CNC Portal Milling Machine FZ 32. High Performance Milling Technology

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1 CNC Portal Milling Machine FZ 32 High Performance Milling Technology

2 FZ 32 HSC Portal Milling Machine with Overhead Gantry with upper moving portal high axial accelerations and perfect surface finishes can be achieved, resulting in an overall economic solution. Low moving masses High structural stiffness High dynamic and surface quality The highly dynamic portal milling machine of the second generation, for sophisticated applications in the aircraft industry and in automotive development. Well balanced technology tailored specifically to accuracy, thermal stability and rigidity requirements for composite and aluminium machining. acceleration values. It has been designed to meet customer needs for the highest cost effectiveness, dependable accuracy and high dynamics. Using the latest FEM simulation techniques it has been possible to create a machine with the greatest possible stiffness which at the same time has low moving masses. With this advanced machining concept based on the Zimmermann overhead gantry technology The side walls form an integral part of the machine housing. Windows on the left or right side whichever the customer prefers offer a good view of the working area. Loading and unloading is carried out through a sliding door at the face side. The FZ 32 is designed for dynamic speed 5-sided machining of aluminium and composite materials as well as for simultaneous finishing of steel with high Dust-proof bellows. Vertical slide / Z-RAM 2-axis milling head VH 2. Heavy duty machine table with sheet covers on all sides. Lamella bellows for the drive systems. Overhead gantry moving in X-direction. Fixed side wall, filled with special concrete. Integrated safety guarding. Encapsulated tool changer outside the machining area, pickup or chain design magazine. 2 CNC Portal Milling Machine FZ 32

3 VH 2 The Compact Wherever low interference contours and reduced moving masses are required, the extremely powerful VH 2 comes into its own. Maximum working areas A particular specialty of the Zimmermann portal milling machine is the mastery of very large working areas due to its optimal structural rigidity. Particularly with very long Z- and / or Y-axes, the mass of the milling head plays an important role in milling accuracy. Above all, deflection and torsion must be kept to a minimum in order to achieve the best possible surface finish and contour accuracy. Where large working areas are required but hardly any heavy materials are to be machined or high machining speeds are needed, the weight optimized VH 2 milling head is an ideal solution. Complicated contours Portal milling machines are being used to machine increasingly complex workpieces with tight contours. Often intricate clamping fixtures are needed which restrict access during the milling process. With its compact design the VH 2 is often ideal for working efficiently in this limited space. Lightweight machines The VH 2 is particularly suitable for medium-volume machining of lightweight materials up to aluminium and for finish machining of steel and cast iron. A new design Low interference contour for better access. Water-cooled worm drive and spindle flange for higher accuracy and to eliminate thermal influences. Higher swivel speeds to reduce overall machining times. Clamping of rotary axes for greater stiffness during roughing. Robust, reliable grease replenishment system to ensure long life and profitability. Applications The VH 2 is basically an allrounder and thus offers great advantages as to order flexibility. However, it really comes into its own where high power combined with low weight and / or compact size is required. Very large working areas and complicated workpieces such as in the design field and in aircraft manufacture are the applications the VH 2 is often at its best. 3

4 FZ 32 Technical Specification Design The portal design with fixed machine bed and a gantry that travels in the X direction offers significant advantages for tool, mould and pattern making as well as for the aircraft industry. The cast-iron machine bed is permanently anchored to the foundation, so that the workpiece does not have to be moved. In this way, machining operations are independant of the weight of the workpiece. The moving mass is made up of the structurally stiff gantry, the transverse and Z-slides, and the milling head. The constant moving masses ensure highly consistent dynamic behaviour a prerequisite for optimum surface finish and workpiece accuracy. This combination of high stability and stiffness, constant moving masses, and a highly dynamic drive make the machine suitable for machining of several types of materials, for example plastics, aluminium, kirksite and fibre-reinforced composite materials. When machining composites, the drives are characterised by very smooth running. The 2-axis milling head VH 2. Machine Frame and Slides The machine bed is made of cast iron; the side walls, gantry and Z-slide are of welded steel construction. The side walls are filled with a special, fibre-reinforced DemTec concrete. The guide, drive and measuring systems for the Y- and Z-axes are protected against contamination by dustproof bellows. The X-axis is fitted as standard with aluminium lamella bellows. 4 CNC Portal Milling Machine FZ 32

