Press Information, August 2013

HYPERTURN 65 Powermill for greater productivity in complete machining operations for complex workpieces
More clearance, more power, more possibilities: with a spindle distance of 1300 mm, a powerful counter spindle which also allows 4-axis machining, a B-axis with a direct drive for complex 5-axis simultaneous milling operations, an additional Y-axis for the lower turret, and all proven, high-quality features of the Hyperturn series, the Hyperturn 65 Powermill is a powerful addition to every machine range. HALLEIN The HYPERTURN series was conceived to gain considerable increases in productivity during series production. Complex as well as costly turning, drilling, milling and gear cutting operations can be carried out in only one work process. Additional clampings and the temporary storage of parts are no longer necessary and workpiece precision is greatly improved. Total production time, fixture and personnel costs, as well as floor space requirements can be drastically reduced by choosing to work with the HYPERTURN. With a spindle distance of 1300 mm, the Hyperturn 65 Powermill has significantly more clearance for simultaneous machining works on the main and counter spindles than comparable models. With 29 kW and 250 Nm the counter spindle now has enough power to machine the workpiece simultaneously with two tools. This "4 axis machining" is a further aspect to improve productivity. A further benefit is the milling spindle, which with 29 kW, 79 Nm and 12,000 rpm, stands for high productivity in the complete machining of complex workpieces. The B-axis direct drive gives the Hyperturn 65 PM good dynamics and contour capabilities with 5-axis simultaneous machining, alongside shorter ancillary times spent changing tools. The additional Y-axis on the lower turret makes extensive milling work possible at the same time as machining with the milling spindle. 20, 40 or 80-piece tool magazines with HSK-T63 give the user more possibilities for complete machining operations of complex workpieces, with simultaneously low set-up times

a company of the Kuhn Group

for individual parts manufacturing and high stability for turning and milling works. The frontal arrangement is easy to set up and ergonomic. As an alternative to the VDI30 or VDI40 12-position tool turret, EMCO offers a new generation of turret with BMT interface and direct drive. Higher stability and precision, and performance data similar to a milling machine, enable the complete machining of turning/milling workpieces. The machine versions with a milling spindle and turret including milling drive (SMBY/SMBY2) have a cross slide underneath with a 12-position radial turret for 12 driven tools working up to speeds of 5000 rpm. The automatic bar machining and/or delivery of unit loads via a robot solution or the EMCO gantry loader offer excellent potential for increased efficiency in automation. In addition to mechanical and electrical performance values, control systems and software are increasingly determining the productive efficiency of machine tools. Emco has therefore fitted the Hyperturn 65 with the SINUMERIK 840D-sl control unit from Siemens. The new user interface enables an intuitive and significantly easier programming of the machine. Utilizing the machine to its full capacity as far as possible is a crucial aspect for increasing productivity - the EMCO CPS Pilot can generate time and cost savings during machining as the software enables customers to plan, program, simulate, and optimize production runs on their PCs using a 3D model of the machine. The combination of the HYPERTURN with the new EMCO CPS Pilot results in extremely positive multiplier effects: the perfect interplay between CPS Pilot and the HYPERTURN means significant cost and time savings can be achieved (see also the press release on EMCO CPS Pilot). The HYPERTURN 65 Powermill is particularly interesting for the serial production of workpieces, for example in the automotive industry, the fields of mechanical engineering and materials handling, but also for the aircraft industry.

a company of the Kuhn Group

Technical details / Concept of the HYPERTURN Mechanical engineering: The machine base is the core of the machine. The extremely rigid and compact welded-steel construction is filled with a special vibration-damping material. Reinforcing materials provide additional rigidity in zones that are subject to intense stress. The high drive power of the main, counter or milling spindle can thus be fully converted without any limitations. The result: improved surface quality, more precise manufacturing tolerances, and longer tool life. Main spindle and drive technology: The high drive power of the spindles, combined with optimal torque curve, ensures economic efficiency in cutting steel, as well as high-speed cutting of aluminum. Highly dynamic Integrated Spindle Motors (ISM), mounted with large precision bearings, allow for a wide range of speeds with exceptional running truth. A symmetrical headstock, in combination with temperature sensors at the bearings and integrated liquid cooling, ensures thermostability. All linear movements take place in preloaded, highly precise roller slides. This results in significant advantages concerning feed rates, zero backlash, service life, lubricant consumption and positioning accuracy. Thanks to the unique sealing system at the guide shoe working in extremely dirty environments no longer poses any problem. As an additional safeguard cover plate strips made of spring steel are clipped onto the guide rails to attain a closed sealing surface. C axis: Technically speaking every spindle is also an axis. It can be brought into any position and positioned with defined feed motion, making it easy to produce complex contours at the periphery or front surface. The software required to program these movements (cylinder interpolation and/or transmit) is already included in the delivery. Synchronized thread cutting and polygonal turning are part of the machines basic equipment.

