The C series Future-proof production with Combined Processing

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1 Some of the options shown are not included in the basic configuration. Design and scope of supply are subject to technical changes Gebr. Heller Maschinenfabrik GmbH Machining Centres HELLER solution competence: Efficiency for your production. Worldwide. The C series Future-proof production with Combined Processing

2 Content Future-proof manufacturing: Combined Processing made by HELLER 4 Machine concept: The C series 6 Extensions and options: Typical extra quality from HELLER 10 Spindle technology: Milling and turning with 5th axis provided by the tool 12 Tool management: When milling and turning go hand in hand 14 Workpiece management: Repeatability and safety 16 Control: Performance for Combined Processing 18 HELLER services: Availability and maximum performance 20 At a glance: HELLER Machining Centres 22 Horizontal, vertical and tilted turning with A and B axis, combined 2 3 with a unique cutting performance.

3 Combined Processing Future-proof manufacturing: Combined Processing made by HELLER In times of cost pressure, constantly changing tasks and requirements, a noticeable trend is that a growing number of tasks have to be handled by fewer and fewer machines. This has the benefit that a one-off investment can help to ensure flexible production today and in the future. What do you require from a state-of-the-art machine? Surely the answer is that it needs to be flexible, versatile, but above all future-proof. An all-rounder with the capability to master a combination of different machining tasks effortlessly. This new range of machines combines the two most important machining processes milling and turning on a single machine. You benefit from our experience as a manufacturer of machining centres and solution provider: in the development of the C series we drew on our comprehensive experience in process engineering. See for yourself what Combined Processing can do for you. Discover HELLER s new range of milling/turning centres. HELLER provides an answer to your needs and any future market requirements: the new C series offers process competence at its best. 4 5

4 Machining concept The C Series: machine concept Space requirements Machine bed and column Drive technology Work area Smaller footprint, reduced costs, faster installation Components and units fully integrated into the machine structure Compact design provides very small footprint in this machine range. No separate foundation required Sizes Optimised with state-of-the-art simulation technology Bed manufactured from epoxy resin concrete: efficient damping of machine movements, reduced emissions, optimised overall weight Steel column with optimised topology in Y axis Statically, thermally and dynamically optimised by means of structural mechanics simulation Enhanced power and precision Proven axis kinematics of the tool: X, Y, C and A Workpiece provides 2 axes: Z, B Linear axes covered with proven concertina covers Optimum chip disposal, higher accuracy Steep and extremely smooth chip chutes, free chip fall from rotary table Clean work area due to integrated flushing nozzles Easy to clean due to good accessibility CP 2000 X = 630 mm Y = 630 mm (SCT: 730 mm) Z = 830 mm CP 4000 / CT 4000 X = 800 mm Y = 800 mm (SCT: 900 mm) Z = 1,000 mm High cutting performance and precision for every machining strategy Cost-effective price Short commissioning times High precision across the overall working range Reduced table deformation and higher precision with drives arranged on the inside Minimal axes positioning times ensure high productivity Reduced downtimes due to contamination Reduced production costs Higher workpiece precision 6 7

5 Machining concept The C Series: machine concept Spindles Rotary table Tool management Workpiece management Highest precision made by HELLER Power Cutting Universal PCU 63: 242 Nm torque, extremely stiff, HELLER zero-spindle system, HSK-T 63 spindle taper Speed Cutting Universal SCU 63: swivel motor spindle, HSK-T 63 spindle taper, high speed, high chip removal rate, robust swivelhead geometry Speed Cutting Tilt SCT 63: A-swivel range from +30 below centre axis to -120, motor spindle integrated in fork head Highly dynamic tool spindles with shortest run-up time (accelerate to 16,000 rpm in 0.5 sec.) Spindle nozzles (optional): air blast at the spindle and spindle flange provides optimum safety and precision Powerful rotary table for highly precise machining Optional 5-point media interface provides high flexibility 5-point media interface (optional) CT: circular table with grooves, optionally available with threaded holes to DIN A1 CP: uses the same pallets as H and F machine series Tool provides 5th axis via HELLER swivel or fork head Storage capacity for up to 240 tools in chain-type magazine Storage capacity for up to 409 tools in rack-type magazine Quick and safe handling of turning and milling tools CT: workshop machine for manual loading designed for a wide range of parts and materials produced in small batches CP: production machine with pallet changer designed for highest availability and productivity for machining of large workloads Combination with pallet pools with 6 pallets per machine, integration into various pallet magazine systems for a customized number of pallets, robot automation Extremely robust turning operation due to hydraulic fixing of the spindle Highest flexibility for milling and turning operations due to unrivalled high torque with HSK-T 63 Adaptation of existing fixtures available on request Safe and precise turning operations due to hydraulic clamping Re-use of existing cutting tools Wide range of tools New operating strategy provides short tool loading times Planned tool changes, minimised downtimes Tool condition monitoring provides high process dependability Short idle times due to optimised chip-to-chip times High cutting capacity for a wide range of tasks: 5-sided machining, complex free-form geometries, demanding turning operations (tilted turning) Allows machining of large workpiece geometries and masses Compact rotary table provides optimised chip flow High machining accuracy through reduced chip deposits and pneumatic cleaning during pallet change High process stability thanks to new rotary table clamping 8 9

