2-5) BIG BORE

HAINBUCH collet chuck (dead-length style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø52mm, incl. internal part-stop, collet changer 440 925 necessary, (nmax.: 7000 rpm), incl. draw adapter Advantage: No axial collet stroke and therefore no unfavorable tension between both spindles during take over!

586630 3- JAW-CHUCK BB-D 175/3 A2-5

SMW-AUTOBLOK® power chuck with through hole type BB-D 175-56-A05 (hydraulically operated). Through hole ø56mm, Incl. 1 set of soft jaws with a serration of 1/16“x 90°. To mount on spindle nose A2-5 / M58x1,5 (DIN55026) (nmax.: 6000 rpm)

SMW Id-No: 162701


586621 SET OF 3 SOFT JAWS

Set of soft jaws WBSA-D165 with a serration of 1/16“x 90° for power chuck SMW BH-D 165 and BB-D 175. Hole spacing: 16,5 mm Groove width: 14 mm

SMW Id-No: 12071680 586622 SET OF 3 HARD JAWS

Set of hard reversible jaws MHB-D130 for power chuck SMW BH-D 165 and BB-D 175. Hole spacing: 16,5 mm Groove width: 14 mm

SMW Id-No: 12081636 438 070R 3 JAW CHUCK KFD-HS 175/3 – A2-5

BIG BORE

RÖHM power-chuck KFD-HS ø175/3 hydraulic operated, for high spindle speed and with large through-hole (ø52), incl. 1 set hardened reversible jaws with a serration of 1/16“x 90°, to mount on spindle nose size A2-5 (nmax.7000rpm)


Set of reversible hard jaws for 438060 and 438 070R with a serration of 1/16“x 90°

R3Y 230 SET OF 3 SOFT JAWS

Set of soft jaws for 438060 and 438 070R with a serration of 1/16“x 90°


571320 3-JAW-CHUCK KNCS-NB 210/3 / A2-5 BB

WITH WIDE MASTER JAWS

SMW-AUTOBLOK® power chuck with quick change jaw system KNCS-NB-210-52-A05 (hydraulically operated). Through hole diameter 52 mm. Incl. 1 set of hardened base jaws GBKB 210 and hardened, reversible top jaws GUA 200, to mount on spindle nose A2-5 / M58x1,5 (DIN55026) with rotating thread ring incl. mounting key (nmax.: 5000 rpm)

SMW Id-No: 162672 571311 SET OF 3 HARD BASE JAWS

Set of hard base jaws type GBKB 210 for power chuck with quick change jaws SMW type KNCS-NB-210 and KNCS-NB-225

SMW Id-No: 138494 571270 SET OF 3 SOFT TOP JAWS

Set of soft top jaws type WAK 200-10 for power chuck with quick change jaws SMW type KNCS-N-210 and KNCS-NB-210/225

SMW Id-No: 012492




CLAMPING CHUCKS: COUNTER SPINDLE A2-4

433 710 POWER COLLET CHUCK 173E / A2-4

SMW- dead length collet chuck, complete with bayonet lock, for short taper A2-4 (DIN 55026), incl. mounting screws and draw tube adaptor, collets not included, Type KSZ-MB 40-A04 (nmax.:6000 rpm), clamping range: ø2-42 mm

Collets refer to >spec_collets_en.doc< 440 931 SPANNTOP-MINI - COMBI AXFIX

COLLET CHUCK (A2-4)

HAINBUCH collet chuck (dead-length style) size BZI 52 for spindle nose size A2-4, max. bar capacity ø32 (ø52) mm, incl. internal part-stop, collet changer 440 925 necessary, (nmax.: 7000 rpm), incl. draw adapter Advantage: No axial collet stroke and therefore no unfavorable tension between both spindles during take over!

586610 3- JAW-CHUCK BH-D 130/3 A2-4

SMW-AUTOBLOK® power chuck with through hole type BH-D 130-32-A04 (hydraulically operated). Through hole ø32mm, Incl. 1 set of soft jaws with a serration of 1/16“x 90°. To mount on spindle nose A2-4 / M44x1,5 (DIN55026) (nmax.: 7000 rpm)

SMW Id-Nr: 162700 586611 SET OF 3 SOFT JAWS

Set of soft jaws WBSA-D125 with a serration of 1/16“x 90° for power chuck SMW BH-D 130. Hole spacing: 16 mm Groove width: 12 mm

SMW Id-Nr: 12071300 586612 SET OF 3 HARD JAWS

Set of hard reversible jaws MHB-D130 for power chuck SMW BH-D 130. Hole spacing: 16 mm Groove width: 12 mm

SMW Id-Nr: 12081306


433 010 3 JAW CHUCK KFD-HS 130/3 – A2-4

RÖHM power-chuck KFD-HSø130/3 hydraulic operated, for high spindle speed (8000rpm) and with large through-hole (ø32), incl. 1 set of hardened reversible jaws with a serration of 1/16“x 90°, to mount on spindle nose size A2-4,


Set of reversible hard jaws for 433 010 with a serration of 1/16“x 90°

433 012 SET OF 3 SOFT JAWS

Set of soft jaws for 433 010 with a serration of 1/16“x 90°




TOOL HOLDER VDI30-AXIAL (DIN69880):

R6Z 850Z TOOL HOLDER PACKAGE – VDI30 STATIONARY TOOLS

Symbol photo !!

