Large-Part Machining
Using special tooling developed by Boehlerit (Kapfenberg, Aus- tria) that is capable of maximum cutting depth of 200 mm with a cutting width of 36 mm, machining time including deburring was done in less than 60 hours. To facilitate machining, the mpmc 1200 is equipped with an opposed spindle with an ad- ditional integrated measuring system. This measuring capability is important because the slots are always machined in a con- tinuous flow and the angular position from the initial position to the end position must not differ by more than a few microns.
The process of cutting slots in rotors weighing up to 32 t was slashed to a total of 60 hours using the mpmc 1200 multi-product machining center from Weingärtner Mas- chinenbau (Kirchham, Austria).
Considering the weight of the workpiece and the require- ment for micron-like accuracy placed special demands on the clamping and mounting of workpieces. According to Weingärtner, commercially available steadyrests are simply not adequate for workpiece weights up to 60 t. So its design engineers developed freely programmable steadyrests with four CNC axes (X1/X2/Y/Z) that can handle workpieces from 100 mm to 1.2 m in diameter with micron accuracy. Freely programmable means in this case that adjustment options for concentricity, depth, height, and length can be made to handle up to 10,000 kg in contrast to the usually available devices which are designed for a maximum of 5 t.
Global Accounts Consider All Possible Solutions Detlef Streichert is global key account manager for DMG Mori (Hoffman Estates, IL) and, as such, works with custom- ers in energy-related oil and gas, aerospace, construction and machinery equipment industries. “With about 300 different machine tools, we can provide multiple possible solutions with different approaches to large-part machining with five-axis and
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five-side machining capability. It doesn’t matter if the customer prefers a vertical or a horizontal machining approach. All of our machines are modular in construction so that we can use a ver- tical machining center with a B axis and a table weight capacity from 1.5 to 10 t, or in the horizontal type of arena, a swivel head for universal five-axis machining capability,” said Streichert. “Using conventional five-axis machine tools, we are taking gear machining out of its specialized niche and handling gear machining with standard machine tools, very smart program- ming systems, and new approaches to standard disk-cutting tools,” said Strichert. “We have worked with Sandvik Coro- mant to develop and use standard disk cutters with inclined forms to machine the involute shape of the gear. With our soft- ware on board, we can create the entire machining process, according to the original print part, and the user can choose between different machining approaches. You can imagine when you talk about gears that were created on a blueprint 30 years ago that not every user, particularly the smaller users, has the luxury of very complex programming systems. So we developed the software for gear machining and involute ma- chining to create the gear shape or create the gear program. We just put in the standard drawing dimensions and then the programmer can create and get the result for any size gears. This is of great benefit to users who can replace the large inventory of special tooling with just three different standard disk cutters. In addition we can put a CBN grinding wheel into our machine tools to finish the gear,” said Streichert. ME
Want More Information? DMG Mori
Ph: 847-593-5400 Web site:
www.dmgmoriseikiusa.com
Fives Giddings & Lewis Ph: 920-921-9400
Web site:
www.fivesmsi.com Mazak Corp.
Ph: 859-342-1700 Web site:
www.mazakusa.com
SB Machine Tools Ph: 847-882-9600
Web site:
www.sbmachinetools.com
Weingärtner Maschinenbau email:
usa@weingartner.com Web site:
www.weingartner.com
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