The F series Setting standards in 5 axis

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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 F series Setting standards in 5 axis

2 Content 5-axis competence 5-axis competence in HELLER quality 5-axis competence in HELLER quality 3 The F Series: Machine concept 4 Innovative spindle technology: Process stability times three 6 The workshop machine: FT 4000 for table loading 8 The production machine: FP 200 / 4000 with pallet changer 12 Control: The choice is yours 16 CAD/CAM integration: From idea to finished product 17 Tool management: Fast, precise, flexible 18 HELLER services: Availability and maximum performance 20 At a glance: HELLER Machining Centres 22 Your investment in a new machining centre has to pay off. To make your production future-proof, you need reliability, precision and high productivity. We are here to help you. Our answer: the new F series. 5-axis machining centres designed to offer more than their competitors. A plus in sturdy engineering: HELLER has been synonymous with milling and high-quality machining since The F series embodies our complete know-how gained from the development of the 5-axis MCH-C series and its predecessors. The F series is a safe investment: it offers productivity and precision from the very first minute. A plus in process experience: Our extensive process experience forms the basis for this 5-axis machine series allowing you to respond swiftly and flexibly to changing machining tasks, whilst ensuring maximum output and optimum quality. A plus in productivity: Highest productivity in continuous operation that is what the F series has been designed for: the FT type for ergonomic table loading, the FP type with pallet changer for compatibility with all HELLER automation systems, 5-sided and simultaneous 5-axis machining, robust machine design, powerful spindles. A plus in flexibility: Cutting costs through complete machining the F series provides the response to this trend in the machine tool industry. Being able to perform as many tasks as possible with the same machine provides flexibility now and in the future. A plus in availability: The F series was specifically designed for robust processes. This means: not chasing after peak values but providing adequate speeds, proven components, truthful characteristics. What are the benefits to you? A machining centre with staying power offering unparalleled opportunities. A plus in service: The HELLER service concept is designed to accompany you from process design, machine installation through to the purchase of new equipment and to ensure constant productivity. What is so special about it? We are wherever you are. All it takes is a phone call. Optimised life cycle costs: The running costs of a machine over its complete lifecycle are easy to calculate from the cost of investment and the cost of operation. Keeping these costs at a minimum, without compromising on the quality and reliability of the machine, is the quintessence of what we do. This is exactly what we have achieved with the innovative manufacturing concept offered by the F series. The savings are directly passed on to you. The F series sets the standards in 5-axis machining providing productivity 2 3 and precision from the very first minute.

3 F Series The machining concept The F Series: machine concept Strong basis for high cutting capacity Bed manufactured from epoxy resin concrete: efficient damping of machine movements, reduced emissions, optimised overall weight Steel column with optimised topology in Y axis with minimal deflection Statically and dynamically optimised by means of structural mechanics simulation Optimised feedback control Optimised resilience and thermo-symmetry Quick chip evacuation for higher precision Z axis with concertina cover below the spindle prevents contaminants from leaving the work area 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 to work area Customised coolant treatment Paperband filter system Vacuum rotation filter system Flexible installation Installation without anchoring Quick installation, easy relocation No separate foundation required Low operating costs Production precision down to the micron Absolute encoded, direct measuring systems High-resolution rotary encoder YRT bearing with integrated measuring system Precise dynamics Proven axis kinematics of the tool: X, Y, C and A Workpiece provides 2 axes: Z, B Linear axes covered with tried and tested concertina covers Ease of operation you can feel Effective safety guarding Optimum access to the work area for workpiece loading Linear guided, smooth opening doors provide optimum access for loading operations Single-handed philosophy: short-stroke doors can be opened with one hand Lowered loading sill at knee height Operating panel at the setting station with integrated flush/air guns Easy to connect to all common HELLER automation systems (FP) Control Programming in the familiar system environment Siemens SINUMERIK 840D sl or Heidenhain itnc 530 Flexibility of choice according to individual requirements: with automation for high-volume output or for manual loading in the workshop High processing power and easy operation Complete integration into the CAD/CAM process chain 4 5

