The turning machine has an integrated pick-up system and self loads chuck parts with a diameter of up to 200 mm, thus saving the user the additional costs and programming time involved with the use of an automated unit. It is no longer necessary to align the automated unit with the machine causing downtime.

The VT 250 is also supplied as standard with a conveyor belt system in which customers can store up to 24 workpieces. The conveyor belt moves the workpieces into the pick-up position. The vertical, high-power spindle makes turning, drilling and threading operations easy. The rigid machine structure creates the requirements for substantial cutting performance in serial production and is ideally suited for fine- and hard machining.

Equipped with specially large roller guides the new machine is predominantly suited for work on short and heavy workpieces with a large diameter. The large guide rails and guide shoe guarantee excellent stability even at  high loads.

On the tool turret 12 tools with the VDI40 shank can be mounted. The basic machine also includes a coolant device and a chip conveyor, which ensures optimal chip removal.

The new VT 250 is also ideally equipped from a control perspective: The new Sinumerik 828D from Siemens is impressively simple to operate and program. The ShopTurn interface particularly facilitates job shops with programming.

EMCO VERTICAL VT 250 – this compact, high-performance machine, developed and produced in line with the “Design to Cost” principle, is your entrance ticket to vertical turning for a very attractive price!

Versions EMCO Vertical VT 250

EMCO Vertical VT 250 – Basic machine without driven tools with belt drive on the main spindle
EMCO Vertical VT 250 – Basic machine with driven tools and belt drive on the main spindle
EMCO Vertical VT 250 M (ISM) – Basic machine with driven tools and hollow spindle drive
EMCO Vertical VT 250 MY (ISM) – Basic machine with driven tools, Y axis and hollow spindle drive

Als Zulieferer für den klassischen Maschinenbau, die Hersteller von Solar- und Windkraftanlagen und der Automobilindustrie und natürlich als Kernkomponenten-Produzent für die EMCO Gruppe. In enger Kooperation zwischen Magdeburg und dem Headquarter wurde eine neue vertikale Drehmaschine entwickelt – als logisches Ergebnis der konsequenten Nutzung der Synergien, die sich aus den unterschiedlichen Erfahrungen und Kompetenzen ergeben. Die Maschine wurde im Rahmen der Hausmesse in Magdeburg am 12.3. den Kunden und Besuchern präsentiert und traf auf breite Akzeptanz.

Mit der EMCOVERTICAL VT250 erweitert EMCO sein Produktportfolio in der Automation um eine Pick-up Maschine für Futterteile, die Rohteile selbständig ohne zusätzlicher Automationseinrichtung lädt. Damit verfügt EMCO neben den standardisierten Automationslösungen wie Portallader, Schwenklader und Roboterzellen über eine intelligente Automationslösung zu einem unschlagbaren Preis/Leistungsverhältnis. EMCO-Stammkunden wie Neukunden können mit dieser Maschine auf eine Automationslösung zurückgreifen, die kurze Beladezeiten, hohe Stabilität, einfache Programmierung und Bedienung, einen kompaktes Maschinenbau und optimalen Spänefluss garantiert.

Neben der Präsentation der neuen EMCO VERTICAL VT 250 mit integrierter Automation für Futterteile bis zu einem Durchmesser von 200 mm standen die zahlreichen Innovationen aus allen Produktbereichen von EMCO – Drehen / Fräsen / Konventionelle Maschinen / Industrial Training im Zentrum des Interesses.

Best-Practice Erfolgsstories aus den diversen Ländern und praxisnahe Präsentationen an den Maschinen im Vorführzentrum bei EMCO boten Gelegenheit für spannende Diskussionen bis in die späten Abendstunden. Wobei auch der Sportsgeist und ganz andere Talente gefordert waren: Bei spannenden Rennen auf einer Carrera-Bahn konnten die Damen und Herren ihren Mannschaftsgeist und ihr Koordinationstalent unter Beweis stellen.