Tool holder package consisting of: 2x - RADIAL tool holder M4 (R3Z350) 1x - RADIAL tool holder M3 (R3Z360) 2x - Collet holder ESX 25 (W1Z480) 1x - Carbide insert drill holder ø25 (R3Z430) 1x - Boring bar holder ø16 (R3Z300W)

R6Z 860Z TOOL HOLDER PACKAGE – VDI30

STATIONARY AND DRIVEN TOOLS

Symbol photo !!

Tool holder package consisting of: 2x - RADIAL tool holder M4 (R3Z350) 1x - RADIAL tool holder M3 (R3Z360) 2x - Collet holder ESX 25 (W1Z480) 1x - Carbide insert drill holder ø25 (R3Z430) 1x - Boring bar holder ø16 (R3Z300W) 1x - Angular milling holder – 90° (R2Z780) 1x - Milling holder straight (440420W) 1x - Set of hand-tools

STATIONARY TOOLHOLDERS:

R3Z 350W RADIAL TOOL HOLDER M4

O.D. Turning tool holder VDI 30 for shanks

20x20

R3Z 360W RADIAL TOOL HOLDER M3

O.D. Turning tool holder VDI 30 for shanks

20x20, overhead (e.g. threading operation)

R3Z 370 AXIAL TOOL HOLDER M4

VDI 30 tool holder to be used for face grooving and face turning 20x20, M4 spindle direction

R3Z 380 AXIAL TOOL HOLDER M3

VDI 30 tool holder to be used for face grooving and face turning 20x20, M3 spindle direction

M4

M3

M4

M3


W1Z 480W COLLET HOLDER ESX 25

VDI30 tool holder for ESX 25 collets with a clamping range from ø 2-16mm and internal coolant supply.

R3Z 480 INDEXABLE DRILL HOLDER ø16

VDI 30 tool holder for indexable drills with a shank ø16mm and internal coolant supply.







R3Z 270 BORING BAR HOLDER ø8

VDI 30 tool holder for boring bars ø8mm and external coolant nozzle.





R3Z 300W BORING BAR HOLDER ø16




ESX 25

ø16

ø20

ø25

ø32

ø8

ø10

ø12

ø16

ø20






573 896 TAPPING HOLDER ESX 25

VDI 30 tool holder for tapping operation with length compensation Tap size:M4-M20

573 877 FLOATING REAMER HOLDER

VDI 30 tool holder for reaming operation with adjustable axially parallel compensation ESX 25

R3Z 220 OFFSET DRILL HOLDER

VDI 30 tool holder for drills clamped in reduction sleeves ø12mm (R3Z 250), 63mm offset to reach center with positioned tailstock.

R3Z 250 SET OF REDUCTION BUSHINGS

Set of 9 reduction sleeves (ø12mm) from ø2 to ø10mm

574 401 BAR-PULLER

Spring loaded 2-jaw bar-puller VDI 30 to work from bar stock without a bar-feeder. for bar diameters ø5-45mm.

574 402 BAR-PULLER

Spring loaded 2-jaw bar-puller VDI 30 to work from bar stock without a bar-feeder. for bar diameters ø10-63mm.

ø25

ø32

ESX 25

ESX 25

63

ø12


R3Z 890 BAR STOP

dampened bar stop ø20mm incl. VDI 30 holder, Note: important to use with „short bar loaders“

DRIVEN TOOL HOLDERS:

R2Z 780 RADIAL MILLING HOLDER – 90°

Used for drilling, milling and rigid tapping operation, ESX 25 collets, clamping range ø2-16mm, length 78mm , i=1:1 - VDI 30 Coupling DIN5480 (Alignment bolt distance: 40/48mm)

440 420W Drilling/Milling holder straight – 95mm

For drilling, milling and synchronized tapping at the main or counter spindle, ER 25 collets, external coolant supply Clamping range ø2-16mm, i=1:1, EK 95mm long - VDI 30


TOOL HOLDER VDI25-RADIAL (DIN69880):

