Alfing Corp. (www.alfing.com) has introduced its new AL-series multi-spindle 5-axis machining center concept designed especially for machining complex, light-metal parts in medium to high volumes. The AL 204 is the leading machine in the series, with four individually driven box spindles arranged for HSK 63 tooling with separate anti-friction ways. Alfing says the primary new production advantage of the series is that it permits higher Z-axis accuracy in a multi-spindle machine than has been possible previously because of the company's new, patented individual spindle compensation. In addition, the placement of the individual spindles ( alternately guided from top and bottom) occupies only half the space required by a traditional 4-spindle machine.
The Alfing AL series provides a fully CNC controlled 5-axis process with an overall working range of X-200 mm, Z-400 mm, Y-450 mm (X-7.8740 in., Y-15.7480 in., Z-17.7165 in.). A multi-axis swiveling trunnion system reduces workpiece changeover time to about 2.0 sec. The D and A axes of this swiveling trunnion quickly bring workpieces into position. Optionally, the A axes can be equipped with up to four B axes, each for machining parts complete in a single set-up. All rotating axes are equipped with torque drives, resulting in long-term accuracy, reduced down time and elimination of excessive wear.
The modular design of the AL series allows for several machine variations to be configured with similar components. The series includes versions of two, three and four-spindle machining centers with individually driven box spindles as well as the standard models with fixed center heads and only one drive in the Z axis.
Depending on customer requirements, all machine models can be equipped with either linear motors or ball screw drives. While the superfast linear machines achieve speed rates of up to 180 m/min (590.5499 ft./min.) and accelerations of up to 20 m/sec2 (65.6167 ft/sec2), the maximum speed with conventional drive technology is at 90 m/min (295.2749 ft/min) and 10 m/sec2 (32.8083 ft/sec2) respectively.
With synchronous motor spindles providing a maximum drive capacity of 58 kW and a max torque of 70 Nm, these new machines can be used to machine a wide variety of light-metal parts.
Based on an average use of 30 (HSK 63) tools per spindle, the AL 204 will be equipped with 120-slot chain magazines. If greater storage capacity is necessary, magazines with up to 320 tool pockets are available. Tool changeover is performed via pick-up method between spindle and magazine. Chip-to-chip time is about. 3 sec.
The AL 204 is standard equipped with a 160 iMB Fanuc CNC, and a Siemens Sinumerik 840D CNC is available as an option. In the fully equipped version, up to 24 NC axes are controlled via two channels.