6 Options Extensions and options: typical extra quality from HELLER 1 Control SINUMERIK 840D solution line Operating modes 2 and 3 included in standard scope of supply Increased operator convenience Pallet and job management Automatic return to home position Graphical diagnostic tools Remote diagnostics of the machine and coolant unit Comprehensive option package 3 Auxiliary equipment Multi-spindle head location Measuring probe Tropical package for ambient temperatures up to 45 C and high humidity Fast tool breakage monitoring Optical or tactile tool measuring for milling and turning tools 2 Automation Standardised interface to linkage systems Automation with pallet pool or pallet magazine with up to 42 pallets or customisable pallet magazine with a wide range of functions Robot automation: automation with drawer-based and skid-based system automation by means of conveyor and paternoster system 4 Chip disposal Hinge band conveyor Paperband filter (PBF) with high pressure pump 50 or 70 bars, 40 μm filtration Vacuum rotation filter (VRF) with high-pressure pump 50 or 70 bars, 40 μm filtration Extraction unit for emulsion on the work area cover Work area flushing Coolant refrigeration unit Tailor-made: the C series provides extensions and options to perfectly customise your machining centre. 11

7 Spindle technology Spindle technology: milling and turning with 5th axis provided by the tool C series with swivel head C series with fork head High-precision turning at full capacity Tool provides 5th axis The 5th axis provided by the tool makes the C series the perfect solution for 5-axis machining and for turning operations: horizontal and vertical turning with B and C axis allows to generate precise outer and inner contours. The HSK-T 63 spindle taper provides high precision and repeatability for tool positioning. Due to the extremely stiff machining units, the C series provides high cutting capacity. Extremely high cutting forces for turning operations The C series is equipped with a spindle fixation providing torsionally stiffness and high repeatability. As a result, it offers high cutting forces at highest process dependability and machining accuracy. Professional turning operations The C series provides professional solutions for performing all kinds of turning operations required in day to day production, e.g. vertical turning with A/C and B axis, horizontal turning with A/C and B axis as well as tilted turning with A/C and B axis. C swivel range from +15 to -195 High torque due to powerful 1PH8 motor Robust guide slide in cast iron HELLER zero-spindle system Media supply directly through the spindle State-of-the-art RMP wireless measuring probe Hydraulic fixing A-axis swivel range from +30 below centre axis to -120 Robust guide slide in cast iron Motor spindle mounted in fork head with bearings Energy and media supplied through the outside of the fork head New cooling system provides reduced thermal growth in the machine and highest precision Media supply through the spindle Hydraulic fixation High performance cutting with Speed cutting with Speed cutting with Power Cutting Universal PCU 63 Speed Cutting Universal SCU 63 Speed Cutting Tilt SCT 63 Transmission provides extreme Swivel motor spindle with energy HSK-T 63 spindle taper rigidity and damping and media supply through For machining up to a +30 1:1 gear train the centre of the swivel head angle below centre axis HSK-T 63 spindle taper HSK-T 63 spindle taper Clearly arranged cutting High chip removal rate High speed: 16,000 rpm geometry Perfectly suited for cast iron, High chip removal rate Run-up time to 16,000 rpm: steel and titanium Swivel head geometry designed 0.5 sec for optimum stability High chip removal rate 12 13

