CNC Portal Milling Machine - F. Zimmermann GmbH

CNC Portal Milling MachineFZ 40High PerformanceMilling Technology

FZ 40The machine conceptMilling head with two rotary axes.Highly sophisticated CNC millingmachines are required in the moderntool, mould and model makingindustry.The characteristic features ofmost workpieces to be processedin tools, forms and models includelarge dimensions, increasinglycomplex free form surfaces andhighest quality when it comes tosurfaces and precision. It is rarefor the same part to occur twice,and the number of variants isconstantly growing.How can these challenges bemet?FZ 40 in gantry design perfectlycombines the advantages of amachine with:■ Large travelling distances.■ Good accessibility.■ Flexible capability.■ 5-sided and 5-axis processingof workpieces.■ Roughing and finishing onone machine.■ Greatest possible dynamicperformance.■ High stability.FZ 40 rounds off Zimmermann'srange of gantry milling machineswith fixed table at the top end ofthe scale, and sets new standardswhen it comes to stability, machiningperformance, precisionand profitability.Roughing and finishing onone machine –not a contradiction?The development of the FZ 40was based on the principle ideaof building a machine which canbe used for both roughing and finishing.This appears contradictoryat first, with roughing tasksneeding the greatest possiblestability and rigidity – criteriademanding a heavy machine,whereas a heavy machine is notwanted for economical use ofHSC finishing. Here the emphasisis on lightly moved masses andthe greatest possibledynamicperformance.In developing theFZ 40 machine,we succeeded tocombine extremerigidity and highdynamic behaviour.Advantagesof this system:■ Complete processingof a workpiece on onemachine.■ Highly profitable.■ Takes up little space.■ Reduces tooling times.■ Greater precision, as the tooldoes not need to be re-alignedbefore finishing.Longitudinal driving above with drive systemsfor the X-axis, guide and measuringsystems.Spindle storage station.Lamella coverings of the drive systems.Clamping table.2 CNC Portal Milling Machine FZ 40

Vertical slide with cover. It containsthe main drive of the roughing spindleand the C-axis of the milling unit(see page 6).Stationary columns made of grey cast iron.Portal moving in X-direction, containsdrive systems for the Y-axis.Safety guarding.3

FZ 40Vertical slide andmilling head unitThe precondition for roughingand finishing on one machineis an especially developed uniquespindle change system - thusachieving optimum flexibility andthe best possible capacity utilizationof the FZ 40.Two different milling spindles areavailable and can be fitted intothe milling head in a pick-up procedure.They are built into themilling head in a cartridge principle.On changing the spindles,the roughing spindle is stored semi-automaticallyin a storagestation between two gantry columnsand replaced by the highfrequencymotor spindle forfinishing. When using the finishingspindle, the main driveis uncoupled from the Z-slide.The whole changing procedureonly takes a few minutes.The main drive of the roughingspindle is located in the verticalslide and is liquid-cooled, as isthe whole milling head.A bevel/spur gear is responsiblefor power transmission. The roughingspindle produces 25 kW at100% ED (optionally 30 kW)and can be driven at a speed ofup to 8 000 rpm. The optionalhigh-frequency spindle produces17 kW (100 % ED) and achieves amaximum of 23 600 rpm. Thetorque of the A-axis is 4 200 Nm(C-axis: 3 200 Nm). For heavyroughing, the A-axis can beclamped with a Hirth-gear insteps of 5° in addition.Finishing spindle for HF machining.HF-motor for finish machining.4 CNC Portal Milling Machine FZ 40

High Speed CuttingServo motor for positioning the millinghead in the C-axis.Vertical slide.With the high-frequency spindlethe FZ 40 can perform highly profitablefinishing.Backlash free precision gear.C-axis of the milling head.Main drive of the roughing spindle.HSC pre-requisites:■ Stable, vibration dampingmachine frame.■ Quick, dynamic and vibration-stiffaxes drives.■ High frequency spindle withHSK tool clamping system.■ Tools and tapers suitable forhigh speed machining.■ Rapid machine control.■ Complete guarding of thework place.Metal-bellow coupling for roughingspindle drive.Milling head.Servomotor and gear for positioning themilling head in the A-axis.Bevel / spur gear for power transmissionto the roughing spindle.Coupling for power transmission to theroughing spindle.Swivel housing for an alternate use of theroughing and of the finishing spindle.Spindle storage station withfinishing spindle.Advantages of the high speedcutting (HSC) with the FZ 40 resultin a remarkable competitiveadvantage:■ High surface quality minimisesmanual re-finishing.■ Low cutting power increasesthe life-time of the machine andof the tools.■ Low heat input in the workpiece,heat emission throughthe chips.■ High rate of metal removal.■ Reduction of the machiningtime.■ Reduction of the productioncosts.Roughing spindle with couplingfor power transmission of themain drive.5