442 511W Tool holder package MT 45 SM – VDI25

Tool holder package consisting of: Stationary tool holder: 3x Double Face and O.D. Turning holder (R2Z810W) 1x Cut-off holder M3 - M4 (R2Z452W) 2x I.D. Turning holder – left (R2Z330W) 2x I.D. Turning holder – right (R2Z350W) 3x I.D. Turning holder – universal (R2Z310W) 4x Collet holder ER25 (R6Z360W) 1x Reduction bushing (ø20mm) (442560W) 1x Reduction bushing (ø16mm) (442550W) 1x Reduction bushing (ø12mm) (442540W) Driven tool holder: 2x Drilling/Milling holder straight – 73mm (R2Z471W) 2x Double Angular Drilling/Milling holder (R2Z401W) 1x Set of hand-tools (446305)

TOOL HOLDER FOR O.D. MACHINING:

R2Z 415W Face and O.D. Turning holder - Universal

Single tool holder for machining at the main spindle or counter spindle. Shank 16 x 16 mm, Spindle direction M3 and M4 - VDI 25 (according to DIN 69880)

R2Z 410W Face and O.D. Turning holder M4 - left

Single tool holder for machining at the main spindle or between both spindles. Shank 16 x 16 mm, Spindle direction M4 - VDI 25 (according to DIN 69880)

R2Z 420W Face and O.D. Turning holder M3 - left

Single tool holder for machining at the main spindle or between both spindles. Shank 16 x 16 mm, Spindle direction M3 - VDI 25 (according to DIN 69880)


R2Z 230 RADIAL-TOOLHOLDER M4 RIGHT

Single tool holder to work at the counter spindle or between spindles. Shank 16x16mm M4 spindle direction -VDI 25 (According to DIN 69880)

R2Z 240 RADIAL-TOOLHOLDER M3 RIGHT

Single tool holder to work at the counter spindle or between spindles. Shank 16x16mm M3 spindle direction -VDI 25 (According to DIN 69880)

R2Z 810W Double Face and O.D. Turning holder

Double tool holder for machining on both spindles for shank 16 x 16 mm, Spindle direction M3/M4 - VDI 25 (according to DIN 69880)

442 770W Double facing and O.D. turning holder

offset in Y axes (VDI25)

4-fold tool holder for O.D. turning on main or counter spindle; Both spindle directions M3/M4 For square shank tooling 4x 16x16mm VDI 25

R2Z 430 Facing and I.D. Turning holder

Axial-tool holder for face machining at the main- or counter spindle for shank 16 x 16 mm, Spindle direction M3/M4 Inclusive EMCO adjustment plate – no alignment necessary !! - VDI 25 (according to DIN 69880)


R2Z 452W CUT-OFF HOLDER M3 - M4

VDI 25-Single tool holder for cut-off blades 26mm height , can be used for M3 or M4 spindle direction by changing set-up, following blades can be used: Sandvik No. 151.2-21-20 (2mm) No. 151.2-21-25 (2,5mm) No. 151.2-21-30 (3mm) No. 151.2-21-40 (4mm) Iscar: No. SGFH 26-1 (1,6mm) No. SGFH 26-2 (2,2mm) No. SGFH 26-3 (3mm) No. SGFH 26-4 (4mm)

TOOL HOLDER FOR I.D. TURNING – VDI25:

R2Z 310W I.D. Turning holder universal

For I.D. machining at the main or counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate – no alignment necessary !! 75mm long - VDI 25

R2Z 315W I.D. Turning holder universal - long

For I.D. machining at the main or counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate – no alignment necessary !! 85mm long - VDI 25

R2Z 330W I.D. Turning holder left

For I.D. machining at the main spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate – no alignment necessary !! 75mm long - VDI 25


R2Z 350W I.D. Turning holder right

For I.D. machining at the counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate – no alignment necessary !! 75mm long - VDI 25

R2Z 320W Double I.D. Turning holder

For I.D. machining at the main and counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate – no alignment necessary !! 75mm long - VDI 25

442 760W Multiple I.D. Turning holder offset in Y

axes (VDI25)

Multiple tool holder for I.D. machining on the main or counter spindle with internal coolant supply; For shank diameter: 4x ø25mm Inclusive EMCO adjustment plate – no alignment necessary !! 75mm long - VDI 25

R6Z 360W Collet holder ER25

Collet holder ø25mm for ER25 collets; Clamping range ø1-16mm

442 520W Reduction bushing ø8mm

Reduction bushing ø25mm for boring bars ø8mm.










R1Z 410 FLOATING REAMER HOLDER

For ESX 16 collets, clamping range ø1-10mm, internal coolant supply.

R6Z 890 BAR STOP

Special made dampened bar stop with a ø25mm shank to be used with an I.D. Tool holder.