4 F Series Spindle technology Innovative spindle technology: process stability times three The F series with swivel head The F series with fork head Swivel range from +15 to 195 High torque due to powerful 1PH8 motor Robust housing in cast iron HELLER zero-spindle system Media supply directly through the spindle Suitable for dry machining State-of-the-art RMP wireless measuring probe Axis swivel range +30, up to 120 below centre axis Robust housing 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 workpiece precision Media supply directly through the spindle High performance cutting with Power Cutting Universal PCU 63 Speed cutting with Speed Cutting Universal SCU 63 Speed cutting with Speed Cutting Tilt SCT 63 The benefits to you: The benefits to you: The benefits to you: Transmission provides extreme rigidity and damping 1 : 1 gear train HSK, SK and BT spindle taper High cutting capacity Perfectly suited for cast iron, steel and titanium Swivel motor spindle with energy and media supply through the centre of the swivel head HSK, SK and BT spindle taper High speed: 16,000 rpm High chip removal rate Swivel head geometry designed for optimum stability Suitable for dry machining For machining up to a +30 angle below centre axis Clearly arranged cutting geometry High speed: 16,000 rpm High cutting capacity with PCT High chip removal rate The F series provides four spindle variants offering flexibility for any 6 7 machining task whilst ensuring highest precision and performance.

5 FT 4000 The workshop machine The workshop machine: FT 4000 for table loading Outstanding accessibility: F series for table loading (FT) Profile: Entry into HELLER 5-axis machining Classic workshop machine for manual loading Flexible, powerful, highly precise For a wide range of parts and materials produced in low volumes Application: For frequently changing tasks and prototype construction Combination of highest cutting capacity and classleading surface finish Facts: Tool provides 5th axis via HELLER swivel or fork head Storage capacity for up to 240 tools in chain-type magazine or 409 tools in rack-type magazine Unparalleled ease of access to work area through three-part work area door Table with large clamping surface, optionally with hardened surface Technical data Model FT 4000 Working range X = 800 mm Y = 800 mm (SCT 900) Z = 1,000 mm Table size Ø 720 Workpiece Ø x height max. 1,020 mm x 1,500 mm Max. workpiece weight 1,400 kg Chip-to-chip time 3.7 s Rapid traverse 60 m/min Acceleration 6 m/s² Tool Ø x length (chain) 160 mm x 450 mm Tool Ø x length (rack) 188 mm x 450 mm Spindle tapers SK 40 / HSK-A 63 / BT 40 Spindles* PCU/PCT 63: 10,000 rpm, 44/46 kw, 242/116 Nm SCU/SCT 63: 16,000 rpm, 40 kw, 80 Nm * S6 40% duty cycle Sample workpiece Formula 1 racing car (aluminium) Integral component (aluminium) Glass mould with cooling bores (cast iron) 8 9

6 FT 4000 The workshop machine FT: enhanced space, user-friendly ergonomics and precision Safety and ease of operation have a crucial impact on the availability of a machine. Faster and more efficient operation minimises operating errors and risk of failure. With the F series you can profit from our application experience day in and day out. Well-designed workpiece management allows you to machine workpieces with a wide range of geometries and weights whilst ensuring high process stability and perfect machining precision. The loading concept of the F series is based on the experience gained from the H series. The result is impressive: more space, less chip accumulating surfaces, higher precision able to take workpiece weights up to 1,400 kg. FT for manual table loading Optimum access to the work area Quick and easy handling of workpieces Exceptionally well suited for workshop operation Ideally suited, e.g. for tool and die manufacturers with frequently changing tasks and small batch sizes Robust rotary table for high workpiece weights Maximum speed: 30 rpm (F 2000/4000) Workpiece support plate in optional design (slots, threads) Hydraulic workpiece clamping (optional: 5-point services interface with 60 or 200 bars oil pressure or 200 bars with proportional technology) Ball screw drive arranged in the centre Hydraulic supply via bored holes in support plates Component maintenance can be performed from outside the work area Convenient manual loading of the FT is guaranteed enabling you to benefit from our application experience every day.

