Machine tools. Milling- and boring machines

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1 Milling- and boring machines

2 Milling- and boring machines Our family owned company develops and manufactures customized machines and designs machine tools based on work piece requirements successfully since The worldwide customer base comes from different industry branches, such as: aviation and aerospace ship building automotive industry power plant components paper machine industry roll maker railway machining machining of forged components aluminum and graphite machining portable machining units for construction and assembly areas In our standard products or customized machines, which are based on standard sub-assemblies and components, only state of the art technology is used. By selecting from the various models of milling heads, different types of tables and tool and pallet changers, our machines are modifi ed based on customer application and machining requirements. Our horizontal milling and boring machines are provided with a special fl ow-controlled hydrostatic, which we were the fi rst company to introduce this technology to the heavy machine tool industry. The same technology is used in combination with oversized guide ways on our rotary tables and shifting tables. Also large portal type milling machines with horizontal and / or vertical headstock and drilling machines are part of our product program. 2

3 Special milling and boring machines Automatic drilling unit SWB 12* For simultaneous drilling of a line of 288 suction holes into roll sleeves in one lifting procedure when producing suction rolls fort he paper machine industry. Work piece diameter mm Minimum distance between drills 35,71 mm Work piece weight, maximum kg Saw milling machine SFQ 60* The machine is used for cross cutting of steel plates. It provides high power and accuracy. At the same time surface quality of the cutting face is much better than on conventional sawing machines. Work piece thickness up to 60 mm Cutting width 4 mm Work piece length kg Work piece weight, maximum kg Special angular drilling machine SPW 24 NC-TC* It is used for drilling angular high pressure ejector holes into wheel hubs on railroad car wheels. Bore diameter, maximum 24 mm Drilling length, maximum 120 mm Power drilling spindle 6,5 kw Special gear milling machine SPZ 1500 NC* Manufacturing of hirth toothing surfaces is the purpose of this machine. The maximum work piece diameter is mm. The tooth shape is path milled by using profi led milling tools (fractional pitch milling method). Power 12 kw Torque, maximum 430 Nm 3

4 Horizontal milling and boring machine series BFR The standard horizontal milling and boring machines of series BFR (RAM-design) and BFS (slide design) have been designed especially for high precision machining of large sized work pieces. Machines are provided with four NC-axes which enable machining of any given path contour including circular milling. The rigid design of the machine enables to machine economically and precise even in extreme positions, with the spindle or RAM moved far out in the upper position. To achieve the outstanding high machine rigidity and at the same time a high accuracy a special fl ow-controlled hydrostatic is used in the machine. This hydrostatic system works with a minimum gap widths and very low amount of oil. It has a positive effect on the static and dynamic performance of the machine. The system is almost free of wear over the machine live cycle and guarantees a constant accuracy over the complete guiding length. Simplifi ed and almost maintenance free gear units guarantee a high availability of the machines and reduced maintenance. Technical data * Horizontal Vertical Drilling spindle RAM X optionally up to mm Y optionally up to mm Z mm W mm Spindle 60 kw up to 100 kw ø 150 up to 200 mm n 1, RPM 4

5 and BFS Essential advantages of hydrostatic with PM-flow controller The special design of hydrostatic with PM-fl ow controller provides high rigidity and stiffness of the guide ways. This design principle enables minimized gap height adjustments and uses proportional fl ow controllers to do this. As a side effect the amount of oil needed is reduced. Also the necessary amount of energy and thus machining costs are minimized. four to fi ve time higher stiffness than with conventional hydrostatic systems adjustment of stiffness through pre-stressing each hydrostatic pocket will be controlled by a separate proportional fl ow controller gap width is constant within a tolerance range and independent from the machining load signifi cantly reduced oil consumption pumps and motors can be selected more economically no infl uence from changing oil viscosity due to changing temperatures Design of accessories according to customer requirements boring spindle with automatic, hydro-mechanical tool retract and internal coolant fl ow through spindle milling heads are provided based on machining requirements automatic milling head changer with pick-up station control unit make SIEMENS or HEIDENHAIN automatic tool changer chip conveyor coolant fi ltration unit operator platform 5

6 Portal type milling machines PFS and PFA Machines of series PFS are specially designed for machining of steel blocks and components. The very rigid design and high power rates ensure that an outstanding machining performance can be achieved. Design of columns and cross rail are based on the high forces during steel machining. Therefore we provided an enhanced and rigid design. For optimized damping both columns are provided in a stable ribbed design. The machine table is guided hydrostatically on two guide ways. Thus a high damping effect during machining is guaranteed. Table drive is performed by an electronically trussed rack and pinion. To reach a high level of automation the machines can be, based on customer requirements, equipped with an automatic tool changer and automatic head changing unit. An integration of chip conveyor, coolant fi ltration unit and table clamping system is part of our standard service program. Technical data PFS 3 / 120 NC * (Example) Travel Table mm Double support on cross rail mm Cross rail vertical mm Side support vertical mm Spindle power P 120 kw Spindle speed n RPM Rapid speed mm/ min Dimensions Total length mm Width mm Table clamping area x mm Height mm Total weight 146 t 6