DRIVEN TOOL HOLDER VDI25

R2Z 471W DRILLING/MILLING HOLDER STAIGHT – 73 mm

For drilling, milling and synchronized tapping at the main or counter spindle, ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max. 8000 rpm, external coolant supply, 73 mm long - VDI 25/coupling DIN 5480

WTO: 420125010-25

ø25

ESX 16

ø25


R2Z 491W DRILLING/MILLING HOLDER STAIGHT –

57,5 MM

For drilling, milling and synchronized tapping at the main or counter spindle, ER 20 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-13mm, max. 8000 rpm, external coolant supply, 57,5 mm long - VDI 25/coupling DIN 5480

WTO: 420120010-25 R2Z 461W ANGULAR DRILLING/MILLING HOLDER

– LEFT

For drilling, milling and synchronized tapping at the main spindle, Inclusive EMCO adjustment plate – no alignment necessary! ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max. 6000 rpm, external coolant supply, 75 mm long (total height: 106 mm!) Not useable for ET332! VDI 25 / coupling DIN 5480

WTO:420525015-25L R2Z 481W ANGULAR DRILLING/MILLING HOLDER

– RIGHT

For drilling, milling and synchronized tapping at the counter spindle, Inclusive EMCO adjustment plate – no alignment necessary! ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max. 6000 rpm, external coolant supply, 75 mm long (total height: 106 mm!) Not useable for ET332! VDI 25 / coupling DIN 5480

WTO: 420525015-25R R2Z 401W ANGULAR DRILLING/MILLING HOLDER

– DOUBLE

For drilling, milling and synchronized tapping at the main and counter spindle, Inclusive EMCO adjustment plate – no alignment necessary! ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max. 6000 rpm, external coolant supply, 75 mm long (total height: 106 mm!) Not useable for ET332! VDI 25 / coupling DIN 5480

WTO: 420525017-25 ADDITIONAL TOOL HOLDERS ON REQUEST !!


446305 SET OF SINGLE-HAND-WRENCH 25-25

Patented Single-hand-wrench size 25 for comfortable clamping and unclamping of Quick Flex-quick-change adaptors. Consisting of two wrenches.

446600 QUICKFLEX®-STARTERSET ER25 Quickflex® starter set size ER25 to be used for several drilling and milling tool holders from WTO, consisting of: Single-hand wrench; 107725000 Doppelschlüssel; 107525020 Clamping wrench ER25; 107525000 Weldon/Wistle-Notch-adaptor ø16mm;

320125016 Milling arbor holder Ø16mm; 320225016 Collet adaptor ER25; 320025016

446605 QUICKFLEX®-STARTERSET ER20 Quickflex® starter set size ER20 to be used for several drilling and milling tool holders from WTO, consisting of: Single-hand wrench; 107720000 Clamping wrench; 107520020 Jaw spanner size 30; 107520000 Weldon/Wistle-Notch-adaptor ø12mm;

320120012 Milling arbor holder Ø16mm; 320220016 Collet adaptor ER20; 320020013

ZETA Collet nut and spanner wrench:

442 410 COLLET NUT ER-25QF-A (WTO)

Collet nut ER-25QF-A short with external thread according to DIN6499. The ZETA®-Safety clamping system is a safe and trouble-free clamping system developed for machine tools.

WTO: 202125001


442 415 SPANNER WRENCH E 32 ZETA/ER25

Spanner wrench for collet nut ER-25QF-A short. The ZETA®-Safety clamping system is a safe and trouble-free clamping system developed for machine tools.

WTO: 107532101


MANUALS: EMCOTURN E45 (828D/0iTF) Standard-Languages: One set included – please confirm one of the standard languages for free.

DE 4047 E45 Instruction Manual / GERMAN Includes information how to install, operate,

maintain and program the machine. The control manuals are provides electronically on a CD-ROM due to environmental reasons.

EN 4047 E45 Instruction Manual / ENGLISH

Includes information how to install, operate, maintain and program the machine. The control manuals are provides electronically on a CD-ROM due to environmental reasons.

TA 4047 E45 Instruction Manual / ITALIAN Includes information how to install, operate,


Additional languages for extra costs:

FR 4047 E45 Instruction Manual / FRENCH


SP 4047 E45 Instruction Manual / SPANISH


SE 4047 E45 Instruction Manual / SCHWEDISH Includes information how to install, operate,


CZ 4047 E45 Instruction Manual / CZECH


DK 4047 E45 Instruction Manual / DANISH



NL 4047 E45 Instruction Manual / DUTCH


FI 4047 E45 Instruction Manual / FINNISH


HU 4047 E45 Instruction Manual / HUNGARIAN


PL 4047 E45 Instruction Manual / POLISH


PT 4047 E45 Instruction Manual / PORTUGUESE


RU 4047 E45 Instruction Manual / RUSSIAN


TR 4047 E45 Instruction Manual / TURKISH


CN 4047 E45 Instruction Manual / CHINESE-SIMPLE



ELECTRICAL DOCUMENTATION:

INCLUDED IN THE BASIC MACHINE!

