MIKRON HPM 1850U

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Contents

MIKRONHPM 1850U with a pallet magazine

MIKRONHPM 1850U

For universal production of high quality parts.The unproductive equipping time within the pallet change time is reduced through use of a pallet magazine.This significantly increases the productivity of the plant.

Automation 14

Options 16

smart machine 17

GF AgieCharmilles 18

Applications 4

Highlights 6

Machining envelope 8

The basic machine 12

Hightech-Spindle 13

The MIKRON HPM 1850U is designedfor universal production of highquality parts.

The machine is characterised by thefollowing features:• A very stable basic machine• A thermo-symmetrical structure• Powerful motor driven spindles• Directly-driven circular / and swivel

axes• High loading weights• Optimal chip flow• A direct measuring system on all

axes.• Scraped support surfaces on the

linear guides for absolute geo-metrical accuracy

The very latest Swiss motor drivenspindles, directly-driven circular andswivel axes and a stable machinebody offer the very best conditions tomanufacture modern toolseconomically and precisely.

High performance milling versushigh speed milling - the one cannotreplace the other!While with high speed milling theobjective is to create as muchsurface on the workpiece as possiblein the shortest possible time, theobjective of high performancemilling is to remove as muchmaterial as possible as efficiently as possible.

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An aircraftstructural partAerospace• Good surface qualities obtained,

also for simultaneous machining• High machining performance• Machining all around the

workpiece thanks to the largeswivelling range

Applications MIKRON HPM 1850U used for a broad spectrum of parts ...

Compact design, good accessibility, large axial travels:MIKRON HPM 1850U

Turbines and compressor discsExtreme high temperature resistant tough steelsAerospace• High stability and precision• Very good surface quality• Absolute process security

Bevel gear wheelHard machiningTransmission• High stability and precision• Very good surface quality• Absolute process security• Quality achieved: Q3

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Highlights MIKRON HPM 1850UEfficient rough as well as precise finish machining

Two loading stations.The pallets can be lowered

hydraulically to a comfortableworking height for loading and

unloading.There is no platform.

This means that the machine takesup less floor space.

A one-piece machine bedmade out of a casting

APS, APS extended, ITC, Adaptive Control.These and further smart machinemodules guarantee even moreflexibility and process security for theproduction of high qualitycomponents.

The pallet can be turnedmanually to offer optimal

access to the workpiece

A pallet magazine forworkpieces up to 1750 kg in weight

The B and C axes can beclamped together for roughmachining.Increased tool life.

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Unusual levels of accessMIKRON machining centers arecharacterised by unusually goodergonomics. The MIKRON HPM 1850U engendersconfidence based on the unparalleledlevels of access offered, independent ofthe respective configuration of themachine.

5650

840

1200

400

2970 (Transport)

4730

6400

840

1030

1170

86513

10

1260

1770 (1400)

1140

(8

60)

5920

840

1200

4007

540

865

1770 (1400)

1140

(8

60)1190

View from above onto the rotary tableof the MIKRON HPM 1850U.Maximum load: 4000 kg

Pallet magazinewith 3 pallets

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Working space MIKRON HPM 1850Uwithout pallet magazine

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MIKRON HPM 1850Uwith pallet magazine

With or without pallet magazine:• Loading by crane and access to the

workpiece are optimal• Perfect dropping away of the chips

due to the steep smooth cabin walls

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MIKRON HPM 1850U

MIKRONHPM 1850U

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Tischvarianten Rundschwenktisch mitT-Nuten-Tischplatte

The basic machine

A thought-through basic design for maximum rigidity

A new-type of construction of the Z-axis. 300 kg lighter than a comparable axis

made out of a casting for the samestability and even better vibration

damping.

Tool magazine for 30 to 238 tools

Low temperature influencesdue to the interconnectedmechanical gantry

The machine bed is cast out of one piece and standson 3 main feet. This leads to a shorter start-up time.

Two levels and distancebetween the guideways ofmore than 800 mm in the X-axis guarantees absolutetorsional rigidity and stabilityduring rough machining.

This particularly plays a role whenheavy workpieces cannot beclamped centrally on the rotarytable and these are turned.

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High techspindle

Constant machining in the HPC area:Core components of high tech motor-driven spindles

The scope of delivery includes thesmart machine module APS (Advanced Processing System) for

reliable recording and display ofvibrations produced during themilling process.

Since 1995 the Swiss company Step-Tec has developed,manufactured, sold and repairedmotor-driven spindles for leadingmanufacturers of machining centersfor milling and drilling applications.

