HYPERTURN 690 MCplus – Strong Performance. Highest Flexibility.

 June 2009     

Sophisticated turning and milling is a breeze with the new HYPERTURN product line: the next generation of highly-productive complete machining with the help of a Y axis, B axis and a high-performance milling spindle. The result for customers: a substantial increase of productivity and economic efficiency.

HALLEIN   –   The HYPERTURN series was conceived to gain considerable increases in productivity during series production. Complex as well as costly milling and drilling and even 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. By expanding the HYPERTURN series with the new EMCO CPS-Pilot customers can now save even more costs while machining, since by using this software they are able to virtually plan, program, simulate and optimize the entire production on a computer running a 3D image of the machine. There are a number of extremely positive multiplier effects as a result of combining the HYPERTURN with the new EMCO CPS-Pilot: costs and effort can be extremely reduced (see EMCO CPS-Pilot press release), due to the perfect interaction between the CPS-Pilot and the HYPERTURN.

EMCO’s typical modular assembly, in combination with the substantial modular system, allows customizing the HYPERTURN 645/665 MCplus to the individual demands of the customer. Moreover, with the help of the two versions of the B axis (QuickMill – PowerMill) it has been possible to once again increase the economic efficiency of the production significantly.This version is equipped with a high-performance milling spindle, including a hollow-shaft motor. The tool carrier is a 30-slot magazine (48 or 80-slot optional) with Capto C5 holders. From this results an extremely wide range of milling possibilities, which can be particularly useful for the complete machining of complicated workpieces that call for high-grade milling.

Whether bar stocks, shafts, flange or cubic parts - with its many different versions the HYPERTURN 690 MCplus is ready for action for an immensely wide range of uses. It is particularly interesting for the serial production of workpieces, for example in the automotive industry, the fields of mechanical engineering and friction bearing technology, but also for the aircraft industry.

EMCO continues to live up to its reputation as an innovator and technology leader and by doing so is keeping its promise to continuously develop, improve and expand its product range. With the expansion of the successful HYPERTURN product line, by means of the new EMCO CPS Pilot (Crash-Prevention-System Pilot), the pioneering mechanical engineering company from Hallein has once again showcased their great understanding concerning the high demands of industrial production.

Technical details/ Concept of the HYPERTURN:

Mechanical engineering:

The machine base is the core of the machine. The extremely rigid and compact cast construction in a monoblock design absorbs vibrations, which can occur during machining and this way promotes precision while working on a workpiece. 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 when machining steel and cast components. 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 machine’s basic equipment.

Y axis:

The Y axis has been integrated into the machine structure to ensure highest stability. The direct load transfer provides immense stability and forms the basis for prolonged tool life and economical production. Its great travel of +/- 100 mm permits complex milling operations.

B axis “QuickMill” version:

Now, for the first time the B axis ”QuickMill” version permits machining slanted bores, areas etc. without the employment of special holders. Due to the interpolation with other linear axes the possibilities are almost endless. Very short tool-change times (0.14 sec) and the use of the standardized VDI tool holder result in high economic efficiency.

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.

Tool holder:

The HYPERTURN 690 MCPlus offers two tool systems – both include a 12-station turret (VDI40) with 12 driven tools. Equipped with a VDI quick-change system, including an EMCO adjustment plate, complex alignments of the axially adjusted tools are no longer necessary. Short switching times accelerate processes. All tool holders are equipped with an internal coolant supply. This prolongs tool life and improves chip removal.

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:

The machine enclosure of the HYPERTURN 665 MC Plus offers a comprehensive protection against flying chips and offers 100% coolant retention. A large safety glass window in the door permits an unobstructed view into the work area. Built-in buttons improve the ease of use of the machine.

Control unit:

Thanks to the SINUMERIK 840D, 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 is reflected in the high precision of each workpiece.

In order to operate the HYPERTURN in an ergonomic manner the swivel control has been placed on the left side of the HYPERTURN. Conversion times are shortened. The full alphanumeric keyboard makes programming easier.

Technical core data:

HYPERTURN

690 MC plus Y

690 MC plus PowerMill

Max. bar capacity [mm]

95

95

Max. speed [rpm]

Main spindle

Counter spindle

Driven tools

3200

3200

3000

 

3200

3200

7000 (12000)

 

Max. drive power [kW]

Main spindle / Counter spindle

37 / 54 / 10,5

 

37 / 54 / 21,5

 

Max. travel [mm]

X1, / X2 / Z1 / Z2

280 / 280 / 1055 / 1090

490 / 280 / 1110 / 1090

Rapid speed X/Y/Z [m/min]

30 / 15 / 30

Number of tool positions

2 x 12

30 / 48 / 80 + 12

 

Machine versions:

 ·  HT 690 MC (TCM): with counter spindle, 1 turret, driven tools

 ·  HT 690 MC (Y): with counter spindle, 1 turret, driven tools and Y axis

 ·  HT 690 MC plus (TCM): with counter spindle, 2 turrets, driven tools

 ·  HT 690 MC plus (Y): with counter spindle, 2 turrets, driven tools and Y axis

 ·  HT 690 (PowerMill): with tailstock, milling spindle, Y-B axis

 ·  HT 690 MC (PowerMill): with counter spindle, milling spindle, Y-B axis

 ·  HT 690 MC plus (PowerMill): with counter spindle, milling spindle, Y-B axis, 1 turret with driven tools

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