PACKING FOR MACHINE:

ZVZ 342 741 STANDARD PACKING E45/MT25/MT45/HT45


ZVP 547 274 CLIMATE PACKING

E45/MT25/MT45/HT45

for transportation over-sea. Consisting of: pallet, dehumidifier, aluminium-cover and miscellaneous

ZVP 302 741 WOODENBOX E45/MT25/MT45/HT45

Additional protection for critical transportation

PACKING FOR MACHINE W/ SWING LOADER

ZVZ 343 223 STANDARD PACKING E45/MT45/HT45

WITH SWING LOADER


ZVP 547 322 CLIMATE PACKING E45/MT45/HT45

WITH SWING LOADER

for transportation over-sea. Consisting of: pallet, dehumidifier, aluminium-cover and miscellaneous

ZVP 303 223 WOODENBOX E45/MT45/HT45 WITH

SWING LOADER

Additional protection for critical transportation.


TECHNICAL DATA

Working range Swing over bed [mm] ø 430 Swing over cross slide (at Y=0) [mm] ø 300 Distance between centres (tailstock centre - spindle nose) [mm] 670 Distance between spindle noses f. counter spindle version [mm] 720 Max. turning diameter w/ axial turret (tailstock-version) [mm] ø 220 Max. turning diameter/ radial turret (counter sp. version) [mm] ø 300 Max. turning length [mm] 510 Max. bar work diameter (Option) [mm] ø 45 (51) Travel Travel in X [mm] 160 Travel in Z [mm] 510 Travel in Y [mm] +40 / -30 Main spindle (Spindle 1) Speed range (Option) [rpm] 0-6300 (5000) Max. torque (Option) [Nm] 78 (100) Spindle nose according to DIN 55026 A2-5 Spindle bearing inner diameter [mm] ø 80 Spindle bore diameter [mm] ø 53 (59) Max. chuck size [mm] ø 160 (175) Counter spindle (Spindle 2) Speed range [rpm] 0-6300 Max. torque [SIEMENS/FANUC] [Nm] 42 / 43 Spindle nose according to DIN 55026 A2-4 Spindle bearing inner diameter [mm] ø 70 Max. chuck size [mm] ø 130 C-axis ( main and counter spindle) Resolution [°] 0,001° Rapid speed [rpm] 1000 Drive power (max.) Main spindle @100/40% duty cycle [kW] 8/13 Counter spindle @100/40% duty cycle[SIEMENS/FANUC] [kW] 7/10 5,5/7,5 AXIAL tool turret / tailstock version Number of tool stations 12 Quick change tool shank according to DIN 55026 VDI 30 Tool shank size [mm] 20x20 Shank diameter for boring bars [mm] ø 32 Turret indexing time [sec] 0,14 Driven tools / coupling DIN5480 Speed range [rpm] 0-5000 Torque of driven tools (@ 20% duty cycle) [Nm] 16 Power of driven tools (@ 20% duty cycle) [kW] 4 Number of driven tools (coupling DIN 5480) 6 Max. duty cycle @ max. speed or max. power [%] 25


RADIAL tool turret / counter spindle version Number of tool stations 12 Quick change tool shank according to DIN 55026 VDI 25 Tool shank size [mm] 16x16 Shank diameter for boring bars [mm] ø 25 Turret indexing time [sec] 0,14 Driven tools Speed range [rpm] 0-6000 Torque of driven tools (@ 20% duty cycle) [Nm] 16 Power of driven tools (@ 20% duty cycle) [kW] 4 Number of driven tools (coupling DIN 5480) 12 Max. duty cycle @ max. speed or max. power [%] 25 Feed drives Rapid traverse speed in X / Y / Z [m/min] 24 / 10 / 30 Feed force in X-axis [N] 4000 Feed force in Y-axis [N] 4000 Feed force in Z-axis [N] 6000 Acceleration from 0 to rapid speed X / Z [m/s2] 6 / 8 Positioning variation Ps in X / Y / Z (VDI 3441) [µm] 3 / 3 / 3 Automatic tailstock Tailstock travel [mm] 510 Tailstock thrust [N] 6000 Tailstock travel speed [m/min] approx. 20 Tailstock bore taper MT 4 Coolant system Tank capacity [l] 250 Pump power @ 3,5 bar / (option 14bar) [kW] 0,57 / (2,2) Delivery @ 3,5bar/1,5bar [l/min] 15/65 Hydraulic unit Multi-circuit hydraulic system for power chuck Oil tank capacity [l] 11 Max. pressure for work holding [bar] 60 Pneumatic unit Air pressure required [bar] 6 Air volume required [l/min] 5 Quality according to DIN ISO 8573-1 Class 4 Lubrication system Guide ways and ball screw (featuring oil saver logic) autom. central oil

lubrication Main spindle, counter spindle (free of maintenance) Grease lubrication Chip conveyor 10-pin Harting plug is includes „Coolant Saver Logic“ software.


