Manufacturers’ precision, surface finish and autonomy reach new levels with GF Machining Solutions’ Mikron MILL P 500 U and MILL P 800 U and the scalable System 3R TRANSFORMER Automation solution with a six-axis FANUC robot or integrated pallet magazines for from five to 12 pallets, as demonstrated at GF Solutions Days, April 17–19, in Schorndorf, Germany.
With their powerful and dynamic material removal capabilities and high stiffness, the Mikron MILL P 500 U and MILL P 800 U enable continuous machining of complex shapes and tough materials while shortening process time. Their advanced thermal stability ensures reliable precision over long machining periods. Furthermore, they deliver exceptional competitiveness by integrating smart Automation and ensure the process reliability essential to precision parts manufacturing segments such as aerospace and machinery parts as well as automotive mold making.
±2 μm precision in X/Y plane
With the Mikron MILL P 500 U and MILL P 800 U, manufacturers of precision parts and molds experience top accuracy and uncompromising process reliability, thanks to the machines’ thermostability and symmetrical design. Even when machining at a fast pace and over long production periods, accuracy and process reliability remain steadfast, so users achieve consistent dimensional precision and 24/7 process reliability.
365 days per year flexibility
Thanks to the Mikron MILL P 500 U’s and MILL P 800 U’s 1.7 g acceleration, 36 kW Step-Tec HPC190 Spindle with a large speed range up to 20,000 rpm, and rotary tilting table capacity of up to 800 kg and workpiece diameters up to 860 mm, manufacturers experience constant dynamic machining as well as 100 percent flexibility in their part production.
The rotary tilting table of the Mikron MILL P 500 U is available in several variations: T-slot and pallet tables accommodating payloads of 200 kg, 400 kg or 600 kg. Incremental, direct angle measuring systems are directly mounted on the swiveling and circular axes to guarantee very high positioning and repeatable accuracy.
Out of these machines’ two tool Spindle choices, Step-Tec’s 20,000 rpm HPC190 with HSK-A63 tool interface is manufacturers’ first choice. This platform Spindle robustly and reliably delivers repeatable accuracy. Its carbon fiber mantle defeats deviations in accuracy related to hot spots and thermal tilt, and the carbon fiber acts as a heat barrier to ensure that the heat is taken out of the Spindle. Moreover, the outer sleeve’s carbon fiber reduces Spindle weight by 6 percent, significantly increasing linear drive dynamics while reducing oscillation in the vertical axis. For the MILL P 800 U, a Step-Tec CoolCore Spindle with 28,000 rpm is also available. This Spindle is dedicated to high-end precision jobs and delivers repeatable accuracy.
For precision parts machining as well as for mold and die, the lighter but still powerful 36,000 rpm Step-Tec HVC150 Spindle with HSK-E50 tool interface supersedes its predecessor. An all-aluminum integral structural part on the rear end reduces the Spindle weight by 17 percent, making it a great choice in power-to-weight ratio. In addition, Step-Tec’s well-proven OptiCool Principle (OCS) delivers excellent polar thermal stability which is ideal for precision machining but also offers best surface finish for mold and die components. Both Spindles feature integrated sensors for total process control such as vibration monitoring along with many other Spindle parameters.
250 percent higher productivity with integrated automation
Precision parts producers and mold makers can more than double productivity with the 12-square-meter Mikron MILL P 500 U’s and MILL P 800 U’s accommodation of limitless integrable Automation solutions through the back.
For example, a scalable System 3R TRANSFORMER Automation solution with a six-axis FANUC robot can be added to the Mikron MILL P 500 U to advance productivity, flexibility and autonomy. Both stationary and rail versions of System 3R Automation solutions with FANUC industrial robots are available. Customizable to users’ needs, these solutions cover a wide range of applications and requirements, from 70–600 kg transfer weight and up to 3,400 mm radial reach to complex transfer movements and parts handling.
The direct benefit of the System 3R TRANSFORMER with a six-axis FANUC robot is cost-effective yet flexible Automation through state-of-the-art technology and smart technical solutions using standardized modules. Moreover, with System 3R’s user-friendly WorkShopManager cell management software, complex Automation is made easy to use.
MSP: full production within 10 minutes of a crash
Mikron MILL P 500 U and MILL P 800 U users pare their downtime from hours to mere minutes, thanks to GF Machining Solutions’ Industry 4.0-supporting smart modules such as Machine Spindle Protection (MSP). MSP prevents Spindle breakdowns while protecting the machine geometry and maximizing machine uptime to reduce costs associated with unexpected Spindle collisions. MSP makes it possible to absorb axial and lateral collisions and then restore perfect accuracy: The Spindle returns to normal operations without any specific maintenance or recalibration, ensuring almost no downtime or collision-related costs.
Source:GF Machining Solutions
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