MIKRONHSM/XSM400 LP, 400U LP,500 LP

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MIKRON HSM 400 LP / 500 LP MIKRON HSM 400U LP

High-speed milling - universal approach to mould-making and production

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Contents

Ultra-highspeed milling - for our demanding customers

GF AgieCharmilles presents newreference machines in 3-axis and 5-axis versions for high-speed andultra-highspeed milling.

Based on the concept of the presentHSM/XSM series, GF AgieCharmillesengineers have developed three newmachine models which represent

optimal answers to all aspects of 3-axis and 5-axis high-speed andultra-highspeed milling needs. TheHSM/XSM LP series (LP = Linear Per-formance) were designed for ultimateprecision and supreme surface quali-ty. The necessary design measuresfocus on the machine bed, cooling,axis drives, motion control and toolmeasurement.

These vertical high-speed machiningcentres, developed for tool and mouldmanufacturing as well as medium-and small-series production of high-quality parts, combine the Swiss ma-chine manufacturer's entire technicalknow-how and extensive developmentexperience.GF AgieCharmilles.

MIKRON XSM 400 LP MIKRON XSM 400U LP

Applications 3-axis 45-axis 6

Highlights 8

Automation 10

Table versions3-axis 145-axis 15

Basic machine 18Feed axes 19Precision 20LP Precision 23High-tech spindles 24Tool magazine 25Chip and dust 26Option: ProdMod 27Options 28smart machine 29About GF AgieCharmilles 30

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MIKRON HSM 400 LPMIKRON XSM 400 LPMIKRON HSM 500 LP

Applications3-axis

HSC milling of a prototype mouldinsert

DieMIKRON HSM 500 LPAlloyed tool steelTool and mold making• Surface quality• Shape accuracy

Watch components MIKRON XSM 400 LPDifferent materialsWatch making industry/ micro-mechanics• Shape accuracy• Smallest geometries• Parts-specific handling

systems

Electrode MIKRON XSM 400 LPTungsten-copperTool and mold manufacturing• High surface quality• Shape accuracy• Very small geometry features

Ball screw drive Linear direct drive

Graphite electrode MIKRON HSM 400 LPGraphiteMold making• High contour accuracy• Efficient graphite machining

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MIKRON HSM 400U LPMIKRON XSM 400U LP

Machining of an injection mould in 5-axis simultaneous operation

Applications5-axis

Watch casing MIKRON XSM 400U LPDifferent materialsWatch making industry• 5-axis simultaneous machining• High surface quality

Impeller MIKRON HSM 400U LPAluminiumAutomobile industry• 5-axis simultaneous machining• High speed• Thin-walled geometries

MedTechMIKRON HSM 400U LPTitanium / CoCrMedical technology• Adequate spindle performance• Machine stability • 5-axis simultaneous machining• Forming and positioning precision

Casting moldMIKRON HSM 400U LPAlloyed tool steelTool and mold making• High surface quality• 5-axis simultaneous machining of thread

with undercut section

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Highlights Precision and quality for tool- and mold-making as well as accurate part manufacturing

Robust tool spindle with vector control and ceramic hybrid bearings

Flexible workpiece

automation Crane loading

Crane loading

Polymer-concrete machine bed with high damping properties

Side window

The MIKRON HSM/XSM LP seriesimpresses with the unrivalled accessibilityof all machines in the series, regardlessof their particular configuration.