Parts-catcher Pneumatically operated [bar] 6 Max. finished part length [mm] 120 Max. finished part diameter [mm] ø 45 (51) Max. finished part weight [kg] 2,0 Painting Red RAL No. 3020 Light - Grey RAL No. 7035 Graphite - Grey RAL No. 7024 Black RAL No. 9004 Power supply Voltage [V] 3x400 / PE Max. voltage fluctuations [%] +/-10 Frequency [Hz] 50/60 Connected load value [kVA] 25 Min. main fuse for machine [A gG,gL] 50 Required short circuit power [kVA] 1100 Operable temperature range [°C] +10 to +35 Dimensions / weight Spindle height above floor [mm] 1100 Machine total height [mm] 1960 Floor space W x D (without chip conveyor) [mm] 2275×1760 Total weight of the machine with tailstock [kg] 3300 Total weight of the machine with counter spindle [kg] 4000 Sound intensity level Average sound emission level [db(A)] 78 According to the following conditions: Measuring method: enveloping surface according to DIN 45 635 Measured point: 1m distance and 1,6 m above the floor Operating mode: max. spindle speed w/ no load

SUBJECT TO TECHNICAL CHANGES!


CONTROL DESCRIPTION: FANUC serie 0 i CNC control / drives

Fanuc serie i CNC control incl. manual Guide i Dialog programming system. Continuous-path control with high sophisticated technology functions using digital drives for standard and complex machining, such as turning, milling, drilling, rigid tapping, polygon turning, ... High dynamical and precise digital drives (i-serie) offer functions such as:

Spindles with C-axis functionality Synchronous spindles Exact Stop and retract function High-speed process signals ...

Interpolation Linear interpolation (G00, G01) Multi-quadrant circular interpolation (G02,G03)

Thread functions Constant lead threading (G33) Multiple thread cutting (G33) Continuous thread cutting(G33) Thread cutting retract

Feed functions Feed mode in increments per minute (G94) Feed mode in increments per revolution (G95) Dwell (G04)

Reference function Reference position return (G28,G30, G53) Coordinate system Local workpiece coordinate system (G52)

Workpiece coordinate system (G53-G59) Workpiece coordinate system preset (G92) Coordinate system (work shift)

Values of coordinate and dimensions

Absolute programming (G90) Incremental programming (G91) Inch (G21) or metric (G20) mode Decimal point programming Diameter programming in X

Spindle functions C-axis contour control (angular programming) Constant surface speed control (G96) Direct spindle speed (G95) Spindle orientation

Tool functions Tool wear and geometry corrector Tool nose radius compensation (G40, G41, G42) Tool offset pairs – 64

Auxiliary functions Standard M-functions Number of miscellaneous M-codes – 4 pairs

Macro Macro B parametric programming


Program creation and edition Part program directory (number and name)

Sub-programs Program block search Extended part program editing function Background editing Registered program – 400 Part program storage - 512 KB

Canned cycles External / internal roughing cycle (G77) Thread cutting cycle (G78) Facing cycle (G79) Canned cycle for drilling (G80, G83, G85) Rigid tapping cycle (M29+G84)

Conversational programming MANUAL GUIDE i

Data in/out Key switch to protect data PCMCIA Interface (additional memory space for

program data) Serial interface RS232

Display FANUC LCD colour display 15“

Displayed data Axes positioning Spindle speed Feedrate display Programmed codes display (T,S,M,F) Modale G codes Parts counter Run hour display Clock

Input increments 0,001mm (0,00001inch) or 0,001°

Override Spindle speed : 50% to 120% Feed rate: 0% to 120% Rapid speed: 0% to 120%

Feedrate range 0,001mm/rev to rapid traverse rate

Manual operations Electronic handwheel (MPG) – optional Manual continuous feed - JOG Feedrate override Spindle override

Execution operations Manual Data Input operation – MDI Automatic Single block Program stop (M00) Optional program stop (M01) Block delete - SKIP Program restart DRY RUN

Alarm and diagnostic functions Emergency functions Alarm messages Alarm history display Operation history display Maintenance history display Help screen Diagnostic screen


Polygonal turning Due to the synchronisation of the main spindle with the driven

tool spindle, the machine is capable to machine flats (square, hexagon,...) on the workpiece very efficient.