8 Tool management Tool management: when milling and turning go hand in hand For a milling/turning centre superb tool handling is a must. Changeover between the machining processes must be smooth, but above all, reliable. The C series is equipped with the proven HELLER tool management system. The benefit to you: you can continue to use your existing milling and turning tools. Tool changer Tool changer with proven technology from the H series Motors arranged outside of coolant and chip area Torsionally stiff housing due to enclosed design Fast tool break monitoring during machining provides high process reliability (optional) Chain-type tool magazine Max. tool diameter 160 mm Max. tool length 450 mm (C 4000) Chain-type tool magazine with max. 240 places Chain speed max. 32 m/min Tool shank cleaning (optional) Tool loading during machining (optional on tool magazine with 160 places, standard on tool magazine with 240 places) Rack-type tool magazine 409 storage places Max. tool diameter 188 mm Max. tool length 450 mm (C 4000) HSK-T 63 spindle taper Tool shank cleaning (optional) Tool loading during machining Perfect precision for any tool Tactile or optical tool measurement (optional): the C series provides the ideal measuring system for any machining operation. Tactile tool measuring is the perfect solution for turning tools, whilst optical measurement works best for checking drilling and milling tools. Reduced positional tolerance of turning tools: spindle fixation ensures high repeatability for turning processes. High quality turning operations can only be achieved when the repeatability of cutting edge positioning is guaranteed

9 Workpiece management Workpiece management: repeatability and safety Perfectly balanced for perfect turning results The C series enables quick and easy manual loading to the setting station or can be used in a fully integrated flexible manufacturing system. In the design of the machine, special emphasis was placed on the integrated balancing function, because high repeatability of centric clamping is an important safety aspect in turning operations. CT for manual table loading Optimum access to the work area through three-part work area door, reduced effort for loading and process monitoring of tools Quick and easy handling of workpieces Ideal machine for workshop operation with small batches and frequently changing tasks Hydraulic workpiece clamping (optional) CP with pallet changer Combination with pallet pool with 6 pallets per machine Integration into various pallet magazine systems: basic design with 2 to 10 pallets per machine (handling via parallelogram), extended version with 8 to 42 pallets per machine (handling via rotary fork), flexible design from 16 pallets per machine (handling via telescopic fork) Robot automation using standardised robot cells or customised solutions The rotary table with direct torque drive provides the necessary power for the turning operation. An integrated balancing function helps the machine operator to determine the balancing weights and to detect and correct inadmissible imbalances, if necessary. As a result, safe operation of the machining centre is ensured. The optional 5-point media interface provides safety and control. It provides support for clamping and unclamping of workpieces

10 Control Control: optimum performance for Combined Processing Combined Processing requires a powerful control capable of combining two completely different machining processes to a plausible machining concept. The control technology of the C series draws on the combined control expertise from the H and F series, so you can rest assured: the control of the C series knows both technologies inside out. Workpiece and pallet management Clearly arranged graphical and tabular visualisation of pallets and programs Easy allocation of NC programmes Preparation of pallet data for pending jobs Clearly arranged display of machining status Siemens SINUMERIK 840D sl High performance for demanding milling/turning operations Highly precise control of speed and acceleration Highly adaptable to requirements in terms of precision and surface finish Exceptionally well suited for machining of sculptured surfaces Remote diagnostics Graphical cycle support (milling + turning) Integrated balancing function Tool management Extensive tool tables Cutting data tables for automatic calculation of spindle speed and feed from workpiece-specific data Replacement tool strategy Tool life and quantity monitoring Tool loading during spindle operation and in automatic mode Integration of drilling, milling and turning tools Consideration of tool compensations depending on tool type (turning/milling) Turning with tilted swivel head Full support for turning operations Fixture balancing Comprehensive graphical cycle support Control-integrated signal evaluation for detecting imbalances Roughing Rough balancing and precision balancing Recessing/undercutting Intuitive graphical user interface ensures optimum mounting of Thread cutting balancing weights Parting Consideration of possible balancing weight positions Contour roughing/contour recessing/contour turn-recessing Display of balancing quality Residual stock consideration Monitoring of imbalances during the machining operation Extended NC instructions for easy switchover between milling and turning operation 18 19

