High Performance 5-Axis Machining Center ECOSPEED ...
High Performance 5-Axis Machining Center ECOSPEED ...
High Performance 5-Axis Machining Center ECOSPEED ...
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Products:<br />
Dörries<br />
Vertical Turning Machines<br />
Vertical <strong>Machining</strong> <strong>Center</strong>s<br />
Droop+Rein<br />
Portal <strong>Machining</strong> <strong>Center</strong>s<br />
<strong>High</strong> Speed <strong>Machining</strong> <strong>Center</strong>s<br />
Scharmann<br />
Horizontal <strong>Machining</strong> <strong>Center</strong>s<br />
Boring Mills<br />
Mecof<br />
Horizontal and Vertical <strong>High</strong> Speed Milling <strong>Center</strong>s<br />
Berthiez<br />
Vertical Turning Machines<br />
Vertical Grinding Machines<br />
DS Aircraft<br />
<strong>Machining</strong> <strong>Center</strong>s<br />
Service<br />
Headquarters:<br />
Dörries Scharmann Technologie GmbH<br />
Hugo-Junkers-Straße 12-32<br />
D-41236 Mönchengladbach-Rheydt<br />
Tel. +49/2166/454-0<br />
Fax +49/2166/454-300<br />
www.ds-technologie.de<br />
information@ds-technologie.de<br />
Sites, Subsidiaries and Service <strong>Center</strong>s:<br />
Dörries Scharmann Technologie GmbH<br />
Product line Droop+Rein<br />
Hofkamp 2, D-33719 Bielefeld<br />
Tel. +49/521/5804-0, Fax +49/521/178006<br />
Dörries Scharmann Technologie Service <strong>Center</strong><br />
GmbH & Co. KG<br />
Am Sülzenbrückener Weg 14, D-99334 Ichtershausen<br />
Tel. +49/36202/77980, Fax +49/36202/779829<br />
Dörries Scharmann Technologie GmbH<br />
Service <strong>Center</strong> South<br />
Wannetal 47b, D-88131 Lindau<br />
Tel. +49/2166/454-700, Fax +49/2166/454-701<br />
Dörries Scharmann Technologie GmbH<br />
Beijing Office<br />
Room 704, Kun Tai Building, No. 10 Chao Wai Da Jie,<br />
Chaoyang District, 100020 Beijing, PR China<br />
Tel. +86/10/65995556, Fax +86/10/65995559<br />
Dörries Scharmann Technologie GmbH<br />
Moscow Office<br />
ul. Tverskaya 16/2, Building 1, 7. Floor, RUS-125009 Moscow<br />
Tel. +7/495/737-4981, Fax +7/495/737-6588<br />
DS Technology (USA), Inc.<br />
7861 Palace Drive, Cincinnati, OH 45249, USA<br />
Tel. +1/513/247-2590, Fax +1/513/247-2599<br />
DS Technology (UK) Ltd.<br />
43/45 Phoenix Park, Avenue Close, Nechells,<br />
Birmingham B7 4NU, United Kingdom<br />
Tel. +44/121/3593637, Fax +44/121/3591868<br />
Berthiez SAS<br />
5, rue Barrouin, F-42029 St. Etienne Cédex 1<br />
Tel. +33/4/77923992, Fax +33/4/77923993<br />
www.berthiez.fr, sales@berthiez.fr<br />
Mecof Srl<br />
Via Molino 2, I-15070 Belforte Monferrato, AL<br />
Tel. +39/0143/8201, Fax +39/0143/823088<br />
www.mecof.it, info@mecof.it<br />
06.2009 - 1.000 E - 09-908b<br />
<strong>High</strong> <strong>Performance</strong><br />
5-<strong>Axis</strong> <strong>Machining</strong> <strong>Center</strong><br />
<strong>ECOSPEED</strong>, <strong>ECOSPEED</strong> F<br />
Dörries Scharmann
2 3<br />
Wing and body components for<br />
civil and military aircraft<br />
is it your<br />
business?<br />
vertical beam<br />
The ultimate goal of the industry is to pro-<br />
duce ever more increasing lighter weight<br />
structural parts with increasing inherent<br />
strength. Previous methods of joining a<br />
number of profiled parts together, has largely<br />
been replaced by machining larger structures<br />
from aluminium billets. Thinner wall sections<br />
and more complex contours in five axis pro-<br />
vide for this possibility to decrease weight<br />
and increase strength.<br />
It is inevitable that as designers make more<br />
use of the modern 3D CAD tools 5 axis<br />