Limit stop switch Software limit switches on any linear axis

Work area limitation Adjustable for the operator

Spindle pitch compensation Available for any linear axes

Back-Lash compensation Available for any linear axes

Control language Language reversible (German or. English)

German English French Italian Spanish

MANUAL GUIDE

MANUAL GUIDE i is the operation guidance to support an operator on many situations such as creating a part program, checking by machining simulation, set-up and actual machining. These operations can be done on the only one screen. ISO code form is adopted as the part program format, it is widely used on many CNC machine tools, furthermore, machining cycles, which can realize complicated machining motions by simple programming, are provided. Stock removal cycle With the „Stock removal“ cycle, a contour programmed can be produced from a blank by means of paraxial stock removal. The contour can include relief-cut elements. The technology (roughing/finishing/complete machining) is selectable. The cycle can be called from any collision-free position.

Thread cutting cycle With the „Thread cutting“ cycle you can machine cylindrical and tapered outside and inside threads with constant lead in longitudinal or face machining. Both single threads and multiple threads can be cut. In multiple thread cutting, the threads are cut one after the other. Infeed is automatic. You can select either constant infeed per cut or constant cross-section of cut. A right-hand thread is determined be the spindle direction. Feedrate and spindle override both have no effect in thread travel blocks. Grooving cycle The grooving cycle allows symmetrical recesses to be produced for longitudinal and facing operations on any straight contour elements. Outside and inside recesses can be made.


Drilling cycle The tool drills at the programmed spindle speed and feedrate to the programmed final drilling depth. Deep hole drilling is performed with a depth infeed of a maximum definable depth executed several times, increasing gradually until the final drilling depth is reached. The drill can either be retracted to the reference plane+safety distance after every infeed depth for swarf removal or retracted in each case by 1mm for chip breaking.

Rigid tapping The tool drills at a programmed spindle speed and feedrate to the programmed thread depth. With this CYCLE84 you can perform rigid tapping operations. No special holder with an integrated length compensation is needed.

Reaming cycle This cycle can be used to ream axial or radial holes.

Milling cycles A wide range of milling cycles can be used for milling operations. This ensure easy programming at the machine and a quick set-up for the production.

Graphical simulation

Fast and realistic simulation incl. Animation. Raw part and machining process is shown in 3D graphics.


CONTROL DESCRIPTION: SIEMENS 828D

CNC control / drives 828D SolutionLine, Sinamics S120

High performance CNC control for ultimate accuracy and machining speed. SINUMERIK 828D and SINAMICS drive and motors are perfectly tailored for state of the art turning machines. Powerful CNC-functions combined with a unique 80bit NANOFP Accuracy (80 bit floating point accuracy from the position control to the internal encoder resolution) enable highest work-piece accuracy at a minimum of machining time. With a flexible CNC programming language and the state of the art ShopTurn machining step programming, single parts as well as large batch series can be programmed and machined with maximum effectiveness. Due to powerful kinematic transformations and a large set of technological cycles, SINUMERIK 828D also meets the demands of high sophisticated machine applications with driven tools and sub-spindle.

Highlights

Modern, colorful and clear user surface Technology overlapping programming (turning, milling,

drilling, tapping,...) Contextual help function and support 3D Graphics and 3D simulation Animated support graphics Simple programming via ProgramGUIDE Calculator function Program preview, USB-port, etc.

Data in/out Via CNC full keyboard at the operator panel, USB-PORT and Ethernet.

Programming SINUMERIK G-code programming with high-level language commands for flexible programming of medium and large batch work-pieces

programGUIDE: technology cycle support for SINUMERIK G-code programs

ShopMill machining step programming for efficient programming of single and small batch work-pieces (CNC option)

Built-in ISO code interpreter Program manager with readable part program names Program manager with full access to all media devices

Display operator panel incl. 10,4“ TFT- colour monitor

Buffered CNC memory 3 MB

Minimum block cycle time 6 ms Max. no. of tools/cutting edges 128/256

Program storage Work piece / part program / sub program directories with alpha-numeric character (max. 24) are used for user friendly and transparent handling.

Sub-program maximum 8 subroutine levels,

Math. calculation functions +,-,,, cos, sin, tan, e-function, In, =, >,<,, etc. System of units Metric or inch (reversible)

Smallest increment unit 0,001mm (0,00001inch) or 0,001°

Input dimension incremental or absolute dimension

Feedrate One to one in mm/rev or mm/min


Override Spindle override: 50% to 120% Feed override: 0% to 120% Rapid override: 0% to 120%

Feedrate range 0,001mm/rev to rapid traverse rate

Threading operation Longitudinal, transversal or tapered with constant or linear in/decreasing lead, single or multiple threads with angular approach or run-out path.

