Provided By
MAG IAS, LLC
Rigid, two-column design includes fixed- and adjustable-rail models, all with multi-processing options for live spindle machining and grinding.
MAG's new vertical turning centers with 5 to 8 meter tables, are engineered to make short work of large-part manufacturing for a variety of industries, including wind and nuclear, offering multiprocessing machining capabilities with high-end specifications like 2500 mm ram travel and 1500 mm minimum height under the rail. The modular machine design is built for high metal removal rates on large parts, with twin columns mounted to the base, 150,000 to 250,000 kg table load capacity, and 350 mm cross-section ram for extreme rigidity and chatter-free machining. Four models, with table diameters of 5, 6, 7 and 8 meters, are being introduced in fixed and adjustable-rail styles. All are engineered for full ram travel to either side of the table center, providing facing capacity that is one meter greater than table diameter for any given model. Powered by a 142 kW (190 hp) table drive, the 5- and 6-meter models have a maximum speed of 72 rpm and constant torque rating of 160,000 Nm (118,000 lb ft), while 7- and 8-meter models have 45 rpm maximum speed and 255,000 Nm (188,000 lb ft) constant torque.
These new VTC models continue MAG's design tradition of building on an extremely rigid platform, with excellent ergonomic and operating features driven by Voice of the Customer research. Customer-driven features include use of standard modular tooling, including KM and Coromant Capto C8; green design with minimal hydraulics; energy-conservation with selectable "sleep" capability; minimal foundation requirements; and innovative chip management and removal that minimizes operator intervention. Ergonomic features include an operator platform that provides an excellent view of the cutting zone, as well as access to the tool and tool magazine. Options for the platform include fixed position, or moveable in vertical, or horizontal and vertical directions. A full machine enclosure meets CE specifications and ensures a dry floor environment.
Robust construction features include heavily reinforced columns and beds. The hydrostatic ram, with 2.5 m stroke, combines wear-free reliability and high rigidity with high vibration damping and thermal symmetry. Full X-axis ram travel allows probing the outside diameter of parts, ensuring highest measurement accuracy, and the large swing capacity better accommodates asymmetric parts, part loading, and operator access. A rail-mounted toolchanger allows for fast, easy tool changes. The rail-mount design, in conjunction with the horizontal and vertical movement of the operator platform, facilitates tool maintenance during the machining cycle. Extended tool magazines are available, too.
Adjustable-rail machine models use twin linear scales on the W axis to ensure precise parallelism between the cross slide and table at all height positions. Available feed thrust in X and Z axes is 45,000 N (10,116 lbs). Linear positioning accuracy in X and Z axes is 0.015 mm (0.0006"), with repeatability of 0.010 mm (0.0004").
Options include a right-angle head and live spindle to allow milling, drilling, tapping and other machining operations, all in the same fixturing. Full contouring with C-axis enables drilling or mill turning of features anywhere on the workpiece, with contouring/positioning by a 360,000-position table. A new automatically changed grinding attachment adds surface finishing to the one-stop processing capabilities of MAG VTC's, allowing finishing of ID, OD and plane surfaces on parts. Ideal for large bearings and gearboxes, the grinding attachment can produce better than 10 micro inch finishes and roundness of less than 60 micro inch, with diameter size control of 0.025 mm (0.001 inches).
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Provided By
MAG IAS, LLC
New floor-type boring mill features powerful, long-reach ram for job-shop versatility
The machine's collinear ram, made from ductile iron, adds a 1-meter W-axis reach to the spindle's existing 1-meter extension. It provides maximum rigidity for full-power cuts by minimizing spindle extension. The ram's 400 x 500 mm cross section is ideally sized for extended reach with rigid support to enable the machine to perform additional operations, helping to reduce time-consuming large-part setups for faster cycle times and less work-in-process. The machine's Ram Displacement Compensation system uses a hydraulically actuated tension rod system to counteract the static loads of attachments, and control ram displacement caused by variations in ram extension and attachment weight. Like all MAG boring mills, the FTR 3500 includes W and Z-axis thermal compensation software to dynamically offset spindle growth.
The FTR 3500 is available in column heights of 2 to 5 meters (6.6 to 16.4 ft) in half-meter increments. Traveling-column design allows virtually unlimited X-axis travel for processing of large and long workpieces or multiple batch parts, while 20 m/min (787 ipm) rapid traverse rates reduce cycle times. The choice of spindle power trains includes two four-speed versions available with spindle diameters of 130 and 155 mm (5 and 6 in). Available horsepower is 56 kW (75hp).
The FTR 3500's rigid box welded column construction, wide way spreads on the column and runway, and steel runway fabrication provide exceptional rigidity and durability for the most demanding machining requirements, resisting deflection and minimizing vibrations. Linear positioning accuracy is 0.015 mm (0.0006 in) and repeatability is 0.008 mm (0.0003 in). Precision roller packs on X, Y and W axes, provide stability, low friction, durability and maintainability for high-performance machining. The Y-axis has a 100 mm (3.94 in) preloaded, anti-friction ballscrew, while the Z and W axes use a 63 mm (2.5 in) diameter ballscrew. The X-axis is driven by an electrically-preloaded rack and pinion system.
Modular design allows economical customization of the FTR 3500, along with industry's fastest machine build and delivery. The machine can be fitted with choice of travels, headstocks, spindle diameters and spindle power, controls, coolant systems, workholding and tool magazines. Front-end options include a range of indexing and rotary tables, auxiliary slides and floor plates. An optional attachment rack enables storage and quick change of contouring heads, programmable boring bars, right angle heads and more to speed production. Optional cartridge-style ram allows for a fixed attachment or attachment changing operations.
"Green" features of the FTR 3500 include a minimal air-oil lubrication system in the headstock, eliminating the need for chillers and ancillary equipment for lower overall ownership cost. Ergonomic enhancements include operator platforms with X-, Y- and W-travel options, and operator convenience packages that include lighting, power, air and workbench options. Custom workzone enclosures are also available.
The service areas of the machine are designed using Visual Uptime Management principles to simplify maintenance and maximize machine availability. Clear, color-coded labeling and note plates assist in accessing and maintaining key utilities for the machine and control.
MAG's new FTR 3500 floor-type horizontal boring mill (HBM) is a versatile, mid-sized job-shop machine, capable of a full 2 m reach inside parts with a ram-supported spindle. The workhorse machine tool is ideal for "heavy metal" milling, as well as precision multi-axis contouring, boring, drilling and tapping on large parts for the construction, oil field and wind energy industries.
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