applications will increase.<br />
To achieve this goal the only real solution<br />
can be provided by high speed machining<br />
where the distortion forces of the tool on<br />
the component are largely eliminated.<br />
This in turn means that a much higher accu-<br />
racy and higher surface quality is demanded<br />
not only from the linear axis but also from<br />
the rotary axis.<br />
To meet these demands the machine’s linear<br />
axis, has to provide a highly dynamic extre-<br />
mely stiff construction.<br />
In the case of complex contours and radii<br />
this can not be provided by the conventional<br />
rotary drives of Fork or Swivel heads.<br />
Typical wing and<br />
body components<br />
from billet or plate<br />
If you are using<br />
these solutions<br />
then its likely you<br />
are not very close at<br />
all.<br />
20 years and<br />
180 rotary axis type<br />
heads shows us that<br />
these head types are<br />
not a high speed<br />
solution.<br />
How close can you get to the …<br />
…digital<br />
standard?<br />
The typical gantry type profiler as designed<br />
in the 1970’s has largely remained unchan-<br />
ged until today. The high mass of the bridge<br />
or cross rail renders it totally unsuitable for<br />
any high speed process.<br />
The Fork Head with its open design concept<br />
lacks the stiffness required coupled with<br />
rotational bearings, a relatively long swivel<br />
length and mechanical geometric alignment<br />
makes it unsuitable for real accurate high<br />
speed application.<br />
Required rotational speed of the C-<strong>Axis</strong> at a 6° angle<br />
speed C-<strong>Axis</strong> [rpm]<br />
800<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
0<br />
40<br />
20<br />
feed [m/min]<br />
0<br />
100<br />
The Swivel Head with its closed design is a<br />
much more stiff solution and goes some way<br />
in the trend of high speed machining but still<br />
suffers from some of the previously menti-<br />
oned difficulties, it is however, also suited<br />
for the machining of titanium and steel.<br />
80<br />
40<br />
60<br />
radius [mm]<br />
20<br />
0<br />
Fork Head<br />
Swivel Head<br />
Fork and Swivel Head - Disadvantages:<br />
Positioning velocity, Angular acceleration,<br />
Weight, Stiffness, Accuracy, Swivel length,<br />
Geometric alignment, Complexity, Slip Rings,<br />
Rotary couplings
4<br />
The KEY - Elimination of rotary<br />
axis<br />
5<br />
A new generation completely<br />
optimised by FEA<br />
A new approach…<br />
…for real<br />
Production gains<br />
With the aforementioned in mind Dörries<br />
Scharmann Technologie has developed a<br />
3 axis head concept of extremely stiff design<br />
that takes account of all of the previous<br />
mentioned difficulties to meet the highly<br />
accurate contouring and radii requirements<br />
including the higher surface quality demands,<br />
by eliminating the need for rotary motions.<br />
n Offers possible platform orientations up<br />
to +/- 40° within a Z-stroke up to 370 mm<br />
n Offers angular velocities and accelerations<br />
of the platform of 15 U/min and 685°/s2 n Positioning speed of 80°/sec around the<br />
tool tip is available in every space angle<br />
n Has a low mass, which leads to lower<br />
acceleration forces in X-and Y-directions<br />
n Offers a max. Z-stroke of 670 mm<br />
Continuous motion<br />
through standard<br />
elements<br />
WHY THE NEED<br />
n Efficiency is the most critical and important<br />
driver in manufacturing industry today. As<br />
business becomes evermore competitive and<br />
cost conscious, the factor of efficiency will<br />