7 FP 2000/4000 The production machine The production machine: FP 2000/4000 with pallet changer Highest productivity: F series with pallet changer (FP) Profile: State-of-the-art 5-axis production machine with pallet changer Designed for highest availability and productivity for machining of large workloads Application: Prepared for unmanned operation using pallet and workpiece automation Flexible for short-term job changes Perfect for production-oriented users with high output Facts: Cutting capacity for a wide range of tasks from 5-sided machining through to machining of complex freeform geometries Simple and cost-effective pallet automation solutions Fully compatible with HELLER H series Technical data Model FP 2000 FP 4000 Working range X = 630 mm X = 800 mm Y = 630 mm (SCT 730) Y = 800 mm (SCT 900) Z = 830 mm Z = 1,000 mm Pallet size 400 mm x 500 mm 500 mm x 630 mm Workpiece Ø x height max. 720 mm x 850 mm 900 mm x 1,000 mm Max. workpiece weight 800 (600)* kg 1,400 (1,000)* kg Chip-to-chip time* 3.5 s 3.7 s Rapid traverse 60 m/min Acceleration 6 m/s 2 Tool Ø x length (chain) 160 mm x 410* mm 160 mm x 450 mm Tool Ø x length (rack) 188 mm x 410 mm 188 mm x 450 mm Spindle tapers SK 40 / HSK-A 63 / BT 40 Spindles** PCU/PCT 63: 10,000 rpm, 44/46 kw, 242/116 Nm SCU/SCT 63: 16,000 rpm, 40 kw, 80 Nm * Limitations see technical data ** S6 40% duty cycle 3 1 Hydraulic housing (cast iron, plastic) Aerospace valve housing (titanium) Housing component from mould and die making (aluminium) 12 13

8 FP 2000/4000 Automation FP: efficient, universal, highly-productive HELLER machining centres are synonymous with productivity. They provide precise and reliable operation over many years even under constant load. We expect the same from our automation solutions: maximisation of productive time and throughput, increase of production and flexibility in terms of modifications. From swift and easy manual loading to the setting station through to a fully integrated flexible manufacturing system the F series is ready for any solution. FP with pallet changer Compatible with horizontal machining centres from HELLER H series and combines with pallet pools with 6 pallets per machine, pallet handling via turntable Integration into various pallet magazine systems: PMB: basic design with 10 to 24 pallets per machine, handling via stacker crane PME: extended version with 8 to 42 pallets per machine, handling via rotary fork PMF: flexible design from 16 pallets per machine, handling via telescopic fork Robot automation with standard robot cell or individual solutions Fully automatic: the FP provides high productivity even under constant load.

9 F Series Control Control: the choice is yours The new F series is equally suited for machining of individual parts in tool and die manufacturing and for the requirements of high-volume production using 5-axis machining. Simply choose the type of control that suits your requirements best: Siemens or Heidenhain. Heidenhain itnc 530 Siemens SINUMERIK 840D sl CAD/CAM integration From idea to finished product For manual operation in the workshop Highly precise control of speed and acceleration Highly adaptable for precision and surface finishes Short block processing time of 0.5 ms Free contour programming DCM dynamic collision monitoring User-friendly setup functions For high output with automation Precise control of speed and acceleration Highly adaptable for precision and surface finishes Exceptionally well suited for machining of sculptured surfaces Graphical cycle support Remote diagnostics via eps Fast, highly precise machining without unnecessary correction loops that is what is required of a 5-axis machining centre. Benefit from maximum flexibility by programming at the machine combined with innovative technology and machining cycles or use the existing CAD/CAM chain at your facilities. Be a master of your processes at any time with the F series. If you are dealing with frequently changing tasks or complex shapes, the machines provide the precision and efficiency you need. Workpiece and pallet management Clearly arranged graphical and tabular visualisation of pallets and programs Easy allocation of NC programs Preparation of pallet data for pending jobs Clearly arranged display of machining status Tool management Extensive tool tables Cutting data tables for automatic calculation of spindle speed and feed from workpiece-specific data Replacement tool strategy Monitoring of tool life and usage Tool loading during spindle operation and in automatic mode 16 17

