The Hyperturn 65 Powermill has a 1,300-mm spindle clearance; a counter spindle that also achieves four-axis machining; a direct-drive B-axis for five-axis simultaneous milling; and an additional Y-axis for the lower turret.

Spindle Design, Functions Adapt for Complex Turning

Dec. 4, 2014
Multiple one-set-up possibilities promote high-value turning, drilling, milling and gear-cutting Counter spindle option Swiveling milling spindle Two interpolating axes

With its multiple set-up possibilities, Emco Maier’s Hyperturn 65 Powermill is a valuable asset for shops machining complex parts. It offers a large spindle clearance of 1,300 mm; a counter spindle that also achieves four-axis machining; a direct-drive B-axis for complex 5-axis simultaneous milling operations; and an additional Y-axis for the lower turret.

Ergonomically designed, the machine is particularly well-suited to serial production of workpieces, for example in the automotive industry, mechanical engineering, and material handling. Mill/turn operations for aircraft parts are another effective application.

Complex and high-value turning, drilling, milling and gear-cutting can be competed in one setup, according to the machine’s developers. Additional handling and part storage is eliminated and workpiece precision is improved.

Total production time, fixture and personnel costs, as well as floor space requirements can be reduced with the Hyperturn, Emco Maier noted.

With 29 kW and 250 Nm the counter spindle is sufficiently powerful to machine a workpiece with two tools simultaneously, making four-axis machining an effective possibility.

Another design advantage of the Hyperturn 65 Powermill is the milling spindle, a 29-kW, 79-Nm torque, and up to 12,000-rpm device that promotes productivity for complete machining of complex workpieces. The B-axis direct drive gives the Hyperturn 65 PM good dynamics and contour capabilities with five-axis simultaneous machining, and faster tool changing. The additional Y-axis on the lower turret makes extensive milling work possible at the same time as machining with the milling spindle.

The milling spindle with HSK-T63 tool interface can be used both for turning and drilling/milling work. It can swivel continuously within a range of +/-120° and clamped at any point. The Y travel is +120/-100 mm, so the most complex of machining work is . This includes gear-cutting operations, turning/milling work for crankpins, 5-axis machining, and much more. The tools can be customized with a 20-piece pick-up magazine, or a 40- or 80-piece chain magazine.

The Y-axis accomplished by two interpolating axes distributes the cutting force in two levels and adds stability to heavy-duty turning and milling. This means the lower turret with integrated milling drive also can be used for complex milling operations at all 12 positions, combined with a Y-axis with +/-50 mm travel.

Various tool magazine selections — 20, 40 or 80 pieces — with HSK-T63 give the user more possibilities for complete machining of complex workpieces, with simultaneous low set-up times for individual parts manufacturing, and high stability for turning and milling works.

As an alternative to the VDI30 or VDI40 12-position tool turret, Emco offers a new turret designed with BMT interface and direct drive.

The machine versions with a milling spindle and turret, including milling drive (SMBY/SMBY2), have a cross-slide underneath with a 12-position radial turret for 12 driven tools, working up to speeds of 5,000 rpm.

Automatic bar machining and/or material delivery via a robot solution or Emco gantry loader, will increase efficiency.

The Hyperturn 65 is controlled by the Siemens Sinumerik 840D-sl CNC package, with a new, intuituve user interface that makes machine programming significantly easier, according to Emco. It’s own CPS Pilot simulation software adds to the productivity because it allows operators to plan, program, simulate, and optimize production runs on a PC using a 3D model.

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