High Performance 5-Axis Machining Center ECOSPEED ...

Products:
Dörries
Vertical Turning Machines
Vertical Machining Centers
Droop+Rein
Portal Machining Centers
High Speed Machining Centers
Scharmann
Horizontal Machining Centers
Boring Mills
Mecof
Horizontal and Vertical High Speed Milling Centers
Berthiez
Vertical Turning Machines
Vertical Grinding Machines
DS Aircraft
Machining Centers
Service
Headquarters:
Dörries Scharmann Technologie GmbH
Hugo-Junkers-Straße 12-32
D-41236 Mönchengladbach-Rheydt
Tel. +49/2166/454-0
Fax +49/2166/454-300
www.ds-technologie.de
information@ds-technologie.de
Sites, Subsidiaries and Service Centers:
Dörries Scharmann Technologie GmbH
Product line Droop+Rein
Hofkamp 2, D-33719 Bielefeld
Tel. +49/521/5804-0, Fax +49/521/178006
Dörries Scharmann Technologie Service Center
GmbH & Co. KG
Am Sülzenbrückener Weg 14, D-99334 Ichtershausen
Tel. +49/36202/77980, Fax +49/36202/779829
Dörries Scharmann Technologie GmbH
Service Center South
Wannetal 47b, D-88131 Lindau
Tel. +49/2166/454-700, Fax +49/2166/454-701
Dörries Scharmann Technologie GmbH
Beijing Office
Room 704, Kun Tai Building, No. 10 Chao Wai Da Jie,
Chaoyang District, 100020 Beijing, PR China
Tel. +86/10/65995556, Fax +86/10/65995559
Dörries Scharmann Technologie GmbH
Moscow Office
ul. Tverskaya 16/2, Building 1, 7. Floor, RUS-125009 Moscow
Tel. +7/495/737-4981, Fax +7/495/737-6588
DS Technology (USA), Inc.
7861 Palace Drive, Cincinnati, OH 45249, USA
Tel. +1/513/247-2590, Fax +1/513/247-2599
DS Technology (UK) Ltd.
43/45 Phoenix Park, Avenue Close, Nechells,
Birmingham B7 4NU, United Kingdom
Tel. +44/121/3593637, Fax +44/121/3591868
Berthiez SAS
5, rue Barrouin, F-42029 St. Etienne Cédex 1
Tel. +33/4/77923992, Fax +33/4/77923993
www.berthiez.fr, sales@berthiez.fr
Mecof Srl
Via Molino 2, I-15070 Belforte Monferrato, AL
Tel. +39/0143/8201, Fax +39/0143/823088
www.mecof.it, info@mecof.it
06.2009 - 1.000 E - 09-908b
High Performance
5-Axis Machining Center
ECOSPEED, ECOSPEED F
Dörries Scharmann

2 3
Wing and body components for
civil and military aircraft
is it your
business?
vertical beam
The ultimate goal of the industry is to pro-
duce ever more increasing lighter weight
structural parts with increasing inherent
strength. Previous methods of joining a
number of profiled parts together, has largely
been replaced by machining larger structures
from aluminium billets. Thinner wall sections
and more complex contours in five axis pro-
vide for this possibility to decrease weight
and increase strength.
It is inevitable that as designers make more
use of the modern 3D CAD tools 5 axis
applications will increase.
To achieve this goal the only real solution
can be provided by high speed machining
where the distortion forces of the tool on
the component are largely eliminated.
This in turn means that a much higher accu-
racy and higher surface quality is demanded
not only from the linear axis but also from
the rotary axis.
To meet these demands the machine’s linear
axis, has to provide a highly dynamic extre-
mely stiff construction.
In the case of complex contours and radii
this can not be provided by the conventional
rotary drives of Fork or Swivel heads.
Typical wing and
body components
from billet or plate
If you are using
these solutions
then its likely you
are not very close at
all.
20 years and
180 rotary axis type
heads shows us that
these head types are
not a high speed
solution.
How close can you get to the …
…digital
standard?
The typical gantry type profiler as designed
in the 1970’s has largely remained unchan-
ged until today. The high mass of the bridge
or cross rail renders it totally unsuitable for
any high speed process.
The Fork Head with its open design concept
lacks the stiffness required coupled with
rotational bearings, a relatively long swivel
length and mechanical geometric alignment
makes it unsuitable for real accurate high
speed application.
Required rotational speed of the C-Axis at a 6° angle
speed C-Axis [rpm]
800
700
600
500
400
300
200
100
0
40
20
feed [m/min]
0
100
The Swivel Head with its closed design is a
much more stiff solution and goes some way
in the trend of high speed machining but still
suffers from some of the previously menti-
oned difficulties, it is however, also suited
for the machining of titanium and steel.
80
40
60
radius [mm]
20
0
Fork Head
Swivel Head
Fork and Swivel Head - Disadvantages:
Positioning velocity, Angular acceleration,
Weight, Stiffness, Accuracy, Swivel length,
Geometric alignment, Complexity, Slip Rings,
Rotary couplings