The facts• Vector regulation for the obtaining

maximum torque in the lowest rota-tional speed range

• A highly stable ceramic-hybridspindle bearing system

• Spindle jacket cooling by means ofa regulated coolant circuit forconstant temperatures during thewhole operating period

• Integrated "smart machine"sensors

Your benefits• The highest levels of precision and

a high machining performance• Shorter acceleration phases• A high torque at lower rotational

speeds• Thread cutting without a compen-

sating chuck

Tool spindles for demandingmachining operationsWhatever machine configuration youchoose you will always obtain thelatest tool spindles with your MIKRON HPM machine. • A high torque

15,000 rpm HSK-A6310,000 rpm HSK-A100The ideal spindle for universal use

• For high spindle speeds 24,000 rpm HSK-A63An oil-air lubrication system withsuction removal of the used oil.Optimal for machining materialswhich should be machined at thehighest cutting speeds or for toolswith a small diameter

Step-Tec is in a position tomanufacture rapidly running and atthe same time, very precise highperformance spindles with anintegrated motor. The machiningtimes for obtaining optimal qualityhave been drastically reduced usingthese high quality motor-drivenspindles.

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TischvariantenPallet magazine Economic efficiency and flexibility through automation:The pallet magazine and the tool magazine in various sizes needing minimum space

FlexibilitySpecial parts can be clamped on andprepared during the main operatingtime, also during series production.

Automated machines can be kept incontinual use, also when only oneshift is being worked in the pro-duction area. A significantly longerrunning time per day is possible inthis way compared to a machinewithout a pallet magazine.

The normal work tableheight is reachedwithout a platformthrough hydrauliclowering.

975

Ergonomics• The pallets in the 2 equipping

places are lowered hydraulically toa height which is comfortable forthe operator

• The lifting and lowering movementsof the pallets are very well absorb-ed vibrations and do not disturb themilling process

• The pallets can be turned manuallywithin the two equipping places360° and locked in position 8x (45°)

• There is no need for a platform• A space-saving design• No additional steps or gratings• Optimal working conditions for the

operator

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Tool magazine

HSK-A100: 30 toolsHSK-A63: 45 tools

HSK-A63: 120 toolsFloor space requirements: 1.5 m2

HSK-A100: 170 toolsHSK-A63: 238 toolsFloor space requirements: 3.8 m2

Tailor-made solutions foryour production requirementsUser-friendly equipping with toolsleads to productivity and processsecurity• Simultaneous machining and

equipping• Simple manipulation• Ergonomic access

2100 mm

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Options Our machines are prepared for a large number of options. They can be configured simply and optimally

A belt filter plant

Touch probe radio RMP 60 Minimum quantity lubricationand cooling

Suction removal of mist

Motor-driven spindle for60,000 rpm

Laser tool measurement

Internal tool coolingA rotating viewing window

Tool magazineHSK-A63: 120 tools

Tool magazineHSK-A100: 170 toolsHSK-A63: 238 tools

Tool magazineHSK-A100: 30 toolsHSK-A63: 45 tools

Operating modes 3+4

smart machine Control unit SIEMENSControl unit HEIDENHAIN

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smart machine The new dimension in modern production

Bringing intelligenceinto the millingprocess is theintended aim of"smart machine".

The facts• Greater accuracy in shorter

machining times• Increase in the workpiece surface

quality as well as the surface andshape accuracy

• Recognition of critical machiningstrategies

• Improvement in the process safety• Reduction of the machine set due to

longer service life• Higher availability• Better operating comfort• Considerable increase in reliability

in unmanned operation

smart machine construction kitsystemEach of the modules fulfils a specifictask. Just like in a construction kit,the user can select the modules thatseem to him to be the best option forimproving his process.

Your benefit Produces the workpieces in a pro-cess-secure and precise manner,increases the reliability in unmannedoperation, increases the service life ofthe machine and significantly reducesproduction costs.

The smart machine is constantlybeing further developed.

The currently available modules canbe found at www.gfac.com

Protection

Precision

Productivity

This includes a range of modules thatare collectively referred to under thegeneric term "smart machine" andthat fulfil various functions. In order tomake the milling process "intelligent",various requirements have to beimplemented. First of all, establishing comprehen-sive communication between man andmachine, which makes preciseinformation that the operator requiresto assess the milling process availableto him. Secondly, supporting theoperator in the optimisation of theprocess, which considerably improvesthe performance. Thirdly, the machineoptimises the milling process, whichimproves the process safety and thequality of the workpiece - above all inunmanned operation.

About GF AgieCharmilles

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Milling

EDM

Laser

Customer Services

Automation

High-Speed and High-Performance Milling CentersIn terms of cutting speed, HSM centers are 10 times faster thanconventional milling machines. Greater accuracy and a better surfacefinish are also achieved. This means that even tempered materialscan be machined to a condition where they are largely ready to use.One essential advantage of HSM is that with systematic integration,the process chain can be significantly shortened. HSM has developedalongside EDM into one of the key technologies in mold and tool making.