become increasingly critical.<br />
n <strong>ECOSPEED</strong> was specifically designed,<br />
exclusively for the purpose of high speed<br />
machining of structural aircraft components<br />
from aluminium alloy plate or billet type<br />
materials.<br />
n <strong>ECOSPEED</strong> was specifically designed to use<br />
conventional well proven machine tool<br />
technology.<br />
n <strong>ECOSPEED</strong> uses components that are mainly<br />
proprietary parts, which can be bought from<br />
suppliers shelves.<br />
n <strong>ECOSPEED</strong> has a machine stiffness that<br />
equals or betters standard machining centre<br />
designs.<br />
n <strong>ECOSPEED</strong> has first class ‘’maintainability’’<br />
features.<br />
n <strong>ECOSPEED</strong> with it’s Z-3 head being<br />
configured through linear axes only, carries<br />
none of the compromises and performance<br />
weaknesses associated with rotary axes.<br />
n <strong>ECOSPEED</strong> is the most efficient machine<br />
tool on the market today for producing aluminium<br />
aerospace type components.<br />
n <strong>ECOSPEED</strong> makes traditional Profiler almost<br />
obsolete for this type of application. As time<br />
passes, this efficiency and technological gap<br />
will widen. In a few years time, companies<br />
using traditional equipment in this field will<br />
become uncompetitive.<br />
n <strong>ECOSPEED</strong> in terms of cost, represents an<br />
economic solution. Although single unit<br />
prices may be higher than a conventional<br />
Profiler, less machines are required for a<br />
given output. Fewer operating personnel are<br />
also required to run the machines.<br />
n <strong>ECOSPEED</strong> provides previously unknown<br />
surface qualities rendering deburring and<br />
fettling to a minimum requirement.<br />
n <strong>ECOSPEED</strong> offers the production of multiple<br />
parts or part sets from a single billet giving<br />
considerable time savings.<br />
n <strong>ECOSPEED</strong> is capable of increasing its levels<br />
of performance still further in the future, as<br />
motor spindle development provides faster<br />
and more powerful units these will be easily<br />
incorporated into the existing design.<br />
applied force: Fx = 1kN<br />
Deflection ∆x = 18 µm<br />
Stiffness kxx = 55 N/µm<br />
applied force: Fy = 1kN<br />
Deflection ∆y = 20 µm<br />
Stiffness kyy = 50 N/µm<br />
applied force: Fz = 1kN<br />
Deflection ∆z = 1 µm<br />
Stiffness kzz = 250 N/µm<br />
Optimisation of machine column<br />
Task:<br />
– Optimisation of wall thickness<br />
regarding thickness and mass<br />
– Easier assembly<br />
Result:<br />
– Stiffness increased 20 % with<br />
same mass<br />
Static deformation (x-direction)<br />
Applied force: Fx = 10 kN<br />
max. deformation: ∆x = 47.6 µm<br />
Stiffness: Kxx = 210 N/µm
6<br />
<strong>High</strong> <strong>Performance</strong><br />
5 axis <strong>Machining</strong> <strong>Center</strong> <strong>ECOSPEED</strong><br />
no risk<br />
solution<br />
Complete machine without covers<br />
showing gantry axis drives.<br />
Headstock with complete freedom of move-<br />
ment without slip rings or rotary couplings.<br />
Column group with extreme low mass<br />
and highest stiffness incorporating all<br />
drives for every axis.<br />
Complete machine with covers showing<br />
optimised chip evacuation with no traps.<br />
Pallet for component mounting prepared for<br />
automatic vacuum connection (option).<br />
Static table group showing pallet<br />
transfer drive, location and clamping<br />
Automatically exchangeable angle heads<br />
(option).<br />