High-performancemachine control

Direct drives on all axes: X, Y, Z, B, C

Machine hood for thermal and acoustic insulation

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Chip managementMajor attention was paid to the chipflow. Steeply inclined chrome steelplates in the workspace promote thefall of chips.• No chip accumulation• Easy cleaning• Flushing system

Process optimisation with OSSThe larger a workpiece is, the more it weighs and the more machining timeand reworking effort it requires. The ability to decisively influence the time factor even after CAD/CAMprogramming is therefore all themore important. The OSS softwaremodule offers specially tailored toolcontrol to suit the machining task.• Precision: Precise path control

according to preset requirements • Speed: Cuts machining time during

roughing and pre-finishing• Surface quality: Reduces reworking

requirements after the finishingprocess

Direct driveThe direct drives in X, Y, Z, B and C permit direct translatory and rota-tional motions of the tool centre point(TCP) without rerouting via a mecha-nical transmission. • Short setting time • No oversteering through drive play

and elasticity • High dynamic rigidity of the attitude

control • Independent of slide position

ITM (Intelligent Tool Measurement)

High-speed pictures

ITM tool measurement registers theentire tool tip up to ø 12 mm onmodern imaging sensors. Specialsoftware digitally cleans and measuresthe digitally captured tool geometry.An idea takes concrete shape: For thefirst time, ITM makes it possible tomeasure tools on a MIKRON machinewith micrometer-range repeatability.

Surface quality

Precision Time

Stability and dampingPrimary prerequisites for maximumprecision and best workpiece surfacequality include damping and stabilityof the components:• Monolithic design• Highly stable portal construction• Machine base of mineral cast with

high damping characteristics• Optimised force distribution within

castings

Ergonomics and process reliability…are key features of this machineseries:• Equally accessible in all upgrade

levels - thanks to workpiece auto-mation via the portal

• Excellent view into the workspace• Access to the workpiece from three

sides • Crane loading• Side window to optimally monitor

machining

650

505

OperationServicing

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MIKRON HSM/XSM 400U LP 25 kgMIKRON HSM/XSM 400 LP 90 kg

System 3RMacro Magnum

18xErowaITS 148

20xSystem 3RMacro

48x

Ergonomic charging and uncharging of the disc type magazine during work preparation

....Dank Automatisierung noch produktiverAutomation withdisc type magazine

Producing more partsin shorter time at lower cost

System 3RDynafix 350 x 350 mm

7x

We recommend: SIGMA FMC (FlexibleManufacturing Cell) and RNS (RemoteNotification System). These smart machine modules arethe keys to even greater flexibility andprocess reliability during the pro-duction of high-quality components.

Pallet magazine is a major plusGF AgieCharmilles has developed itsown, fully integrable pallet magazineswith customer needs in mind. The disc magazine can be loadedduring operation and the CNC controlis very easy to operate. The automation solution for widelyapplied industrial standards with aload capacity of up to 90 kg per palletfor the HSM 400 LP and 25 kg for theHSM 400U LP.Along with the modular tool magazi-nes, this turns the compact millingcentre into a highly productive andflexible manufacturing cell.

System 3RGPS 240 x 240 mm

10xSystem 3RDynafix 280 x 280 mm

7xErowaUCP 320 x 320 mm

7x

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....Dank Automatisierung noch produktiverInterface for auto-mation systems

Producing more partsin shorter time at lower cost

The MIKRON HSM 400U LP Robot Integrated. Loading and unloading takes place frombehind through the portal.

A standardised robot interface allowsthe MIKRON HSM/XSM-LP series tobe operated with robot systems fromreputable vendors.

Regardless of the handling systemused, the accessibility of the machineremains outstanding...

...even when networking with other machines.

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Table versions 3 axis

Process-oriented tool clamping - the integrated automation interface

Combat unproductive timesFully integrated zero-point clampingsystems are standard equipment onthe MIKRON HSM/XSM 400 LP. The machines rely on widely usedclamping systems from manufac-turers System 3R and Erowa.

MIKRON HSM/XSM 400 LPUp to 120 kg load capacity

MIKRON HSM 500 LPUp to 200 kg load capacity

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Table versions 5 axis

Speedy results with HSC simultaneous machining

Circular swivel table MIKRON HSM/XSM 400U LP.Up to 25 kg load capacity

The excellent dynamics of the circularswivel tables with direct drives in theMIKRON HSM/XSM 400U LP machinesachieve genuine HSC simultaneousmachining on all 5 axis - anotherdevelopment by GF AgieCharmilles:

• Extremely dynamic and fast: Rota-tion and swivelling with directdrives in the B and C axis up to 250 min-1

• Extremely accurate and precise:Liquid-cooled motors and absolutemeasuring systems

• Extremely stable and flexible:hydraulic clamping in the rotationand swivel axis plus integratedzero-point clamping system with aB-axis swivel range of 220°

• Ergonomic and clean: no interferingedges for optimal access and fall ofchips

Achieve more...