11 Services Services Full-Service plus HELLER can be relied on When you invest in a machining centre today, you need to be certain that the solution will deliver highest availability and maximum performance. With services from Heller this is guaranteed. HELLER operates six service bases in Germany and provides customer support close to you from 20 service facilities around the globe. More than 400 service employees worldwide provide support to ensure the availability of your machines around the clock every day. For you, HELLER service support means that you can combine our services according to your needs whilst we help to maximise added value. Service plus provides the typical extra quality from HELLER. You can choose from various base modules or opt for our Full-Service plus package. No matter which type of service agreement you choose, the availability of your machine is guaranteed. In addition, we can provide you with the know-how and skills you need with our hands-on training courses. Practical and theoretical training ensures that your staff is optimally prepared for their everyday tasks. Hands-on focused training courses are held by specialists according to subject in operation, programming and maintenance. Full-Service plus comprises all base modules as well as spare parts service, scheduled and unscheduled repairs. Base module Maintenance plus Higher availability, reduced downtimes Regular maintenance at fixed intervals in accordance with a service agreement incl. documentation Package includes spare parts subscription Condition analysis incl. repair recommendations and cost-effective implementation Dedicated contact person and service engineer Wear parts subscription plus Reduced costs, higher reliability Cost-optimised wear parts packages Function-oriented condition analysis Base module Remote service plus Fast fault identification, immediate response Online fault diagnostics Machine gives direct alarm notification via / text message Event monitoring Base module Manufacturer inspection plus Continual monitoring, documentation and consulting Function-oriented condition analysis Participation in HELLER product improvement programme Annual inspection and re-adjustment of main assemblies Annual geometry check incl. measuring protocol Condition-based consulting in terms of optimisation and preventative maintenance Documentation of machine condition Unplanned downtimes are minimised Availability of the machine is maintained Service engineer knows your machine inside out to provide preventative maintenance with recommendations for follow-up actions Downtimes can be scheduled, costing certainty Ad-hoc response and cost savings due to RDS (Remote Diagnostics Service) One dedicated contact person Training plus Training by professionals Customer-specific or standardised training of your staff (at HELLER or at your premises) Training packages for programming (5-axis programming, process monitoring, measuring probe, turning), operation (basic course, advanced course, C-head), mechanics and electrics NC simulation tools for programming courses Product-specific qualification Training by practitioners for practitioners High productivity right after commissioning Targeted usage of the machine Efficient problem solving 20 21

12 Machining Centres Made to work At a glance: HELLER Machining Centres H series 4-axis horizontal machining High performance and precision from light-metal machining through to heavy-duty cutting. For varying batch sizes and a variable range of parts and materials. Work area: 630x630x630 mm 3 1,000x1,000x1,000 mm 3 Spindle taper: SK 40 / HSK-A 63 / BT 40 SK 50 / HSK-A 100 / BT 50 Spindles: 6,000 24,000 rpm / kw / 40 2,292 Nm F series setting standards in 5 axis Workshop machine FT: wide range of parts and materials, low volumes, frequently changing tasks. Production centre FP: high- production capacity with 5-axis / 5-sided machining, flexible response to job changes. Working area: 630x630x830 mm 3 800x800x1,000 mm 3 Spindle taper: SK40 / HSK-A 63 / BT 40 Spindles: 10,000 16,000 rpm / kw / Nm MCH series universal high-performance machining Superior machine dynamics, optimum positioning and circular accuracy, reduced idle times. Suitable for high chip removal rates as well as flexible production. Work area: 1,250x1,000x1,000 mm³ 2,000x1,400x1,250 mm³ Spindle taper: SK 50 / HSK-A 100 Spindles: 6,000 12,500 rpm / kw / 460 1,145 Nm C series Combined Processing Milling/turning centre for horizontal, vertical or tilted turning with A and B axis and powerful 5-axis machining, future-proof productivity. Work area: 630x630x830 mm 3 800x800x1,000 mm 3 Spindle taper: HSK-T 63 Spindles: 10,000 rpm / 44 kw / 242 Nm 16,000 rpm / 34 kw / 68 Nm MCH-C series flexible 5-axis heavy-duty cutting High-torque flexible machining from heavy-duty cutting at 822 Nm through to finish machining at max. 8,000 rpm. High precision and outstanding machining quality. Work area: 1,000x1,000x1,100 mm 3 1,600x1,200x1,700 mm 3 Spindle taper: SK 50 / HSK-A 100 Spindles: 6,000 (8,000) rpm / 43 kw / 822 Nm 22 23