FZ 40Technical specificationThe CNC gantry milling machineDesignFZ 40 is a modular machine conceptfor combining many diffe-The sandwich design with alternatingcast and welded structu-The 5-axis milling head version with theinserted roughing spindle.rent working areas, controls andres achieves optimum vibrationmilling heads.damping. Gantry columns,systems are in a protected locati-Drive axesgantry slide and the cross slideare cast structures; the longitudi-on outside the contaminationand chip zone.FZ 40 is available as 5-axis, 3+1nal beam, the gantry and theand 3-axis version:vertical slides are welded steelThe clamping table permanentlycomponents with generouslyanchored to the foundations anddimensioned ribbings.the gantry moving in X-directionmake it possible to process work-ZYXThree linear axes (X, Y, Z) are driven withthe FZ 40 machine in principle.The drive, guide and measuringsystems have been moved upwardsto reduce the mass beingmoved, thus increasing rigidity.pieces regardless of weight.The whole machine has beensubject to strength tests and opti-CAll guide, drive and measuringmised in complicated FEM tests.AWith the 5-axis machine 2 rotary axes( A and C) are driven in the milling headin addition.▼ Automatic tool changer.▼▼ Roller rotation guides and digital feedservo drives.All linear axes have pre-tensionedlinear roller bearings size 55 inthe X axis and 45 in the Y and Zaxis. For each axis there are 6 (Yaxis8) guide carriages installedAThe 3+1-axis machine has 3 linear axes togetherwith 1 automatically positioningclamped axis (A-axis).(X-axis left and right). The feedmovement of the axes is producedby ball screws size 80 / 63.The machine is rated for roug-The most simple design of the FZ 40 seriesis a 3-axis version with a rigidly integratedvertical motor spindle.(e.g. 50 kW/240 Nm)hing of steel and cast iron.Together with the spindle changeconcept and the high-frequencyspindle, the machine can also beused for finish machining.6 CNC Portal Milling Machine FZ 40

Foundation and erectionStable foundations are requiredfor erection of the CNC portalmilling machine FZ 40.The fixation of the columns andthe clamping table is made byfoundation anchors which arecast into the foundation. Only inconnection with the foundationmaximum stability and accuracyare guaranteed.Controls and drivesThe basic version of the machineis equipped with digital feed servodrives make Siemens.In principle it is possible for differentmakes and types of controlsto be combined with FZ 40machines. Modern controls offerfunctions such as "look ahead",jolt limiting, spline interpolationand 5-axis machining. Optionalsystems for measuring and digitisingare available. As a rule, FZ 40machines are equipped withcontrols made by Siemens, Heidenhainor Fidia; other makesare possible on special request.The FZ 40 can be combined with differentmakes and types of numerical controls.7

FZ 40Equipment and OptionsEquipment and Options 5 axis 3 + 1 axisCooling system ■ ■Cooling unit for milling head and main drive ■ ■Switch cabinet air-conditioning ■ ■Safety guarding ■ ■Tool changer 12-, 15-, 30-, 50- or 120-fold ■ ■Chip conveyer ■ ■Minimum quantity cooling ■ ■Measuring touch probe ■ ■Tool measuring ■ ■Digitising ■ ■A-axis as positioning clamped axis■Roughing spindle■Simultaneous A-axis■Simultaneous C-axis■Storage station for milling spindles■High-frequency spindle ■ ■Special voltage ■ ■Special painting ■ ■■ Standard■ OptionFZ 40 SpecialversionsThe modular conception of theFZ 40 allows highly specializedmachine variations forcustomised applications. Withsuch individualised machines,excellent economical andefficient production processescan be realised.The stiff and oversized designof the X-beams and the columnsgives the flexibility for specialconfigurations of the machine.FZ 40 “Tandem”■ Two similar bridges.■ Saves one machine.■ Simultaneous machining withtwo milling heads.■ Independant machining ofone or two workpieces.■ Requires less space.■ Reduces processing and leadtimes by almost 50 %.FZ 40 “Duo”■ One bridge, 2 milling heads.■ Saves one machine.■ Simultaneous machining withtwo milling heads.■ Machining of two similar ortwo symmetric parts.■ Requires less space.■ Reduces processing and leadtimes by almost 50 %.8 CNC Portal Milling Machine FZ 40