MIKRONHSM/XSM400 LP, 400U LP,500 LP

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Basic machine For uncompromising demands

Polymer-casting machine bedHigh rigidity and a compact appearan-ce are attention-getting benefits ofthe self-contained portal design.

Cross slideThe weight and rigidity of the crossslide are optimised to stand up to thehigh dynamic requirements. Polymer concrete

The polymer concrete features highthermal inertia and excellent dampingproperties. Oils or cooling lubricants are notaffected by ageing processes.

Pyramidal configurationThe pyramidal structure ensuresoptimal weight distribution whilestabilising and rigidifying the cuttingprocess.

Closed structureThe O-shaped portal is outstandinglysuitable for automation solutions byGF AgieCharmilles or other manu-facturers.

Distribution force to the foundationBecause of their unrivaled axial dyna-mics, machines of the XSM LP seriesmust be connected to three fixedpoints in the floor foundation.

Up to 6x better damping propertiesthan grey cast iron.

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�m

1

0

-1

-2

-30 0.2 0.4 0.6 s 1.0 0 0.2 0.4 0.6 s 1.0

Zeit Zeit

Grey cast iron Polymer concreteAm

plitu

de

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Feed axis Reconciling dynamics and precision

Dynamics and precisionMechanical drive systems have a basicdisadvantage: a loss of precisionmust be accepted to achieve a highlydynamic configuration. This effect isnot relevant for customers in auxiliarymotions such as tool changing oraxial positioning. An HSC machinechanges the situation: During cuttingcontrol, high dynamics must be com-bined with great precision. This iswhere the linear direct drive showsall its advantages.

• Short setting time • No oversteering through drive play

and elasticity • High dynamic rigidity of the attitude

control • Independent of slide position

Advantages• Oustandingly precise, accurate

workpiece machining due to theextremely rigid drive and controlconcept.

• Excellent long-term precision dueto the reduction of friction-inducedwear by the direct drive and centraloil lubrication

• Reduction of main operating timesdue to extremely high dynamicparameterisation (OSS)

• Reduction of auxiliary times by highrapid-traverse speeds

• Reduction of maintenance andservicing, since the lack of ballscrew drives or transmissionsreduces the number of wearingparts.

Linear directdrive

Central oillubrication

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Dynamic precision

Path measurement systemsDirect path measurement systems in the linear and rotational axis arestandard equipment on all MIKRONHSM/XSM LP machines.

• Tried and tested Heidenhain pre-cision

• Resolution in the nanometer range• Protected by sealing air

Precision HSC core components: Static and dynamic precision

Static precision

Swiss thoroughnessBefore delivery, every MIKRONHSM/XSM LP machine undergoes anextensive quality check in our air-con-ditioned assembly hall in accordancewith GF AgieCharmilles acceptanceguidelines. Quality-consciousness means addedvalue.

LightsourceLED

Scanningreticle

Referencemark

Photo-voltaiccells

Condenserlens

Glassscale

Gratingperiod

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Precision HSC core components: Thermal precision

Cooling conceptThe MIKRON HSM/XSM LP series ushers in a new era of precision cut-ting. Since high axis feeds over longperiods always heat the drive assem-blies, the MIKRON HSM/XSM LP se-ries beats the problem with an inge-nious cooling management system.Each of the linear axis as well as thecircular swivel unit have their owncooling cycles. The heat is thereforesystematically led out of the machineinstead of being distributed inside it.