10 F Series Control Tool management: fast, precise, flexible What do you require in terms of tool management from a 5-axis machining centre made by HELLER? You might wish to utilise your existing stock of tools, use a wide range of tools and large tool geometries; you require a flexible solution that will meet your production requirements in the most efficient way. At the same time, tool loading times and downtimes as well as idle times should be minimised. No problem: the new F series can provide all of this! Tool changer Motor arranged outside of coolant and chip area Optimised accessibility for belt tensioning Torsionally stiff housing due to enclosed design (only assembly openings) Easy exchange of motors on the ZT1 axis due to use of elastomer coupling Chain-type tool magazine Max. tool diameter: 160 mm Max. tool lengths: 350 mm on F 2000, 450 mm on F 4000 Chain-type tool magazine with 54, 80, 160 or 240 storage places Max. chain speed: 32 m/min Tool axis moves along the chain path Optimised tool provisioning time Magazine only fixed to console Tool loading parallel to machining Rack-type tool magazine 409 magazine places Max. tool diameter: 188 mm Max. tool lengths: 410 mm on F 2000, 450 mm on F 4000 Reduced space requirements due to double-sided arrangement Magazine access Loader axes with NC technology Leakproof floor pan, no leakage of coolant or lubricant Manually operated rotary station, optional: automatic rotary station HSK, SK and BT spindle tapers Proven basic structure: tools aligned in Z direction, storage and retrieval unit moves in X, Y and Z direction Short tool selection path Compact, space-saving layout F series ensures short loading times, short downtimes and short idle times.

11 Services Services HELLER services: availability and maximum performance When you invest in a machining centre today, you expect to get a solution that delivers highest availability and maximum performance. That is why HELLER services are practically inextricably linked to the machine. From remote service equipment, commissioning and training through to predictive maintenance and spare parts supply. HELLER provides a complete range of services to ensure long-term costeffective operation of advanced high-tech machining centres incorporated in efficient manu facturing solutions. HELLER services are available around the globe offering unrivalled performance. Global presence to serve our customers worldwide Transnational services Global service standards in HELLER quality Customised service concepts for global players Group-wide service agreements Designated contact person (responsible for communication, technical support and implementation of standards at subsidiaries) Service solutions and service standards Industry-specific and customer-specific solutions Upgrades to expand your machining centre s task profile Efficient solutions providing higher availability and precision Cost reduction through standardised services (rebuilds, repairs, training, upgrades) Relocation Service Complete relocation of your machining centres from one source Upgradable with production support on site Planning, professional preparation for transport, implementation and re-commissioning from one source (HELLER and other brands) Additional options: inspection by manufacturer, overhaul of main assemblies, training, acceptance Fast-response spare parts concept High availability of spare parts, flexible, global supply Supply of exchange parts (reconditioned spare parts with special savings) Service kits (ready-made spare part packages) Fast response thanks to our own repair shop Standardised spindle repair HELLER Academy for technical staff development Customer-specific or standardised training of your staff (at HELLER or at your premises) Training for operators, programmers and maintenance staff (hands-on instruction on main assemblies) Practice-oriented, modular training materials NC simulation tools for programming courses Direct support via teleservice and service hotline Rapid troubleshooting via teleservice (RDS) Dedicated contact person on site Short response times and 24/7 standby service Predictive planning of maintenance measures (CDS) HELLER services provide optimum availability of your machining centre ensuring maximum productivity.

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