7 Machining of aluminum parts requires different machine performance than machining of steel. Therefore we have developed the machines of series PFA. They are based on our modular system and can be modifi ed economically and easy depending on the specifi c machining requirements. The machine consists of the following main sub-assemblies: fi xed columns and vertically adjustable or fi xed cross rail shuttle table with 2 separate clamping surfaces on the machine table headstock with integrated vertical slide, main spindle drive and work spindle drive As a standard also this series is provided with columns in steelwelding design. A special ripped design guarantees very good damping performance. The shuttle table consists of two parts, a cast iron bed and a cast iron clamping plate. It is provided with a high performance feed drive. The modular design of the machine simplifi es service and maintenance on the machine. Thus the non-productive time is minimized. Service work can be performed almost without loss in production. The gantry type milling machine PFGA X-32 for example, was developed fort he high-speed aluminum machining as it is important fort he aviation and astronautics industry. Machines of this series can be provided with up to 8 separate headstocks. Each spindle is provided with a power of 32 kw in continuous operation. Thus 8 work pieces can be machined simultaneously. Two separate clamping surfaces on the machine table guarantee clamping of the work piece during primary processing time whereby the non-productive times are reduced. The machine is completed with a high dynamic tool changer, either travelling with the portal or installed fi xed at one end of the table. In total the machine is provided with 27 NC-axes. 7

8 Roll neck milling machine WZF For machining of roll necks various operations with high metal removal rates need to be performed on one special machine tool. The machines of the series WZF are specially designed for roll machining. They can be adjusted fl exible for different neck shapes and sizes. Flat necks and slot necks can be machined on the fi xed work piece simultaneously with 2 spindles. A moving portal positions the spindles next to the roll necks. The short length of the tools guarantees a high metal removal rate. Machining of the wobbler neck can be performed without swiveling of the work piece. All in-feed and machining movements are performed on the tool side. The columns can be adjusted in cross direction therefore no additional movement of the spindle in cross direction is needed. For optimized operation of the machine and free sight on tools and work piece, control and all control functions are performed from a platform which is mounted on the back side between the columns. Technical data WZF 71 x 5000 * (Example) Travel Bed slide mm Cross adjustment column 840 mm Height adjustment headstock mm Boring spindle 300 mm Spindle Spindle power P Diameter Speed, step less adjustable Torque, maximum 2 x 71 kw 170 mm RPM Nm 8

9 Deep hole drilling machines series TFB and ABD Machines of series TFB are specially confi gured based on the different machining requirements. Depending on the required accuracies the machine is provided with a rotating tool, with rotating work piece or with rotating tool and rotating work piece at the same time. Our machines can be provided with hydrostatic guide ways and cutting speed of up to 200 m/min. The deep hole drilling machines are provided for twist drilling, tapping and milling operations. Also a combined machine for outside and internal machining of cylindrical is part of our product program. The drilling can be performed as reaming, bore out or core drilling operation. Confi guration of the bore oil unit is done together with our experienced sub-suppliers and will be fully integrated into the machine and the control system. Machines of series ABD are designed for turning and boring of cylindrical work pieces. Simultaneous machining of inner and outer work piece side is possible. The work pieces are supported in enhanced heavy duty steady rests with four square quills as support. Both series can be provided with various accessories (e.g. chip conveyor, coolant fi ltration unit, cooling unit, turning attachment, and others) depending on the customers requirements. Technical Data * Work piece diameter Drilling diameter Work piece length up to mm up to mm up to mm Headstock drive up to 460 kw 9

10 Work piece turning tables and shifting tables We can provide tables of various sizes and for any machining operation. The conventional worm / worm gear drive has been replaced successfully with the Master-Slave drive. Together with load controlled hydrostatic and a maximum clamping area of the table, we have various tables of this type running in production. The combined rotary and shuttle table can be provided in (2) versions: Technical data * Table plates Weight on table Travel from mm x mm up to mm x mm 10 up to 120 t up to mm Stationary version for setting up on fi xator elements on a foundation. The table plate is at the same height as the machine fl oor plates. or Portable version for direct set-up on the machine fl oor plates. Fixing of the table with clamping screws in the T-slots. rotary tables shuttle tables combined rotary and shuttle tables tilting tables rotary tilting tables swing tables 10

11 Milling heads for any machining task Modern machine tools need to machine a wide range of different work pieces. Also the machining task changes constantly and needs machine tools with a high degree of fl exibility. Power and speed of the milling heads need to be designed according to the changing conditions. In a lot of cases a special milling head is needed, which is not part of the standard program. We are experienced in modifying and designing heads especially for such cases. Based on customer requirements the milling heads are provided with automatic swiveling or, can also be provided with manual axis adjustment. The following heads are only some samples from the large number of types which can be provided: 1. NC-fork head 2. NC-orthogonal positioning milling head 3. NC-universal milling head 4. Universal milling head (manual axis adjustment) 5. Special milling head 6. Special milling head 7. Special milling head

12 The customer is the focus of everything we do. Together with him we want to fulfill his aims and requirements! Certifi ed to EN ISO 9001 Certifi cation Registration No.: Rottler Werkzeugmaschinen GmbH Ingenieurbüro und Maschinenbau Hauptstrasse 39 D Mudersbach Germany Phone: (+49) Fax: (+49) Anlagen Maschinenbau Automation GmbH Hauptstrasse 39 D Mudersbach Germany Phone: (+49) Fax: (+49) Internet:

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