Brochure FZ 100 - F. Zimmermann GmbH

FZ100Portal Milling MachineTHE PORTL TO SUCCESSPREMIERE

WITH 6XES INTO A NEW DIMENSIONWith the new FZ 100 portal milling machine Zimmermannhas managed to achieve 6-axis machining using the newly developedM3 ABC 3-axis milling head. This concept sets newstandards in the volume machining of aluminium, compositeand model making materials as well as in the Hihg SpeedCutting of steel and cast iron, where conventional 2-axis forkheads with A- and C-axis have long reached their limits in the5-axis simultaneous machining.Performance: Machining four times faster is possibleThe machining time for typical operations such as the millingof pockets with sloping sides, for example in structural componentsfor aircraft manufacture, can be drastically reducedby the additional B-axis. But also, in almost every other case,simultaneous machining using the M3 ABC becomes muchmore productive.Surface: Perfect quality thanks to the six axesThe 3-axis head avoids the pole position of the traditional2-axis A-/C-head at A = 0°. Thus for the first time, particularlyin mould and pattern making, optimal 5-axis simultaneousmachining with the highest possible surface finish is availablein practice. A real revolution!Compensation: Highest accuracy possibleFor the first time the geometric errors of the milling machinecan be fully compensated. Besides the overall improvementin quality, machine accuracy can now be easily recalibrated atregular intervals over a period of many years without loss ofproduction.Taking all these advantages together we can clearly speak ofa new dimension in portal milling technology. In the followingpages you can learn more about this highly productive technology.The unique third axis is clearly visible.This B-axis can be moved simultaneouslyby ±15°.Typical structural components for aircraftmanufacture have inner slopingsides with a setting angle of three to fivedegrees. With the M3 ABC milling headthe machining of pockets in combinationwith an ideal feed rate is perfect.MaterialsSteel and cast iron(HSC finishing)Light alloysComposite materialssuch as CRP and GRPCNC Portal Milling Machine FZ 100 | Zimmermann 3

The world's first 3-axis milling head:M3 ABCUp to now 2-axis fork heads with A- and C-axis have beenused for 5-axes machining in portal milling machines.This method has the disadvantage that there is a pole at thezero position of the A-axis, where the C-axis of the millinghead is ineffective. The C-axis cannot swivel the milling spindlewhen the milling spindle is in the vertical position. Even theslightest change in orientation requires large rotation of theC-axis. This leads to the following disadvantages:Considerably reduced productivity and surface finish insimultaneous machining (thus mould makers often only usean oriented tool in so-called 3+2-axis machining).No compensation for errors in the machine geometry ispossible. This results in steps on the surface when millingwith oriented tools.A completely new dimension in productivityThe revolutionary, design-related increase in speed can beespecially clearly demonstrated based on the example of astructural component with sloping side walls of 3° to 5° as iscommon in the aircraft industry.Even in the corners of the pockets, where an A-/C-headis almost stationary, the M3 ABC achieves a constantlyhigh feed rate, thus leading to a significantly less tool wear.Only minimum rotation is needed to achieve any angle oforientation with the three axes available – thus saving a lotof time.The pirouette-like retraction of the C-axis after each cycleis no longer necessary.1Machining time100 % 25 % 50% 25%A-/C-head A-/B-head A-/C-head M3 ABCwith limited on gimbals with infiniteC-axisC-axis3-axis simultaneous milling withoutpole situation and still large swivelranges – this is only possible with theM3 ABC.The key to the innovation is thespecially developed, very rigid andprecise curved guideways of the B-axis.In spite of the three axes, the M3 ABCis amazingly compact.1Typical structural component from the aircraft industry with sloping pocket sides.Comparison of different types of milling head for 5-axis machining. It must beemphasized that the M3 ABC has a significantly larger swiveling angle in comparisonto the A-/B-head and subsequent machining with additional angle heads is notnecessary.4