proven<br />
technology<br />
Layout showing rail guided vehicle, pallet<br />
buffer stations and load/unload station<br />
Example layout of<br />
two machine system<br />
Comfortable component handling, (horizontal loading,<br />
vertical transfer and machining)<br />
5 axis machining example<br />
We are designing and manufacturing<br />
customer specific machines and variants of<br />
<strong>ECOSPEED</strong>.<br />
If you have any additional requests please<br />
contact us.<br />
7
8<br />
<strong>High</strong> <strong>Performance</strong><br />
5 axis <strong>Machining</strong> <strong>Center</strong> <strong>ECOSPEED</strong> F<br />
<strong>ECOSPEED</strong> F<br />
<strong>ECOSPEED</strong> F was designed for machining<br />
smaller structural Aircraft parts.<br />
Table sizes from 1,500 x 2,500 mm to<br />
2,000 x 3,000 mm offer you a range<br />
below <strong>ECOSPEED</strong> with the same tech-<br />
nical advantages.<br />
Configuration<br />
n Stationary column, moveable table<br />
group<br />
n Horizontal motor spindle, vertical<br />
component<br />
n 5-axis machining capability by<br />
Sprint Z3-head<br />
n Rotatable load / unload station with<br />
2 pallets horizontal loading – vertical<br />
machining<br />
n Stand alone machine extendable to<br />
FMS<br />
Advantages<br />
n Dramatic productivity increase<br />
n <strong>High</strong>est chip removal rate<br />
n Extreme high accuracy<br />
n <strong>High</strong>est acceleration / deceleration in<br />
all axis<br />
n Eliminate fettling, polishing, deburing<br />
n Improved chip management (free chip<br />
flow)<br />
n Advantageous price / performance ratio<br />
Oil mist extraction data<br />
capacity 2,400 m3 /h<br />
air exchange > 1/min<br />
coolant contents in cleaned air 10 mg/m3 <strong>ECOSPEED</strong> F pallet changer<br />
(horizontal loading, vertical machining)<br />
completely independent of machine<br />
eliminating interference to work spindle<br />
when loading components<br />
<strong>ECOSPEED</strong> F X-axis drives with master<br />
slave concept<br />
Electronically pre-loaded X-axis drive<br />
n Double pinion, electronically<br />
pre-loaded by 2 drives<br />
Advantages<br />
n backlash elimination<br />
n <strong>High</strong> stiffness<br />
n <strong>High</strong> positioning accuracy<br />
n Easy maintenance by reduced number<br />
of elements<br />
The angular milling head ensures<br />
full 5 sided machining.<br />
9<br />
Uni directional moments, rapid traverse<br />
Opposing moments pre-loaded area,<br />
feed mode<br />
Uni directional moments, rapid traverse
10 11<br />
Technical data <strong>ECOSPEED</strong><br />
facts<br />
X-axis<br />
Y-axis<br />
Z-axis<br />
Angle orientation<br />
Z-stroke at ± 40°<br />
Pallet size in X-axis<br />
Pallet size in Y-axis<br />
Tool magazine<br />
Coolant<br />
Chip evacuation<br />
Process control<br />
Oil mist extraction unit<br />
CNC Control<br />
Video<br />
Acc./Dec. in X<br />
Acc./Dec. in Y<br />
Acc./Dec. in Z<br />
Rapid traverse in X<br />
Rapid traverse in Y<br />
Rapid traverse in Z<br />
<strong>High</strong> rotary positioning velocity<br />
<strong>High</strong> rotary acceleration<br />
Spindles<br />
Positional accuracy according<br />
3,300 - 15,800 mm<br />
2,500 mm<br />
670 mm<br />
± 40°<br />
370 mm<br />
7,000 * 15,000 mm<br />
1,500 * 2,500 mm<br />
min. 125 tools / HSK-A 63/80<br />
Minimum Quantity Lubrication /<br />
Flood and Through Tool Coolant<br />
Hinged belt conveyor<br />
Extraction volume 100,000 cm 3 /min<br />
Component probing, Tool life<br />
management, Tool length control,<br />
Tool measuring, Tool coding,<br />