a company of the Kuhn Group

The "Powermill" turning/milling spindle: The powerful milling spindle with HSK-T63 tool interface can be used for both turning and drilling/milling work. The milling spindle can be continuously swiveled within a range of +/- 120 and clamped anywhere. With a useful Y-travel of +120/-100 mm, even the most complex of machining work can be carried out. This includes gear-cutting operations, turning/milling work for crankpins, 5-axis machining, and much more. The tools can be prepared according to the customer's requirements with a 20-piece pick-up magazine, or a 40 or 80-piece chain magazine. Y-axis in the turret slide: The Y axis was realized by two interpolating axes. That results in a distribution of the cutting force in two levels and adds stability to heavy-duty turning and milling. This means the lower turret with integrated milling drive can also be used for complex milling operations at all 12 positions, combined with a Y-axis with +/-50 mm travel. Tailstock: In the tailstock version the HYPERTURN is particularly suited for mass machining shaft parts. The tailstock is completely NC controlled and can be positioned using a recirculating ball spindle. This enables the movement interpolating with other axes, saving machining time. Work area: The work area offers superb ergonomics, which results in very good accessibility to the individual components. Generously designed free space provides for an optimum chip flow even when machining critical materials. All guides are covered with sheets made of Niro to prevent damages. Machine enclosure new design: The flush front with a large viewing window is inspired by the well-known design of the EMCO milling machines, the Linearmill 600 and MMV 2000. The HYPERTURN 65 PM machine housing provides all-round protection against chips and is 100 % coolant proof. A large safety glass window in the door provides a clear view of the

a company of the Kuhn Group

work area. The ergonomically designed operating panel can be slid horizontally as far as the center of the machine door. The control panel can be swiveled 90 vertically and up to 10 horizontally. Control unit: Thanks to the SINUMERIK 840D-sl, the HYPERTURN is equipped with one of the most advanced controls on the market. The drive and control package, which is entirely digital, is able to handle up to 10 channels and 31 axes. Technology cycles simplify both turning, as well as milling operations. By the means of coordinate transformations (TRANS, RED, SCALE, MIRROR), any number of machining processes can be realized in the space. Complex machining requirements can therefore be realized quickly and efficiently. The superior quality of the Sinumerik 840D-sl is reflected in the high precision of each workpiece. The full alphanumeric keyboard makes programming easier.

a company of the Kuhn Group

Technical Data: HYPERTURN Max. bar capacity [mm] Max. speed [rpm] Main spindle Counter spindle Milling spindle Driven tools Max. Drive power [kW] Main spindle at 100/40% duty cycle counter spindle at 100/40% duty cycle Milling spindle at 100/40% duty cycle Driven tools Max. Traverse path [mm] Travel in X1/X2 Travel in Z1/Z2 Travel in Y1/Y2 Rapid speed X/Y/Z [m/min] Tool storage capacity Number of driven tools 65 Powermill 65 (76.2) 0 - 5000 (4000) 0 - 5000 0 - 12000 0 - 5000 21 / 29 21 / 29 29 / 22 6.7 405 / 260 1050 / 1050 220 / 100 30 / 12 / 30 20 (40 / 80) 12

Models: HYPERTURN 65 PM - SYB: with main and counter spindles, milling spindle, B and Y axes and 20-tool station magazine HYPERTURN 65 PM - SMYB: with main and counter spindles, lower tool system including milling drive, milling spindle, B and Y axes and 20-tool station magazine HYPERTURN 65 PM - SMY2B: with main and counter spindle, lower tool system including milling drive and Y axis, milling spindle, B and Y axes and 20-tool station magazine

a company of the Kuhn Group

High performance turning and milling center

Controller: The Sinumerik 840D solution line controller on the HYPERTURN 65 PowerMill is located to the right of the working area and can be swivelled in a moving panel. This guarantees optimum ergonomic conditions for setting up the machine and moving it into position.

a company of the Kuhn Group

Adequate space between the two spindles for simultaneous machining on the main and counter spindles.

The milling spindle, which has a drive output of 29 kW and a torque of up to 79 Nm, with a top speed of 12,000 rpm, allows the most complex of turned and milled parts to be manufactured. Gearing can also be produced on both spindles.

a company of the Kuhn Group

About EMCO The Salzburg machinery company EMCO is one of the leading manufacturers of machine tools in Europe. Its two commitments "Made in the Heart of Europe" and "Design to Cost" are the main factors in the success of the international company, which stands for functional design and the highest quality standards. EMCO currently employs some 630 staff at a total of 5 production facilities in Austria, Germany and Italy.

Further information can be found online at www.emco-world.com Further information and requests for pictures: EMCO Maier Ges.m.b.H. Contact: Christa Vergnes, e-mail: Christa.Vergnes@emco.at Salzburger Strasse 80, Postfach 131, 5400 Hallein-Taxach AUSTRIA Tel.: +43-6245-891-0, Fax: +43-6245-86965 Internet: www.emco-world.com

a company of the Kuhn Group