Great flexibilitySimilar machining speeds to the M3ABC can be achieved,in certain cases, using a parallel kinematic milling head oran A-/B-head on gimbals. However, these solutions have arestricted swivel angle and thus often require subsequentmachining with additional angle heads. This does not apply tothe M3 ABC: It has three degrees of freedom and large swivelangles, thus offering complete flexibility in the way it is used.Surface finishMachining is performed at all times with the optimal highfeedrate and always with an optimally oriented tool. For thefirst time in 5-axis simultaneous machining the sixth axisensures a perfect surface finish.DesignAt first sight the patent pending M3 ABC milling head looks likea normal fork head. It is equipped with a C-axis with a swivelrange of ± 360° and an A-axis which can rotate the millingspindle ± 110°. The design innovation is the additional B-axisbetween these two axes with a swiveling range of ± 15°.To achieve this axis, an extremely rigid and accurately curvedguideway has been specially developed. Thanks to the thirdaxis, a C-axis with infinite rotation is now no longer required.Compact structureThe curved guideway has the advantage that the milling headis extremely compact despite the additional axis, thus furtherincreasing the flexibility and performance.SpindleThe M3 ABC uses high-performance, well proven spindles fromWeiss company. Other spindles are available as an option.CNC Portal Milling Machine FZ 100 | Zimmermann 5

Overhead, weight-optimized and structurally rigid portal movingin the X-direction, for high dynamic performance and precision.Weight-optimized vertical slide with high bending strength forlarge Z-ranges.Backlash-free portal drives on both sides with rack and pinionmechanism well away from the dirt zone, guided on both sides.Compound-filled side columns.3-axis M3 ABC milling head. The heart of the machine makesthis the world's first 6-axis portal milling machine.Worktable made of cast iron with T-slots, permanentlyanchored to the foundations.Completely enclosed protective housing through closed sidewalls, back wall and a front sliding door with large inspectionwindows.6

A strong portal designfor perfect 6-axis machiningPortal milling machines are very versatile, making theman ideal basis for the new 6-axis machining. The constructionwith fixed side walls and an overhead portal moving in theX-direction results in very low and constantly moved masses.Thus the machine has a consistent dynamic performanceleading to excellent surface finish, even with very large components.The large degrees of freedom in all axes are greatlyenhanced by the 3-axis milling head, permitting optimal finishmachining in a single set-up.Design of the side columnsThe side columns are manufactured in one piece up to a lengthof eight meters. To achieve an extremely rigid structure, theyare made of welded and heat-treated steel, and filled withfiber-reinforced special compound (DemTec). In this way, ourlong standing system supplier ensures easy assembly, highlong-term stability and practically no need for maintenance.The design also ensures the highest possible temperaturestability, oscillation and vibration damping so that high dimensionalaccuracy and surface quality can be achieved. The especiallyrigid structure ensures extremely good dynamic performanceand excellent contour accuracy and is thus clearlysuperior to conventional cast iron or welded steel constructions.The portalThe overhead dynamically driven gantry portal enables 6-axissimultaneous machining and 5-sided machining with thehighest precision and speed. The low moving masses ensureexcellent dynamic performance.Mechanical constructionTo achieve the ideal machine structure, the dynamically rigiddesign was optimized in multi-level series of FEM calculations.Separate FEM calculations are carried out for each type ofmachine and each individual size. Analysis of the design iscarried out using the latest mechatronic overall closed-loopsimulation approach, taking into account the motors, drivesand control system parameters.Modular conceptFrom the start, the basic construction of the new FZ 100 wasdesigned to make it as easy as possible to adapt all the basicparameters to the customer's specific demands. Travels,work areas, options and much more can thus be configuredflexibly.The result of this design is a unique combination of performance,short machining times, flexibility, highest qualitysurface finish, excellent rigidity over a long period of time andthus all-in-all extremely cost-effective.CNC Portal Milling Machine FZ 100 | Zimmermann 7

