MIKRONUCP 600 Vario

GB

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The MIKRON UCP 600 Vario by GF AgieCharmilles is an impressive 5-axis solution for automated pro-duction. In addition to the compactbasic machine, the Vario system has a wide variety of high-performancemilling spindles, a scalable, modulartool magazine system, the well-provenMIKRON pallet magazine as well as asuitable cleaning and disposalsolution for each chip/coolant situ-ation. The customer is free to decidehow variable his MIKRON UCP 600Vario should be. However, one point is guaranteed not to change - accessi-bility to the machine and its peripheralunits is as unique as ever!

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Contents Applications5-axis Machining 45-axis Simultaneous Machining 6

Highlights 8-9

Automation 10-11

Table variations5-axis Rotary Tilting Table 15Torque Rotary Tilting Table 16

High-tech spindles 17

Tool Magazines 18

Options 20

smart machine 21

Product RangeGF AgieCharmilles 22

MIKRONUCP 600 Vario

System Vario - the solution for automated production

Light Alloy SupportAluminumAircraft industry• 4-side machining in one clamping • High spindle speed• High cutting volumes

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Applications Wide range of workpieces...

Endoscope DeviceMoulded blank with high contentof chrome/nickelMedical technology• Multi fixture systems• High position and molding

tolerances• High positioning accuracy• Difficult to cut and high-strength

material

Ventilator HousingAluminumVentilation technology• 5-axis positioning machining • High material removal rate• High positioning accuracy• Flexible production

The standard version of the rotarytilting table is most suitable formachining workpieces in multipleclamping devices.

Forging Die for Drive TrainManganese steelAutomotive industry• 5-axis machining• Difficult-to-cut material• Micro- and needle chips• Contouring accuracy• High spindle speed

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Wide range of workpieces...Specifically for 5-axis simultaneous machining

Due to the Tailstock, long thinparts can also be machined onthe direct driven table.

The MIKRON UCP Vario with Torque Rotary Tilting Table for high performance 5-axis simultaneous machining.

Cutting RollerHardened steelPaper industry• High precision• Tailstock required• High spindle speed• Workpiece automation possible

Cylinder HeadAluminum alloyMotorcycle industry• Complete machining in one

clamping • Combined 5-axis

positioning/simultaneousmachining

• High positional tolerance

Blower HousingAluminumAircraft industry• High 5-axis simultaneous part• Tailstock required• Workpiece automation possible

Bone RaspSpecial alloyMedical technology• High performance milling of

high-alloyed materials• Tailstock required• Workpiece automation possible

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Highlights The MIKRON UCP 600 Vario can be turned optimally to the customer's requirements

The outstanding feature of MIKRONmachining centers is their exceptionalergonomics. What is impressive aboutthe MIKRON UCP 600 Vario is itsunrivalled accessibility, which is notdependent on the machine'sconfiguration.

Software modules for efficient andcontrolled work

Flexible workpiece automation

Magazine for up to 220 tools

requiring little space

High performancespindles

Versatile rotary tilting tables

Upright cabin walls guaranteegood chip fall

Laser tool measuring protectedfrom the working area

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Ergonomic, effortlessly accessible,clear insightEnthusiasm in the workplace can bebought! Due to its accessibility andview on the workpiece, the Varioseries is the most valuable asset forhelping employees of any company tobe even more efficient.

• Impressive design - ergonomic pro-tective cabine enclosure with largewindows ensures excellent illumi-nation and an optimal view to themachining process

• Elaborated working area designprevents a built up of chips

• Heavy workpieces can be easilyloaded by crane

• Abrasion-resistant screens and therotating viewing window ensureperfect view on the machining pro-cess at all times (option)

Full chip control In the working area of the MIKRONUCP 600 Vario, any collection of chipsis consistently avoided.Due to the elaborate detailed engine-ering, chip accumulation is avoideduntil the flowing chips have beenreliably and economically separatedfrom the coolant and disposed of.

• A 400 mm wide scrapper chipconveyor removes all types of chips

• An edge filter integrated in the in-ternal coolant system reliably se-parates the smallest chips from thecoolant

• Overload protection with automaticreturn function in the event of chipbuild-up

• Mini belt filter to remove the finestchips from the coolant

• Easy-to-clean equipment

• Through-spindle coolant supplywith belt filter and infinitelyvariable, adjustable pressure (18 to70 bar)

Heidenhain digital control systemThe latest generation HeidenhainiTNC 530 digital control system and aclearly structured operating panelmake the MIKRON UCP 600 Vario aprocess-sure and user-friendlymachining center:

• Process reliability including shortbriefing and safe operation bymeans of pre-defined workingcycles

• Ethernet connection for fast CAMdata flow

• Simple dialog-controlled pro-gramming

• Parallel programming, free contourprogram, free definable sub-pro-gramming

• The hand wheel included in thescope of supply brings youclose to the cutting point, if required

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Automation Automatic workpiece magazine enables unmanned production.smart machine SIGMA FMC and RNS render services.