Tool balancing / Pre-setting,<br />
Post processor<br />
Basic machine capacity 2,400 m 3 /h<br />
Siemens SINUMERIK 840 D<br />
Video monitoring inside machine housing<br />
9.81 m/sec 2<br />
9.81 m/sec 2<br />
9.81 m/sec 2<br />
65 m/min<br />
50 m/min<br />
50 m/min<br />
80°/sec<br />
≥ 685°/sec 2<br />
(eg. 115 ms to full speed)<br />
80 kW, 46 Nm, 30,000 rpm<br />
120 kW, 83 Nm, 30,000 rpm<br />
VDI/DGQ 3441<br />
<strong>Axis</strong> Working Area<br />
X-axis<br />
Y-axis<br />
Z-axis<br />
A/B-axis<br />
up to 3,000 mm<br />
above 3,000 mm up to 8,000 mm<br />
above 8,000 mm<br />
2,500 mm<br />
<strong>ECOSPEED</strong><br />
670 mm<br />
+/- 40°<br />
and more<br />
3,800 - 6,300 mm<br />
2,500 mm<br />
670 mm<br />
± 40°<br />
370 mm<br />
3,500 - 6,000 mm<br />
2,000 mm<br />
38, 57, 93, 129 tools / HSK-A 63/80<br />
Minimum Quantity Lubrication /<br />
Flood and Through Tool Coolant<br />
Hinged belt conveyor<br />
Extraction volume 100,000 cm 3 /min<br />
Component probing, Tool life<br />
management, Tool length control,<br />
Tool measuring, Tool coding,<br />
Tool balancing / Pre-setting,<br />
Post processor<br />
Basic machine capacity 2,400 m 3 /h<br />
Siemens SINUMERIK 840 D<br />
Video monitoring inside machine housing<br />
9.81 m/sec 2<br />
9.81 m/sec 2<br />
9.81 m/sec 2<br />
50 m/min<br />
50 m/min<br />
50 m/min<br />
80°/sec<br />
≥ 685°/sec 2<br />
(eg. 115 ms to full speed)<br />
80 kW, 46 Nm, 30,000 rpm<br />
120 kW, 83 Nm, 30,000 rpm<br />
P<br />
10 µm<br />
+ 1.5 µm/1,000 mm<br />
+ 2.0 µm/1,000 mm<br />
10 µm<br />
8 µm<br />
10 arc. sec.<br />
<strong>ECOSPEED</strong> F<br />
and more<br />
Ps<br />
5 µm<br />
+ 0.5 µm/1,000 mm<br />
+ 1.0 µm/1,000 mm<br />
5 µm<br />
4 µm<br />
5 arc. sec.<br />
<strong>Performance</strong> analysis<br />
comparison<br />
<strong>Performance</strong> characteristics<br />
1975 - 2000<br />
(5-axis machining)<br />
Year of construction<br />
Producer<br />
Spindle power<br />
Spindle speed<br />
Feedrate<br />
Acceleration<br />
* year of Retrofit<br />
Time comparison<br />
vertical beam (see page 2)<br />
Control<br />
No. of spindles<br />
Power<br />
Speed<br />
max. Feed<br />
time for 8 components<br />
time for 1 component<br />
Unit FPV 2,500/25 FPA 2,500/24 FPA 3,000/33 <strong>ECOSPEED</strong><br />
(kW)<br />
rpm. * 1,000<br />
m/min.<br />
<strong>Performance</strong> characteristics 1975 - 2000<br />
(Technology Development)<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
FPV 2,500/25<br />
1975<br />
FPA 2,500/24<br />
1987*<br />
Spindle Power (kW)<br />
Spindle Speed (rpm.*1,000)<br />
Feedrate (m/min)<br />
Acceleration (m/s 2 )<br />
m/s 2<br />
FPA<br />
1998*<br />
(kW)<br />
rpm. * 1,000<br />
m/min.<br />
min.<br />
min.<br />
1975<br />
Droop + Rein<br />
<strong>ECOSPEED</strong><br />
2000<br />
20<br />
4<br />
4<br />
0.1<br />
1987*<br />
Droop + Rein<br />
30<br />
12<br />
8<br />
0.2<br />
Bosch CC<br />
4<br />
33<br />
6,000<br />
10<br />
480<br />
60<br />
1998*<br />
Droop + Rein<br />
Unit Droop + Rein FBV 3,200 <strong>ECOSPEED</strong><br />
40<br />
24<br />
20<br />
1.5<br />
<strong>Performance</strong> characteristics 1975 - 2000<br />
(Efficiency)<br />
800<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
0<br />
FPV 2,500/25<br />
1975<br />
FPA 2,500/24<br />
1987*<br />
FPA<br />
1998*<br />
Material removal rate (dm 3 /h)<br />
Part production time (h),<br />
based on five different EUROFIGHTER parts<br />
2000<br />
DST<br />
75<br />
24<br />
50<br />
10.0<br />
Siemens Sinumerik 840 D<br />
1<br />
75<br />
24,000<br />
50<br />
272<br />
34<br />
<strong>ECOSPEED</strong><br />
2000