5 Z X Y The FZ 32 always has as standard three driven linear axes (X, Y, Z). Tool changer with chain. Rack and pinion drive. C A On the 5-axis machine, the milling head can also be swivelled two axes (A, C), both driven. Drive System Independent of the supplier of the control system, all axes are equipped with Siemens Simodrive digital drives. The power transmission is carried out by means of a rack and pinion drive with electronically preloaded motors in all three linear axes X, Y and Z. The control-system gantry function ensures that the two X-axis drives are synchronised. Linear guides: Pre-loaded circulating-roller linear bearings, size 55 on the X-axis, and size 45 on the Y- and Z-axis. Up to 8 bearing carriages per axis. Rack and pinion: Rack and pinion, quality level 5 with two electronically preloaded motors per drive unit in the X- and Y-axis one unit for backlash-free motion and drive in the Z-axis. Measuring systems The three linear axes, X, Y and Z, are equipped with direct length measuring systems with Comparison of different structural materials for the side walls based on the most important functional criteria. DemTec Castings Steel Heidenhain glass-scales (steel meters / for axes with over 3 m travel). The measuring systems are protected against dirt and dust by a compressed air barrier. Milling spindle The milling spindle can be supplied with a power of 45 kw whereas the speed of rotation is 25 min -1 (optional 3 min -1 with oil-air-lubrication). In both cases, the spindle is supported in preloaded, ceramic, hybrid spindle bearings. The bearings have labyrinth seals with a compressed air protection. To minimise downtime in the event of damage, the spindle cartridge can be changed very quickly and easily. As an innovation the spindle is equipped with a permanent lubrication with automated grease replenishment system. This enables higher speeds and above all a longer life. Controls The FZ 32 has been designed so that it can be combined with various makes and types of control. Modern control systems provide functions such as Look ahead, jerk limitation, spline interpolation, and 5-axis machining. Equipment and software solutions for many additional tasks are available as an option. Damping Rigidity Thermal conductivity Thermal accumulation capacity 5

6 FZ 32 Technical Data Machine FZ 32 Working ranges X-axis 2 4 mm 1 Y-axis 3 4 mm 1 Z-axis mm 1 Worktable size Length 2 4 mm Width 3 mm Height 35 mm Max. worktable load 2 kg/m 2 T-slots (longitudinal) 18 H12 Distance T-slots 25 mm Feed drives Feed drive X, Y and Z-axes up to 5 mm/min. Acceleration of linear axes 2,5 3,5 m/s 2 Accuracy 2 Positioning accuracy X-axis Positioning accuracy Y-, Z-axis Repeatability X-axis Repeatability Y-, Z-axis,3 mm,2 mm,15 mm,1 mm Milling head VH 2 Swivel ranges A-axis + 95 / or ± 11 C-axis (Z = 125 mm/z=15mm) ± 3 / ± 36 Performance Torque A-, C-axis 8 Nm Acceleration A-, C-axis 3 /s 2 Feed rates A-, C-axis 6 /s perm., 9 /s max. Accuracy 2 Positioning accuracy A, C-axis 15 =,41 Repeatability A, C-axis 1 =,27 Axes clamping Clamping A-axis Clamping C-axis Torque A-, C-axis hydraulic spring clamp 1 6 Nm Milling spindle Universal Power S1 max. (1 % ED) 45 kw Max. torque S1 (1 % ED) 67 Nm Max. speed Permanent greasing 25 min -1 Oil-air lubrication 3 min -1 Constant power range from 6 4 min -1 Tool holder Distance swivel axis spindle nose Tool clamping Tool unclamping Lubrication HSK 63 A 32 mm Spring clamp hydraulic Perm. grease lubrication + automatic grease replenishment system (opt. oil-air lubrication) 1 Other dimension on request 2 According to VDI / DGQ 3441 Subject to technical changes 6 CNC Portal Milling Machine FZ 32

7 VH 2 Milling spindle performance diagrams Permanent greasing Md [Nm] Oil-air lubrication Md [Nm] kw Torque Md Power P P [kw] Nm n [min -1 ] 45 kw 67 Nm n [min -1 ] 45 Torque Md Power P P [kw] Dimensions X-axis approx. 2 4 mm Y-axis approx. 3 mm Height approx mm Z-axis mm Worktable length 2 4 mm Width 5 5 Worktable width 3 mm Length approx mm All dimensions shown are examples of the FZ 32 in the minimum and maximum configurations. Special variations within this range are also possible. Options FZ 32 Air-conditioned control cabinet Safety guarding Simultaneous A-axis Simultaneous C-axis Coolant system Minimal quantity lubrication Measuring touch probe (wireless, cable) Options FZ 32 Tool changer 15, 3, 5, 8 positions Tool measuring (laser, tactile) Special painting Chip conveyer Extraction system Partitioned working area Clamping A- / C-Achse Standard Option 7

8 High Performance Milling Technology FZ 5 FZ 42 FZ 38 FZ 37 Zimmermann is synonymous with CNC portal milling machines on a big scale. Specialisation and our high rate of innovation has put our technology out in front worldwide. A uniquely wide and finely tuned programme, including a large number of different machines and milling heads, enables you to choose the perfect machine for every application, thus offering you the ideal solution with regard to quality and cost-effectiveness. FZ 35 FZ 32 FZ 3 FZ 25 FZ 15 F. Zimmermann GmbH Goethestraße D-7377 Denkendorf, Germany Phone +49 (7 11) Fax +49 (7 11) [email protected] Apollo