HYPERTURN 65 Powermill – For Increased Productivity in Complex Complete Machining

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2020-02-04 12:11:00

More clearance, more power, more possibilities: With a spindle distance of 1400 mm, a powerful counter spindle allowing for 4-axis machining, a B-axis with direct drive for simultaneous 5-axis milling operations on complex parts, an additional Y-axis for the lower turret and all of the tried and tested characteristics found in the Hyperturn series, the powerful Hyperturn 65 Powermill is the ideal complement for your machine tool.
 

HALLEIN – The Hyperturn series has been designed to achieve further productivity increases in series production. Complex and sophisticated turning, drilling, milling and gear cutting operations can be carried out in only one work process; there is no need for re-clamping or temporary storage. The workpiece precision has been enormously improved, whereas it is possible to reduce the overall production times, the space requirements, the tooling expenses and the personnel costs to a significant extent.
In contrast to comparable models, the Hyperturn 65 Powermill features a spindle distance of 1400 mm, which results in significantly more space for simultaneous machining on the main and counter spindle. With 29 kW and 250 Nm on the main and counter spindle, the machine has enough power to machine one workpiece simultaneously with two tools. This so-called “4-axis machining” is another advantage when it comes to increased productivity. Another “top performer” is the milling spindle. With 22 kW, 60 Nm and 12000 rpm, it stands for high productivity in the complete machining of complex workpieces. Thanks to its directly driven B-axis, the Hyperturn 65 PM achieves high dynamics and contour accuracy in simultaneous 5-axis machining. The non-productive times related to tool changes are reduced as well. Thanks to the additional Y-axis on the lower turret, it is possible to perform comprehensive milling operations in parallel with the milling spindle's machining operations.

The 40-, 80- or 120-station tool magazines with HSK-T63 offer more options for complex complete machining ? with low set-up requirements in the manufacture of individual parts and high stability in turning and milling operations. The integrated tool magazine does not need to be disassembled for transport purposes, which results in shorter commissioning times and reduced transport costs. The frontal arrangement simplifies the set-up process and ensures ergonomic working conditions.

A new generation of tool turrets with BMT interface and direct drive offers increased stability and precision. The performance data, which are similar to those of a milling machine, allow for the complete machining of turned and milled parts.

With automatic bar machining and/or piece goods loading using a robot solution or an EMCO gantry loader, the potentials for increased efficiency in automation can be exploited very well.

A machine tool's performance is not only determined by its mechanical and electrical performance values. In this regard, both the control technology and the software are becoming increasingly important as well. That is why EMCO equips the Hyperturn with the SINUMERIK 840D SL control by Siemens. The new user interface allows for intuitive and thus significantly easier machine programming.

EMCONNECT, the new assistant for control and production processes, is included in the machine's standard equipment. EMCONNECT is a digital process assistant for the comprehensive integration of customer- and system-specific applications for controlling the machine and the production flow. As the operating sequences focus on the user and their requirements, it is possible to create more efficient work processes without losing sight of the machines' outstanding reliability in all operating modes.

When it comes to achieving increased productivity, it is crucial to utilise the machine to the maximum extent possible. With EMCO's CPS Pilot, customers save time and money on their machining projects, because they can use this software to plan, programme, simulate and optimise the production process with a 3-D picture of the machine displayed on their PC. By combining the HYPERTURN with the new EMCO CPS Pilot, it is possible to create extremely positive multiplier effects: the perfect interplay between CPS Pilot and HYPERTURN results in significantly reduced costs and efforts.

The HYPERTURN 65 Powermill is particularly interesting for the serial production of workpieces, e.g. in the automotive, aircraft and engineering industries or the area of fastening technology.
A new machine design reinforces the EMCO brand: The repositioning of the brand – which is also reflected in the claim and commitment “beyond standard” – is now also being implemented in the machine design. As central brand ambassadors, the machines now feature a new look, a look that constitutes a functional and visual upgrade. This upgrade is reflected in a variety of design changes: In order to ensure efficient processes, user-friendliness and a clear arrangement, the machines' main interaction areas (such as the work area) have been highlighted in both colour and shape. The operating panel comes with homogeneous aluminium surfaces, ergonomically adjustable controls and an intuitive user interface. The housing features a reduced and precise design. Clean contours and precise joint patterns convey superior product quality. The recognition value of the technically sophisticated and ergonomic machines is fully guaranteed by the new design of the EMCO product family.