The pallet magazine proves itssuperiorityWith the MIKRON UCP 600 Vario,automatic production is ensured bythe low-cost integration of the palletmagazine. Supplemented with themodular tool magazine, the compactmilling center becomes a highly pro-ductive and flexible manufacturingcell.

• Configuration as System 3R(Dynafix GPS) or Erowa (UPC) ver-sion. Others on request.

• Repetitive machining is executedwithout interruption in multi-shiftoperation.

• The machine's efficiency isincreased with an accordinglyhigher profit

Tool magazineThe tool magazine is structured as acircular hanging shelf. Therefore it isalmost arbitrarily scalable.75, 120, 170 and 220 tool positions areavailable as standard. Separation ofthe central gripper from the transferhandling results in a short changingtime.

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P

500

500

630

544 cm

544

cm

We recommend: SIGMA FMC (FlexibleManufacturing Cell) and RNS (RemoteNotification System). These and otherSmart Machine modules ensure stillmore flexibility and process reliabilityin the production of high-qualitycomponents.

MIKRON UCP 600 Vario with workpieceautomation via the WorkMaster 3Rsystem

Interface for robot solutionAn example of automation on theworkpiece side of the MIKRON UCP600 Vario via a robot solution. Due tothe robot interface, the MIKRON UCP600 Vario can be fitted with robotsystems from reputable suppliers.

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MIKRONUCP 600 Vario

MIKRONUCP 600 Vario

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Table variations Clamping workpieces, powerful and precise

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5-axis machining offers considerableadvantages for large and small com-ponents. By means of 5-axis tech-nology it is possible to machine a widevariety of shapes and surfaces in onechucking.

Rotary tilting table with radial grooves Rotary tilting table with parallel grooves Rotary tilting table for GPS 240

The large tilting range of theMIKRON UCP 600 Vario rotarytilting table enables 5-sidedcomplete machining in onechucking.

• Most suitable for 5-sided, 5-axis-positioning and up to 5-axis contourmachining

• Rotary tilting table available aspallet version:System 3R (Dynafix, GPS) or Erowa(UPC)

• Rotary tilting table available asgenerously dimensioned table topversion (ø 450 mm with star-shapedor parallel T-slots)

• Cartesian (rectangular) alignmentof the axes - results in coherenttool/workpiece movement duringthe milling process

• Direct measuring on the B and C-axis

• Optional version with increasedprecision available

5-side/axis machining in one set-up

The scope of supply includes:smart machine module ITC-5X (Intelligent Thermal Controlfor 5-axis) for higher precision with 5-axis machining.

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MIKRON UCP 600 Vario with torque rotary tilting table (Torque RTT)

Tailstock for special applicationsThe tailstock also enables longer,thinner parts to be machined on theMIKRON UCP 600 Vario with torquerotary tilting table (Torque RTT). Ifrequired, the overarm can also bedismantled, in order to machineworkpieces without.

Unmanned production is also ensuredhere. Workpiece automation islikewise possible using the tailstock.

Directly driven rotary and tilting axesThe MIKRON UCP 600 Vario is mostsuitable for 5-axis simultaneous HPCmachining (High Performance Milling).The A and B-axis are driven by torquemotors.

The System 3R MacroMagnum 156pallet can be overstretched:Maximum workpiece diameter withdismantled tailstock: 350 mmMaximum workpiece diameter withmounted tailstock: 300 mm

The maximum workpiece height is 450 mm loaded manual and 350 mm loaded automatical.

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101

0

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High-tech spindles

Tool spindles for demanding machining

Tool spindles for demandingmachiningWhichever machine configuration youchoose, with a MIKRON UCP 600 Varioyou get the most up-to-date toolspindle technology:Vector control, highly stable ceramichybrid spindle bearing, and spindlecasing cooling using a controlledinternal coolant system for consistenttemperatures for the entire workingduration.