Tool spindleEven greater precision with Step-TecOpticool technology• Cooling of the front roller bearings• Low thermal flow in the tool inter-

face• Increases accuracy when working

with the measuring probe on themachine

Measuring probeEven greater precision with new Ther-mo-Lock measuring probe technology. • Easy set-up • Inhibits thermal flow between mea-

suring probe and tool spindle• Increases accuracy when working

with the measuring probe on themachine

• Two strong partners: Thermo-Lockand Opticool

Thermal precision

HSM/XSM 400(U) LP

Time

This safeguards geometric stability,which in turn ensures extremely highmotion control repeatability.

All electrical heat sources in theMIKRON HSM/XSM LP machines arewater-cooled.

• X, Y, Z, B, C drives• Tool spindle with Opticool techno-

logy• Electrical cabinet

Uncompensated thermal growth in amachine axis

Standard Machine

Five separate cooling circuits

Liquid cooled primary and secondary drive

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Precision ITM - the breakthrough in tool measuring

ITM (Intelligent Tool Measurement)ITM tool measurement registers theentire tool tip up to ø 12 mm onmodern imaging sensors. Specialsoftware digitally cleans and mea-sures the digitally captured toolgeometry. An idea takes concreteshape: For the first time, ITM makesit possible to measure tools on aMIKRON machine with micrometer-range repeatability.

D = 0.204 mm

Detection of foreign particles

Measurement of smallest tool diameters

Test-piece with continuously increasing Z-level.Step to step: 2 �mOrthogonal cutting to zero point Z-level withintermittent measuring cycle of employedspherical cutting tool.

+1 �m

�

�

+4+2

0-2

+6

+4

+6

+2

0

-2

2 �m

+1 �m

D =

1 m

m

s =

38’2

20 m

in-1

D =

2 m

m

s =

19’1

10 m

in-1

D =

3 m

m

s =

12’7

40 m

in-1

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LP Precision When fractions of a micrometer count...

Target value: optical surface

Target value: 3D dimensional accuracy

�m

s

• Axis construction based on selectedmachine elements for the highestlevels of precision

• The specific smart machine modu-les OSS Precision and ITC Precision

Despite extremely precise cutting onthe work piece the machine still de-monstrates full high-speed-cuttingcharacteristics:MIKRON HSM 400(U) LP PrecisionMIKRON HSM 500 LP Precisionwith 42 m/min and 0.7 g

Extremely precise machining is pos-sible through highly precise imple-mentation of NC commands (0.1 �m)which manifests itself in the targetvalues 3D dimensional accuracy andoptical surface quality.

Target value curveActual value curveUpper toleranceLower tolerance

Minimum deviation - 0.00145Maximum deviation + 0.00155

Ra 0.02 �mRz 0.12 �mRt 0.18 �mRmax. 0.18 �m

0.1 �m

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*

*

The applications shown are justexamples. The results can onlybe achieved under certainprocess parametersand environmentalconditions.

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High-tech motor spindle

HSC core components from Step-Tec

Tool spindles for challengingmachining tasksWhatever machine configuration youchoose, a MIKRON HSM/XSM LPmachine gives you state-of-the-arttool spindle technology.

The facts• Vector control for full torque in the

lowest range• Ultra-stable ceramic hybrid spindle

bearings• Spindle mantle cooling by means of

a controlled coolant cycle for con-stant temperatures throughoutworking times

• Oil-air lubrication system withsuction disposal of used oil

• Integrated "smart machine" sen-sorics

• Cooling between tool interface andfrontal spindle bearings in theOpticool spindles

You benefit from• Precise high-performance• Shorter acceleration phases• High torque• Thread cutting without compen-

sation chuck

The delivered package includes thesmart-machine module APS (Advan-ced Processing System) for reliabledetection and display of vibrationsduring the milling process.

Step-Tec has developed, produced,sold and repaired precision high-per-formance spindles for leading manu-facturers of machining centers formilling and drilling applications since1995.