4
The KEY - Elimination of rotary
axis
5
A new generation completely
optimised by FEA
A new approach…
…for real
Production gains
With the aforementioned in mind Dörries
Scharmann Technologie has developed a
3 axis head concept of extremely stiff design
that takes account of all of the previous
mentioned difficulties to meet the highly
accurate contouring and radii requirements
including the higher surface quality demands,
by eliminating the need for rotary motions.
n Offers possible platform orientations up
to +/- 40° within a Z-stroke up to 370 mm
n Offers angular velocities and accelerations
of the platform of 15 U/min and 685°/s2 n Positioning speed of 80°/sec around the
tool tip is available in every space angle
n Has a low mass, which leads to lower
acceleration forces in X-and Y-directions
n Offers a max. Z-stroke of 670 mm
Continuous motion
through standard
elements
WHY THE NEED
n Efficiency is the most critical and important
driver in manufacturing industry today. As
business becomes evermore competitive and
cost conscious, the factor of efficiency will
become increasingly critical.
n ECOSPEED was specifically designed,
exclusively for the purpose of high speed
machining of structural aircraft components
from aluminium alloy plate or billet type
materials.
n ECOSPEED was specifically designed to use
conventional well proven machine tool
technology.
n ECOSPEED uses components that are mainly
proprietary parts, which can be bought from
suppliers shelves.
n ECOSPEED has a machine stiffness that
equals or betters standard machining centre
designs.
n ECOSPEED has first class ‘’maintainability’’
features.
n ECOSPEED with it’s Z-3 head being
configured through linear axes only, carries
none of the compromises and performance
weaknesses associated with rotary axes.
n ECOSPEED is the most efficient machine
tool on the market today for producing aluminium
aerospace type components.
n ECOSPEED makes traditional Profiler almost
obsolete for this type of application. As time
passes, this efficiency and technological gap
will widen. In a few years time, companies
using traditional equipment in this field will
become uncompetitive.
n ECOSPEED in terms of cost, represents an
economic solution. Although single unit
prices may be higher than a conventional
Profiler, less machines are required for a
given output. Fewer operating personnel are
also required to run the machines.
n ECOSPEED provides previously unknown
surface qualities rendering deburring and
fettling to a minimum requirement.
n ECOSPEED offers the production of multiple
parts or part sets from a single billet giving
considerable time savings.
n ECOSPEED is capable of increasing its levels
of performance still further in the future, as
motor spindle development provides faster
and more powerful units these will be easily
incorporated into the existing design.
applied force: Fx = 1kN
Deflection ∆x = 18 µm
Stiffness kxx = 55 N/µm
applied force: Fy = 1kN
Deflection ∆y = 20 µm
Stiffness kyy = 50 N/µm
applied force: Fz = 1kN
Deflection ∆z = 1 µm
Stiffness kzz = 250 N/µm
Optimisation of machine column
Task:
– Optimisation of wall thickness
regarding thickness and mass
– Easier assembly
Result:
– Stiffness increased 20 % with
same mass
Static deformation (x-direction)
Applied force: Fx = 10 kN
max. deformation: ∆x = 47.6 µm
Stiffness: Kxx = 210 N/µm

6
High Performance
5 axis Machining Center ECOSPEED
no risk
solution
Complete machine without covers
showing gantry axis drives.
Headstock with complete freedom of move-
ment without slip rings or rotary couplings.
Column group with extreme low mass
and highest stiffness incorporating all
drives for every axis.
Complete machine with covers showing
optimised chip evacuation with no traps.
Pallet for component mounting prepared for
automatic vacuum connection (option).
Static table group showing pallet
transfer drive, location and clamping
Automatically exchangeable angle heads
(option).
proven
technology
Layout showing rail guided vehicle, pallet
buffer stations and load/unload station
Example layout of
two machine system
Comfortable component handling, (horizontal loading,
vertical transfer and machining)
5 axis machining example
We are designing and manufacturing
customer specific machines and variants of
ECOSPEED.
If you have any additional requests please
contact us.
7

8
High Performance
5 axis Machining Center ECOSPEED F
ECOSPEED F
ECOSPEED F was designed for machining
smaller structural Aircraft parts.
Table sizes from 1,500 x 2,500 mm to
2,000 x 3,000 mm offer you a range
below ECOSPEED with the same tech-
nical advantages.
Configuration
n Stationary column, moveable table
group
n Horizontal motor spindle, vertical
component
n 5-axis machining capability by
Sprint Z3-head
n Rotatable load / unload station with
2 pallets horizontal loading – vertical
machining
n Stand alone machine extendable to
FMS
Advantages
n Dramatic productivity increase
n Highest chip removal rate
n Extreme high accuracy
n Highest acceleration / deceleration in
all axis
n Eliminate fettling, polishing, deburing
n Improved chip management (free chip
flow)
n Advantageous price / performance ratio
Oil mist extraction data
capacity 2,400 m3 /h
air exchange > 1/min
coolant contents in cleaned air 10 mg/m3 ECOSPEED F pallet changer
(horizontal loading, vertical machining)
completely independent of machine
eliminating interference to work spindle
when loading components
ECOSPEED F X-axis drives with master
slave concept
Electronically pre-loaded X-axis drive
n Double pinion, electronically
pre-loaded by 2 drives
Advantages
n backlash elimination
n High stiffness
n High positioning accuracy
n Easy maintenance by reduced number
of elements
The angular milling head ensures
full 5 sided machining.
9
Uni directional moments, rapid traverse
Opposing moments pre-loaded area,
feed mode
Uni directional moments, rapid traverse