• Optionally 12,000, 20,000 or 42,000rpm

• Precise high performance - fromthe conventional to the universal toHSC machining

• Vector control for full torque in thelower speed range

12,000 min-1

For conventional tool technologiesand programs:

• ISO 40 spindle taper• Infinitely variable speed range - no

slump in performance• Set up with internal coolant supply

for use in production• Acceleration and braking time:

1 second each• Ceramic hybrid bearing with life-

time lubrication

20,000 min-1

For machining a wide variety ofmaterials:

• HSK-A63 spindle taper• Infinitely variable speed range -

no slump in performance• Set up with internal coolant supply

for use in production• High retention powers• Face stop of the tool taper - better

run-out• Ceramic hybrid bearing with oilmist

lubrication

42,000 min-1

In combination with a highperformance control system, thishigh-speed spindle enables access toHSC machining.Special HSC tool technologies are:

• HSK E-40 spindle taper• Infinitely variable speed range - no

slump in performance• Finely balanced 3-phase motors• Specific tool holders - exceptionally

precise work• Optimum run-out due to face stop

of the tool holder• Ceramic hybrid bearing with oilmist

lubrication

The scope of supply includes:smart machine APS (AdvancedProcessing System) for reliablemeasuring and display ofmilling vibrations, and ITC(Intelligent Thermal Control)for higher workpieceprecision.

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Tool Magazine Standard and higher demand

External magazine for up to 220tools• With optionally 75, 120, 170 or even

220 tool positions

• Short tool changing and tool pre-paration time

• Small machine footprint

Optional• Laser tool measuring• Tool cleaning by air blast• Sigma FMC for efficient tool

management

Tool loading made easy: goodaccessibility at all times, even duringmachining.

Magazine integrated in the machinebase• For 30 (ISO 40, HSK-A63)

or 36 (HSK-E40) tools

Tools CompactlyHoused

Due to the different tool magazinesizes, with the MIKRON UCP 600Vario it is possible to respond indivi-dually to customers' requirements -from single part production to serialproduction of complex parts.

Circular arranged magazine withhandling system for 75, 120, 170or 220 tools

P

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Options The machines are geared up for a multitude of options. Consequently, they can be simply and optimally configured.

Chip conveyance for higherrequirements

Infrared touch probe

Signal light

Minimum quantity coolinglubrication

Mist extraction system

Operating mode 3+4

Laser tool measuringBelt filter System Basic

Belt filter unit System Highperformance

Dust extraction system

Through-spindle cooling

Pallets

Cleaning pistol Rotating viewing windowsmart machine module

Further options:

• Extended accuracy• Abrasion-resistant screen• Extended warranty• Robot interface

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smart machine The new dimension in modern production

Bringing intelligence into the millingprocess is the intended aim of "smartmachine". 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.

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 Producing the workpieces in a pro-cess-secure and precise manner,increasing the reliability in unmannedoperation, increasing the service lifeof the machine and significantlyreducing production costs.

The smart machine is constantlybeing developed further.

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

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About GF AgieCharmilles

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

High-Speed and High-Performance Milling CentersIn terms of cutting speed, HSM centers are 10 times faster than conventionalmilling machines. Greater accuracy and a better surface finish are also achieved.This means that even tempered materials can be machined to a condition wherethey are largely ready to use. One essential advantage of HSM is that withsystematic integration, the process chain can be significantly shortened. HSMhas developed alongside EDM into one of the key technologies in mold and toolmaking.

HSM Spindle TechnologyDevelopment, production and sale of the motor spindles that form the corecomponents of modern HSM centers. The spindles rotate at speeds between 10 000 and 60 000 rpm.

Tooling, Automation, SoftwareTooling for fixing workpieces and tools; automation systems and system softwarefor configuring machine tools and recording and exchanging data with the varioussystem components.

Services and ConsumablesService, maintenance, spare parts and consumables for EDM, milling and HSMsystems as well as for other machine tools; consumables include filters, wire,graphite, copper electrodes and special resin.

EDM

Milling

Automation

Spindle

Service

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GF AgieCharmillesWe enable our customers to run their businessesefficiently and effectively by offering innovativeMilling, EDM and Automation solutions. A comprehensive package of Customer Servicescompletes our proposition.

Achieve moreWe commit to a promise. That promise is“Achieve more.” It’s a commitment to create the right conditions for our customers to obtaincompetitive results. When our customers win, we win.

Contact

Mikron Agie Charmilles AGIpsachstrasse 16CH-2560 NidauTel. +41 (0)32 366 1111 Fax +41 (0)32 366 11 66info@mikron-ac.com

www.gfac.com

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