FZ 40Erection plans and dimensionsLXYSafetyguarding(includedin delivery)ServiceflapHTLCoolant tank(on both sides)FZ 40 from the right-hand side with the machine bed installed atfloor level. Safety guarding not marked.FZ 40 from the front side. The fixing of the machine to the foundationcan be seen in the drawing beneath.TL0Fixing screwAligning elementTBBZTBTool changer 12 positions (50A (E) / 80A)Electricity3 x 400 V 50 HZCasting compoundSpindle storage stationFoundation anchorFZ 40 from the top.Fixing the machine to the foundation.Dimensions min. max.X Working range X-axis 3 000 mm 10 000 mmY Working range Y-axis 2 000 mm 4 000 mmZ Working range Z-axis 1 000 mm 2 000 mmL Total length of machine 6 800 mm 13 800 mmB Total width of machine 5 800 mm 7 800 mmH Total height of machine 4 700 mm 6 700 mmTL Length of table 3 000 mm 10 000 mmTB Width of table 2 000 mm 4 000 mmAll dimensions given are the maximumand minimum examples of the FZ 40machine.Special sizes on request.9

FZ 40Technical dataTechnical data FZ 40Working rangesX-axis3 000 – 10 000 mmY-axis2 000 – 4 000 mmZ-axis1 000 – 2 000 mmA-axis ± 95°C-axis ± 200°Table sizeLength3 000 – 10 000 mmWidth2 000 – 4 000 mmHeight350 mmMax. work-table loading 30 000 kg/m 2T-slots (longitudinal) 22 H12Distance T-slots250 mmFeed drivesFeed linear axes0–20000 mm/min.Rotation speed rotary axes 50°/sAcceleration linear axes 2,5 m/s 2Accuracy Axis to VDI / DGQ 3441Positioning X P =30µmaccuracy Y, Z P =20µmRepeatability X Ps = 15µmRepeatability Y, Z Ps = 10µmResolution of A, C 0,0001°measuring systemsPositioning A, C P =15“=0,0041°accuracyRepeatability A, C Ps = 10“ = 0,0027°Technical data FZ 40Milling unit5-axis versionRoughing spindle 25 kWOutput S1 100 % ED 25 kW from 1000 rpmonwardsTorque S1 100 % ED 240 NmSpeed8 000 rpmTool holder HSK 80 A or SK 50Distance swivel axis 330 mmto spindle noseRoughing spindle 30 kWOutput S1 100 % ED 30 kW from 1000 rpmonwardsTorque S1 100 % ED 286 NmSpeed8 000 rpmTool holder HSK 80 A or SK 50Distance swivel axis 493 mm/330 mmto spindle noseHigh-frequency spindleOutput S1 100 % ED 17 kW from12 000 rpm onwardsTorque S1 100 % ED 13,7 NmSpeed23 600 rpmTool holderHSK 50 ADistance swivel axis 493 mmto spindle nose3+1-axis versionOutput S1 100 % ED 25 kWTorque S1 100 % ED 40 NmSpeed28 000 rpmTool holder HSK 63 F (HSK 50 A)Distance swivel axis 352 mmto spindle noseTool clampingspring clampTool unclamping hydraulicSpindle changing time approximately 5 min.10 CNC Portal Milling Machine FZ 40

Milling headwith roughingspindle25 kW5-axisMilling headwith roughingspindle30 kW, optional5-axisMilling headwith finishingspindle17 kW5-axisMilling headwith rigidlyintegrated finishingspindle25 kW3+1-axisVertical motorspindle3-axisMd [Nm]24020015010050Md [Nm]286250200150100240 NmTorque Md25 kWPower PP [kW]20150 00 1000 2000 3000 4000 5000 6000 7000 8000n [min -1 ]503500Md [Nm]1613,71210864200Md [Nm]5040302010286NmTorque Md30 kW01000 2000 3000 4000 5000 6000 7000 8000n [min -1 ]40 NmTorque Md25105Power PP [kW]3025201513,7 Nm17 kW1716141210864205000 11800 15000 20000 23600n [min -1 ]Torque Md25 kW105Power PP [kW]Power PP [kW]20150 00 6000 12000 18000 24000 28000n [min -1 ]25105Technical data on demand.11

High PerformanceMilling TechnologyStyrofoamMilling TechnologyFZ 50FZ 20 SFZ 40FZ 15 SFZ 37FZ 35Zimmermann-Bokö standsfor CNC portal milling technique.Specialisation and a high innovationpace lead to the technicalhead start.A diversation and finely classifiedprogramme of numerous machinetypes enable the choice of theperfect machine for every targetedapplication area.FZ 32FZ 30FZ 20BK 4 · 3·2LMCF. Zimmermann GmbHGoethestraße 23 – 27 · D-73770 DenkendorfPhone +49 (7 11) 93 49 35 - 0 · Fax +49 (7 11) 93 49 35 - 35info@f-zimmermann.com · www.f-zimmermann.comApollo 11 05.03