10 11
Technical data ECOSPEED
facts
X-axis
Y-axis
Z-axis
Angle orientation
Z-stroke at ± 40°
Pallet size in X-axis
Pallet size in Y-axis
Tool magazine
Coolant
Chip evacuation
Process control
Oil mist extraction unit
CNC Control
Video
Acc./Dec. in X
Acc./Dec. in Y
Acc./Dec. in Z
Rapid traverse in X
Rapid traverse in Y
Rapid traverse in Z
High rotary positioning velocity
High rotary acceleration
Spindles
Positional accuracy according
3,300 - 15,800 mm
2,500 mm
670 mm
± 40°
370 mm
7,000 * 15,000 mm
1,500 * 2,500 mm
min. 125 tools / HSK-A 63/80
Minimum Quantity Lubrication /
Flood and Through Tool Coolant
Hinged belt conveyor
Extraction volume 100,000 cm 3 /min
Component probing, Tool life
management, Tool length control,
Tool measuring, Tool coding,
Tool balancing / Pre-setting,
Post processor
Basic machine capacity 2,400 m 3 /h
Siemens SINUMERIK 840 D
Video monitoring inside machine housing
9.81 m/sec 2
9.81 m/sec 2
9.81 m/sec 2
65 m/min
50 m/min
50 m/min
80°/sec
≥ 685°/sec 2
(eg. 115 ms to full speed)
80 kW, 46 Nm, 30,000 rpm
120 kW, 83 Nm, 30,000 rpm
VDI/DGQ 3441
Axis Working Area
X-axis
Y-axis
Z-axis
A/B-axis
up to 3,000 mm
above 3,000 mm up to 8,000 mm
above 8,000 mm
2,500 mm
ECOSPEED
670 mm
+/- 40°
and more
3,800 - 6,300 mm
2,500 mm
670 mm
± 40°
370 mm
3,500 - 6,000 mm
2,000 mm
38, 57, 93, 129 tools / HSK-A 63/80
Minimum Quantity Lubrication /
Flood and Through Tool Coolant
Hinged belt conveyor
Extraction volume 100,000 cm 3 /min
Component probing, Tool life
management, Tool length control,
Tool measuring, Tool coding,
Tool balancing / Pre-setting,
Post processor
Basic machine capacity 2,400 m 3 /h
Siemens SINUMERIK 840 D
Video monitoring inside machine housing
9.81 m/sec 2
9.81 m/sec 2
9.81 m/sec 2
50 m/min
50 m/min
50 m/min
80°/sec
≥ 685°/sec 2
(eg. 115 ms to full speed)
80 kW, 46 Nm, 30,000 rpm
120 kW, 83 Nm, 30,000 rpm
P
10 µm
+ 1.5 µm/1,000 mm
+ 2.0 µm/1,000 mm
10 µm
8 µm
10 arc. sec.
ECOSPEED F
and more
Ps
5 µm
+ 0.5 µm/1,000 mm
+ 1.0 µm/1,000 mm
5 µm
4 µm
5 arc. sec.
Performance analysis
comparison
Performance characteristics
1975 - 2000
(5-axis machining)
Year of construction
Producer
Spindle power
Spindle speed
Feedrate
Acceleration
* year of Retrofit
Time comparison
vertical beam (see page 2)
Control
No. of spindles
Power
Speed
max. Feed
time for 8 components
time for 1 component
Unit FPV 2,500/25 FPA 2,500/24 FPA 3,000/33 ECOSPEED
(kW)
rpm. * 1,000
m/min.
Performance characteristics 1975 - 2000
(Technology Development)
80
70
60
50
40
30
20
10
0
FPV 2,500/25
1975
FPA 2,500/24
1987*
Spindle Power (kW)
Spindle Speed (rpm.*1,000)
Feedrate (m/min)
Acceleration (m/s 2 )
m/s 2
FPA
1998*
(kW)
rpm. * 1,000
m/min.
min.
min.
1975
Droop + Rein
ECOSPEED
2000
20
4
4
0.1
1987*
Droop + Rein
30
12
8
0.2
Bosch CC
4
33
6,000
10
480
60
1998*
Droop + Rein
Unit Droop + Rein FBV 3,200 ECOSPEED
40
24
20
1.5
Performance characteristics 1975 - 2000
(Efficiency)
800
700
600
500
400
300
200
100
0
FPV 2,500/25
1975
FPA 2,500/24
1987*
FPA
1998*
Material removal rate (dm 3 /h)
Part production time (h),
based on five different EUROFIGHTER parts
2000
DST
75
24
50
10.0
Siemens Sinumerik 840 D
1
75
24,000
50
272
34
ECOSPEED
2000