Individual system solutionsfor every applicationAs well as the standardmachine, Zimmermann offersturn-key system solutions tosatisfy all additional technicaldemands.We apply our technicalexpertise and tailor-madeproject management to thetask: from the first idea tothe very end of the project.Zimmermann supplies everythingfrom a single source.Dust and swarfWhether to do with the healthaspects of fine dust orquestions of contaminationwith chips, from chip conveyorsto full enclosure of theFZ 100, there are a wide rangeof solutions.Clamping tablesLogistical considerations,size, weight, part geometry,etc. – there are aspects toconsider when choosing theright clamping table and theappropriate loading systems.Tool changerAs the link between the workpieceand the machine, toolchangers of different designscan be supplied.Clamping technologyThe FZ 100 can be equippedwith a variety of holdingfixtures devices, dependingon batch sizes, the range ofcomponents or the changeovertimes required.CNC Portal Milling Machine FZ 100 | Zimmermann 9

FZ 100Technical dataMachine FZ 100Working rangesX-axis 2 800, 3 800, 4 800,5 800, 7 800 mm 1Y-axis 2 900, 3 400, 3 900 mm 1Z-axis 1250, 1 500, 2 000 mm 1Table sizeLength3 800–8800mmWidth3 000 – 4 000 mmHeight220 mmTable load max. 20 000 kg/m 2T-slots (longitudinal) 18 H12 (optional 22 H12 )Distance between T-slots 250 mmFeed drivesFeed X,- Y-, Z-axisup to 60 000 mm/min.Acceleration of linear axes up to 4 m/s 2Accuracies 2Positioning accuracy X-axisPositioning accuracy Y-, Z-axisRepeatability X-axisRepeatability Y-, Z-axis0,030 mm0,020 mm0,015 mm0,010 mmMilling headM3 ABCSwiveling rangeA-, B-, C-axis ± 110, ± 15, ± 360°PerformanceA-axis torque825 Nm (opt. 1 050 Nm)B-, C-axis torque1 200 NmA-, B-axis clamping2 000 NmC-axis clamping3 000 NmFeed rate A-, B-/C-axis180, 120°/sAccuracies 2Positioning accuracy A-, B-, C-axis 15"Repeatability A-, B-, C-axis 10"Milling spindlePerformance S1 max. (100 % ED)Torque S1 max. (100 % ED)Max. speedConstant performanceTool holderSwiveling axis – spindle noseTool clampingTool releaseLubricationM3 ABC60 kW95 Nm22 000 rpmas from 6 000 rpmHSK 63 A321 mmspring clamphydraulicPermanent lubricationwith automaticreplenishment systemM3 ABC Milling spindle performance diagramUniversal spindle 60 kW TorqueMd Performance PMd [Nm]P [kW]2007060 kW601505095 95 Nm4030502010000 6000 10000 15000 22000 30000 35000 n [min -1 ]1Other dimensions on request2According to VDI 230-2 / DGQ 3441, based on basic machine, depending on the lengthWe reserve the rights to make technical changes10

Equipment options FZ 100DimensionsSimultaneous A-axisSimultaneous C-axisSimultaneous B-axisA-, C-, B-axis clampingControl cabinet air-conditioningHousingsMinimum quantity lubricationCoolant system (internal, external)Toolchanger 30, 50, 100 positions or moreMeasuring probe■■■■■■■■■■X-axis approx. 2 800 – 7800 mmHeight approx. 5 500 – 6 600 mmWorktable width3 000 – 4 000 mmWorktable length 4 000 – 9 000 mmLenght approx. 6 000 – 11 000 mmWidth approx. 7100 – 8 100 mmTool measurement■Special clampingSpecial paintingChip conveyorsDust extractionClamping fixturesClamping table variants■■■■■■Z-axis 1 500 – 2 000 mmPartitioned work area■Y-axis approx. 2 900 – 3900 mmAll dimensions shown are examples for the FZ 100 in minimumor maximum design configurations. Special sizes deviating fromthis are also possible.■ Standard■ OptionalCNC Portal Milling Machine FZ 100 | Zimmermann 11

FZ 100FZ 35FZ 15M3 ABCVH 3F. Zimmermann GmbHPortal Milling MachinesGoethestraße 23 – 27D-73770 DenkendorfGermanyPhone +49 711 934935-0Fax +49 711 934935-300info@f-zimmermann.comwww.f-zimmermann.comFZ 42FZ 32VH 6VH 2FZ 38FZ 30VH 5VH 12FZ 37FZ 25VH 4VH 1Apollo11 11.2008