Synchronous tapping Taps can be machined with any spindle without compensation holder. Speed and feedrate is fully synchronised.

Work shift Adjustable or programmable via FRAMES (TRANS,ROT, MIRROR,SCALE)

Spindle speed Input in rpm or V-const. m/min

Spindle speed limitation Adjustable or programmable

Coordinate system Cartesian or polar coordinates and cylinder-coordinates

Tool data Tool offset selection via T- and D-number (PowerMill: „Random access“ tool management for the tool changer, tool life management,... )

Cutter radius compensation Programmable via G40,G41,G42

Real-time clock Time is still set after the machine is switched off.

Machining time The time between cycle start and end of program (M30) is shown on the control. Machining segments can be timed individually.

Limit stop switch 2 Software limit switches on any axis

Work area limitation Adjustable for the operator

Spindle pitch compensation Available for any axes

Back-Lash compensation Available for any axes

Cylinder interpolation Simplified due to TRACYL (X/Y/Z)

Face side interpolation Simplified due to TRANSMIT function - (X/Y/Z))

Helical interpolation Enables internal and external thread milling.

Program simulation

Graphical CNC simulation in 3D rendering and also in the planes

Block search Program number, line number and target position can be searched.

Dry-run Used to test the program without spindle rotation and coolant. The feed override controls any axis movement.

Access protection Several programs, tool data, work shifts, etc. can be locked via a key switch.

Back-ground editing Programs can be written and edited while the machine is in production.

Machining from external Programs can be loaded and executed via a network or USB-Port.

Diagnose function Continuous condition monitoring due to the integrated diagnose system. Alarms are display in plain text format.

Program coordination Programs can be synchronized by using WAITMARKS.

Operating modes

JOG AUTOMATIC MDA – Manual Data Automatic REPOS REFERENCE


ProgramGUIDE and ShopTurn cylces

Contour calculator

Free contour programming; An integrated contour calculator calculates any missing parameter for you, provided that they can be computed from other parameters. You can chain a maximum of 50 contour elements. Contour transition elements “radius and chamfer” are also provided to help you chain contour elements. The programmed contours are transferred to the edited parts program.

Machining cycles

Stock removal cycle With the „Stock removal“ cycle, a contour programmed in a subroutine can be produced from a blank by means of paraxial stock removal. The contour can include relief-cut elements. The technology (roughing/finishing/complete machining) is selectable. The cycle can be called from any collision-free position.

Grooving cycle The grooving cycle allows symmetrical and asymmetrical recesses to be produced for longitudinal and facing operations on any straight contour elements. Outside and inside recesses can be made.

Undercut cycle With this cycle, undercuts to DIN509 of forms E and F can be produced with usual loading for a finished part diameter > 3mm.

Thread cutting cycle With the „Thread cutting“ cycle you can machine cylindrical and tapered outside and inside threads with constant lead in longitudinal or face machining. Both single threads and multiple threads can be cut. In multiple thread cutting, the threads are cut one after the other. Infeed is automatic. You can select either constant infeed per cut or constant cross-section of cut. A right-hand thread is determined be the spindle direction. Feedrate and spindle override both have no effect in thread travel blocks.


Drilling cycle The tool drills at the programmed spindle speed and feedrate to the programmed final drilling depth. Deep hole drilling is performed with a depth infeed of a maximum definable depth executed several times, increasing gradually until the final drilling depth is reached. The drill can either be retracted to the reference plane+safety distance after every infeed depth for swarf removal or retracted in each case by 1mm for chip breaking.

Rigid tapping The tool drills at a programmed spindle speed and feedrate to the programmed thread depth. With this CYCLE84 you can perform rigid tapping operations. No special holder with an integrated length compensation is needed.

Tap drill-milling cycle With a special tap-drill the core hole of the thread can be drilled and the thread milled right after.

Milling cycles A wide range of milling cycles can be used for milling operations. This ensures easy programming at the machine and a quick set-up for the production.

Engraving cycle Allows to engrave text along a line or an arc. The text can be fixed or variable. E.g. date, clock time, part number, etc. can be written on the part.

Simulation

Simulation 2D-simulation of tool path 3D-simulation of finished part and tool path Calculation of cutting time Background editing while the machine is running

SUBJECT TO TECHNICAL CHANGES!

Documents

TECHNICAL SPECIFICATION EMCOTURN E 45 · technical specification emcoturn e 45 with sinumerik 828d or fanuc serie 0i tf or ... 3-axes cnc-lathe with counter spindle, driven tools,