Electric Discharge MachinesEDM can be used to machine conductive materials of any hardness (forexample steel or titanium) to an accuracy of up to one-thousandth ofa millimeter with no mechanical action. By virtue of these properties,EDM is one of the key technologies in mold and tool making. There aretwo distinct processes – wire-cutting EDM and die-sinking EDM.

Laser ablationLaser ablation supplements and extends the technologies offered byGF AgieCharmilles. Our laser technology enables you to producetexturizing, engraving, microstructuring, marking and labeling of 2Dgeometries right through to complex 3D geometries. Laser ablation,compared to conventional surface treatment using manual etchingprocesses, offers economic, ecological and design advantages.

Operations, Machine and Business SupportCustomer Services provides with three levels of support all kind ofservices for GF AgieCharmilles machines.Operations Support offers the complete range of original wear partsand certified consumables including wires, filters, electrodes, resin andmany other materials.Machine Support contains all services connected with spare parts,technical support and preventive services.Business Support offers business solutions tailored to the customer’sspecific needs.

Tooling, Automation, SoftwareTooling for fixing workpieces and tools; automation systems and systemsoftware for configuring machine tools and recording and exchangingdata with the various system components.

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www.gfac.com

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© Mikron Agie Charmilles AG, 2010The technical data and illustrations are not binding.They are not warranted characteristics and are subject to change.

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Technical dataMIKRON HPM 1850U

MIKRON HPM 1850U

Working rangeLongitudinal X mm 1850Cross Y mm 1400Vertical Z mm 720/905A-axis ° -20/+120 (110)C-axis ° n x 360Number of simultaneous axis pce. 5 axis/5 simultaneous

Feed rateFeed rate / Rapid traverse X, Y m/min 15 / 40Feed rate / Rapid traverse Z m/min 15 / 40Feed rate / Rapid traverse A min-1 11 / 20Feed rate / Rapid traverse C min-1 30

Working spindleWorking spindle 10 0̀00 Spindle power 40% ED kW 34

HSK-A100 Spindle torque 40% ED Nm 324Working spindle 15 0̀00 Spindle power 40% ED kW 38

HSK-A63 Spindle torque 40% ED Nm 193Working spindle 24 0̀00 Spindle power 40% ED kW 30

HSK-A63 Spindle torque 40% ED Nm 75

Accuracy XYZ ISO 230-2(97)Accuracy A �m 10 / 8 / 6Repeatability R +/- �m 6 / 5 / 4

Work tableClamping surface mm Ø 1600Max. workpiece weight kg 4000

AutomationPallet magazine Positions 3Pallet size mm x mm 1000 x 1250Tool magazine Positions HSK-A63 45, 120, 238

Positions HSK-A100 30, 170

Control unitHeidenhain iTNC 530Siemens 840 D

WeightMachine weight kg 25`000 - 31’500

smart machineAPS, APS extended, Adaptive control, ITC

Ancillary servicesProgramming courses •Technology courses •Service training courses •

5650

840

1200

400

2970

47306400

840

1030

1170

865

1310

1260

1770

(140

0)

1140 (860)

2920 {4

130}

421

0

104518004730

8271100

5650

1730

1130886 (874)

30°

(20°

)

20° 4130

{421

0}

950

{103

5}

{130

} 45 Z

= 90

5

206 (194)

{885

(843

)} 77

0 (75

8)

772

1850

X=1850

HPM 1850Uwithout Pallet magazine

HSK-A63 (HSK-A100){with increased through}

4210

1800

7540

1720

18001600

2920

5920

840

1200

400

7540

865

1770

(140

0)

1140 (860)

1190

11301850

885 (873)

30°

(20°

)

20°

X= 1850

30

134

4210

935

385 (373)

750

(738

)Z=

905

HPM 1850Uwith Pallet magazine

HSK-A63 (HSK-A100)

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300.

216

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Nm 38 kW / 40% ED S6

30 kW100%ED S1

193 Nm40% ED S6

75 Nm40% ED S6

30 kW / 40% ED S6

24 kW100%ED S1

60 Nm100% ED S1

152 Nm100% ED S1

0

14

3038

kW

kW

kW

min-10

16

152193

1900

6300

1500

0

Nm 3434 kW / 40% ED S6324 Nm40% ED S6

248 Nm100% ED S1

3126

97

0

min-1

324248

0

1000

1500

3000

1000

0

Nm

0

222430

min-10

10

6075

3480

2000

024

000

HPM 1850UHSK-A100 / 10’000 min-1

HPM 1850UHSK-A63 / ISO-B40 / 15‘000 min-1

HPM 1850UHSK-A63 / 24000 min-1