Technical Details / The HYPERTURN Machine Concept

Construction
The machine bed constitutes the core of the HYPERTURN. The extremely rigid and compact welded steel construction is filled with a special, vibration-absorbing concrete material (HYDROPOL®). Additional reinforcements enhance the rigidity in more highly stressed areas. Thus, it is possible to use the high drive power of the main, counter or milling spindle without any restrictions. The result: better surface qualities, narrower production tolerances and longer tool lives.

Main Spindle and Drive Technology
The main spindle is available in two sizes. The standard bar capacity is 65 mm. It provides a maximum output of 29 kW at a torque of up to 290 Nm. A SuperBigBore spindle (102 mm) is available as an option. Resting on large precision bearings, the built-in, highly dynamic spindle motors (ISM) allow for a very wide speed range teamed with excellent smooth running characteristics. Thermostability is achieved with a symmetrically designed headstock, temperature sensors on the bearing points and liquid cooling.

All linear movements occur on pre-tensioned, highly precise roller guides. The result: crucial advantages with regard to traverse speeds, zero backlash, service life, lubricant quantities and positioning accuracy.

Thanks to the unique sealing system on the guide shoe, there is nothing that speaks against using the machine in heavily soiled environments. In order to achieve a closed sealing surface, the guide rails are additionally protected with spring steel cover plates.

C-Axis
From a technological point of view, each spindle is also an axis. It can be moved into any position with a defined feed rate. Complex contours on the periphery or even on the front surface are thus easily feasible. The software for programming these movements (cylinder interpolation and/or TRANSMIT) is included in the scope of supply. Synchronised thread cutting and polygonal turning are included in the standard equipment.

“Powermill” Turning/Milling Spindle
The powerful milling spindle with HSK-T63 tool interface can be used for turning, drilling and milling operations. The milling spindle is infinitely rotatable by ± 120° and can be clamped in any position. With a usable Y-stroke of +120/-120 mm, it is possible to perform even the most complex machining processes, such as gear cutting operations, turning/milling of crankpins, 5-axis machining and much more. Depending on the customer's wishes, the tools will be provided by a 40-station pick-up magazine or by an 80- and/or 120-station chain magazine.

Workroom
The workroom guarantees superior ergonomics, i.e. it offers excellent access to the individual components. Large clearances ensure an ideal chip flow, also when critical materials are being machined. To prevent damages, all guides are covered with stainless steel.

Machine Cladding – New Design
The cladding of the Hyperturn 65 PM offers comprehensive protection against flying chips. It is 100% coolant-tight. A large safety glass door offers an unobstructed view into the workroom. The ergonomically arranged operating panel can be moved horizontally towards the centre of the machine door. The brand-new control panel is vertically adjustable by 90° and within 200 mm.

Control
Equipped with a Sinumerik 840D sl, the Hyperturn comes with one of the most advanced control units available on the market. The fully digital drive and control package handles up to 10 channels and up to 31 axes. ShopTurn/Mill and technology cycles simplify both turning and milling operations. Coordinate transformations (TRANS, ROT, SCALE, MIRROR) make it possible to realise any machining process. Complex machining requirements can be quickly implemented. The Sinumerik 840D sl is reflected in the high precision of each workpiece. The alphanumeric keyboard simplifies programming.

Technical Key Data:

Machine Versions:

- HYPERTURN 65 PM – SYB: with main and counter spindles, milling spindle, B- and Y-axes and 40-tool station magazine

- HYPERTURN 65 PM – SMYB: with main and counter spindles, lower tool system including direct drive for milling, milling spindle, B- and Y-axis and 40-tool station magazine

• Follow @CNCTimes