30'000 min-1 42'000 min-1 54'000 min-1

HSM/XSM 400 LP • • •HSM/XSM 400U LP • • •HSM/XSM 500 LP • • •HSM LP Precision • •

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Tool magazine Individual solutions tailored to your production needs

Tool automation in everyconfiguration level• Simple or double-row disc

magazine • Reliable "pick-up" changing system• Feed control via light beam• Capacity of up to 68 tools• Tool lengths up to 200 mm*• Tool diameters up to Ø 65 mm*• Tool weights up to 1.2 kg*• Orientation of the touch probe

Available model sizes:HSK-E32 : 20; 40 toolsHSK-E40* : 18; 36; 68 tools

Double-row HSK-E40 magazine with a capacity of 68 tools

User-friendly tool feedingProductivity and process reliability areensured by lateral tool feeding• Simultaneous machining and

feeding • Simple feed monitoring through

large glass panel• Ergonomic access

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Chip and Dustmanagement

Well thought-out machine concept for maximum autonomy

Chip disposalChip disposal should be handledautomatically without any interventionby the operator. The key to successfulautomation is a good concept.

Equipment versionsChip forms and volumes are deter-mined by the work material and themachining strategy. The options offer-ed range from a simple chip pan toversions with a coolant tank…

and chip flushing, ...

Clean workspaceThe interior casing of the MIKRONHSM/XSM LP machines is steeplyinclined. The slanted sides help tooptimise both the fall of chips andcleansing with flushing systems.

or with chip auger ...

and lift-up chip conveyor. They comewith or without a filter system.

Vacuum removal of graphite

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Option: ProdMod

Automated parts manufacture: 24/7

Built to withstand tough productionconditionsA flushing system reliably keeps theworkspace doors free of chips.

Cooling lubrication through thespindle (IKZ)With IKZ you can bring the cooling lu-bricant with high process reliability tothe tool cutter. Differing tool diame-ters do not require new alignment ofthe coolant hoses.The purity of the lubricant is vital tothe life cycle of the spindle. A filtersystem is therefore essential.ICS machining with a high-perfor-mance chip conveyor and a filtersystem solves the problem.

Thanks to its flexibility and reliabilitythe MIKRON HSM/XSM ProdModproduct series is a benchmark forautomated production of high qualityparts.

• Efficient management of chips• Washing away system in the interior• Feed of coolant through the middle

of the spindle• Extended tool-storage capacities

(168x oder 308x)• Integrated laser tool measuring

system

Extended tool magazineThe tool storage device is built as acircular hanger with 168 or 308 toolpositions. The central gripper isseparated from the delivery mecha-nism so that a short wait occurs whenswitching. Time for changing tools: < 2 sec.Time for preparing tools: < 10 sec.

*

* Available on demand.

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Options Tailor-made equipment

Further options:

• Rotating window• Dust extraction system• Beacon• Laser tool measurement• ITM (Intelligent Tool Measurement)• ...

High performance belt filterunit

Mist extraction system

Touch probe TIAutomation interface (open)Automation interface (closed)

Lift-up chip conveyor Chip flushing Spiral chip conveyor

smart machine Module(www.gfac.com)

Mist extraction systemMinimum quantity lubrication

Cooling lubricant container

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smart machine The new dimension in modern production

Bringing intelligenceinto the millingprocess is the inten-ded aim of "smartmachine".

The facts• Greater accuracy in shorter machi-

ning 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 kit sys-temEach 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 Producing the workpieces in a pro-cess-secure and precise manner,increasing the reliability in unmannedoperation, increasing the service lifeof the machine and significantly redu-cing production 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 precise infor-mation that the operator requires toassess the milling process available tohim. Secondly, supporting the opera-tor in the optimisation of the process,which considerably improves the per-formance. Thirdly, the machine opti-mises the milling process, whichimproves the process safety and thequality of the workpiece - above all inunmanned operation.

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About GF AgieCharmilles

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. With our laser technology we enable 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.

Contact

www.gfac.com

Achieve more...

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

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