ZIMMERMANN INC. is offering the new five-axis portal milling machine developed by parent company F. Zimmermann GmbH for its new FZP machine series: Zimmerman is targeting model-, tool-, and die-making operations that must deliver perfect parts at competitive prices, and within tight deadlines. The FZPs are customizable, space-saving, and highly thermostable, according to the developers, features that are ensured by the new thermosymmetrical design with a center-guided Z-slide.
“An evolution is a progressive process. A revolution, by contrast, is a fundamental and lasting structural change of a system - this is exactly what we have done with the development of our new FZP machine line," stated Zimmermann technical director Daniel Demlang. Customers of model, tool, and die makers demand workpieces with near-perfect surfaces and consistently high dimensional accuracy, and the key to achieving this is manufacturing equipment that minimizes rework, to ensure fast delivery times.
"Our customers are burdened by increasing cost pressure and the demand for ever-higher quality, while simultaneously increasing delivery deadline pressure for components. Reducing throughput times for workpieces was one of our main goals with the newly developed FZP series in terms of design," Demlang explained. "Stable process control and high machining quality are decisive factors for the cost-effectiveness of our systems."
Customizable by length and width. "With our new FZP line, we primarily want to empower customers to compete successfully in the market for the long term," said Demlang. The developers have placed particular emphasis on the customizability of the machines. Their structure can be varied in length and width with different vertical slides and gantries, thus adapting to a wide range of workpiece sizes. The "lightest" machine in the FZP line is the new FZP32 with a working range of up to X = 10, Y = 4, and Z = 2.5 meters (393x157x98 in.)
Users can machine block materials, plastics, as well as CFRP, GFRP and aluminum, among other materials, he said.
Due to the large working area, it is also possible to mill components completely without reclamping. "The modular design of the machine offers the possibility to consider different options. Automation solutions, such as a pallet changing system, a positionable rotary table, dust extraction bells and an individualized tool clamping system are all possible," the technical director explained.
Thermosymmetrical construction. It was important to the developers to build the FZP line for maximum dimensional accuracy during workpiece machining. This is because changing temperatures in the machine shop, as well as long machine running times, inevitably influence the machining quality. So, the Zimmermann developers designed these new portal milling machines thermosymmetrically - a concept that was used successfully for the first time at Zimmermann in 2017 in the compact FZU portal milling machine line and was enthusiastically received by customers.
"The idea of the thermosymmetrical design is based on the fact that inevitable thermal influences can be absorbed to a considerable extent by the design of the machine structure," Demlang explained. In the portal milling machines of the FZP line, Zimmermann has arranged the milling spindle, guides, and other accuracy-determining components in such a way that their heating is either absorbed or can expand in non-critical directions. The gantry's center-guided Z-slide in double-bridge design, for example, has an octagonal cross-section that makes it particularly stable. "With this design, we achieve very high thermosymmetric stability," said Demlang.
Comparable systems usually use complex cooling or software-based compensation for this purpose.
"Our concept is future-proof, especially when the demands on quality and surface continue to rise," Demlang promised. Companies that do not have an air-conditioned machining facility and are therefore particularly exposed to temperature fluctuations in their production also will benefit from this concept. And this is where the new design further scores points, according to Demlang. The design of the structure alone reduces the effects of the influencing variables to a minimum.
VH10 milling head, with extraction. The Zimmermann VH10 milling head is used on this new machine line. The fork head is designed in monoblock versions made of cast iron. The compact construction has only minimal interference contours, achieves high clamping forces and thus enables stable component machining. Zimmermann optionally equips the VH10 milling head with process cooling via cooling lubricants and minimum quantity lubrication. To reduce throughput times, a powerful spindle with 34 kilowatts (45 HP) at a maximum speed of 24,000 rpm is used as standard in the milling head, "We have now also equipped the VH10 with a dust extraction bell around the milling tool," Demlang noted. This makes it suitable for abrasive and harmful materials such as GRP or CFRP, which are becoming more common in aircraft construction. The dust-extraction system captures the dust directly at the point of origin, which greatly reduces contamination of the interior.
Flexibility by design. Facility conditions often are a challenge for installation of large milling machines. Free installation space is usually scarce and machine concepts must offer a high degree of flexibility in installation. The Zimmermann developers have applied symmetry not only to the basic structure of the gantry, but also to the complete machine concept. This allows the customer to individually determine specific connections or peripheral attachments. "We can then simply position the peripherals as required by the individual situation without making any major design changes to the new FZP32," Demlang said. Overall, the ratio of floor space to workspace has been optimized with this new development.
Zimmermann equips the new machine line with larger tool magazines or even pallet changers on request. This allows users to reduce non-productive time and make their production more automated. Another feature: "Milling-turning applications are increasing, especially in aircraft construction, for example in turbine production," said Demlang. "For this purpose, we also equip our milling machines with carousel rotary tables on request.” Regardless of the task the customer needs to perform, Zimmermann's experts can supply the machines in a customer-specific, optimized way with their modular plant construction kit (MAB). Learn more at www.zimmermann-inc.com