25 Auszubildende können hier an industriegerechten EMCO Dreh- und Fräsmaschinen ausgebildet werden.

Thomas Glück, Geschäftsführer des BBZ Elbe, sieht in dem selektiven Programm von EMCO und Festo großes Potential für seine Auszubildenden und seine Ausbilder. Laufende Fortbildungen, topaktuelle Updates der Unterlagen und Support im Unterrichtsalltag sind nur ein paar Highlights des Leistungspakets.

Bildunterschrift v.l.n.r.:
Thomas Glück, Geschäftsführer BBZ Elbe,
Dr. Stefan Hansch, Geschäftsführer EMCO Group
Alexander Bickel, Vertriebsleiter Festo Didactic

The EMCO VERTICAL VT 250, a pick-up machine for chuck parts that automatically loads blank parts without the need for an additional automated unit, has helped to expand EMCO’s portfolio of automated products. In addition to standardized automation solutions such as gantry loaders, swing loaders and robot cells, EMCO is now able to offer an intelligent automation solution at an unbeatable price/performance ratio. This machine provides both regular and new EMCO customers with a reliable automated solution that guarantees short loading times, excellent stability, simple programming and operation, compact machine design, and optimum chip flow.

On closer examination of the technical data, it becomes clear: Due to the solid machine construction and the strong technical data, the machine is perfectly suited for steel machining. The EMCOMILL E350 is equipped with a powerful and at the same time smooth inline milling spindle with direct drive (10,000 rpm, 7 kW, 41 Nm) and SK30 tool taper, a high feed rate in the linear axes, a fixed 20-tool magazine with a fast two-arm changer. The variable encoding of the tool positions enable short tool changing times. Linear guideways free of play provide high precision and dynamics. EMCO payed alot of attention to the ergonomics when designing the machine. Therefore, the work area is optimally accessible and the machine’s components are easy to clean and to maintain. Low-maintenance central lubrication and the coolant unit that is easy to clean contribute to this, as well.

The EMCOMILL E350 is especially applicable for the production of small parts in small and medium lot sizes. Small parts up to a size of 350 x 250 x 300 mm can be machined quickly and precisely.

Due to its modular construction the CNC milling machine can be adapted to your individual requirements. Especially, the various options the machine can be equipped with are meant by this.  Looking for higher performance? The EMCOMILL E350 can be equipped with a spindle with 24000 rpm maximum spindle speed on request. Even the number of axes is extendible to 4 by attaching a dividing unit. The automatic workpieces and tool measuring that is done in the machine, or, the automatic removal of chips by the chip conveyer. The list of possible options is long and comprehensive. The resulting flexibility is pointed up foremost by the machines diverse fields of application: automotive suppliers and job shopper can machine their orders equally easily as branches with enormously high precision demands like juwelers and watch makers or the medical technology.

For improving the productivity at medium lot sizes the EMCOMILL E350 can be perfectly equipped with automation solutions for example with EMCO ROBO LOAD 10 that loads parts automatically into the machine.

Even the control is a special highlight of the EMCOMILL E350. With the new Sinumerik 828 D, the user programms with the latest technology with user convenience. Programming with ShopMill or ISO is possible.

With an enclosed welded steel design, the machine structure offers maximum stability and thermal symmetry. Short force flows ensure optimal precision and excellent surface qualities on the workpiece. The basic machine includes a screw conveyor for chip removal with default cleaning in the work area.

As the tool magazine holds 30 tool stations ready for use, complex machining processes can be carried out simply and efficiently.

Depending on the production requirement, a powerful mechanical spindle with a maximum speed of 10,000 rpm or a motor spindle with a maximum speed of 15,000 rpm can be selected.

The MAXXMILL 500 can be programmed using the latest control technology from either Siemens or Heidenhain. The control unit is attached to a control panel that is equipped with a rotary and pivotal function. This guarantees ergonomic work processes.

Naturally, the EMCO commitment of ‘Made in the Heart of Europe’ also applies to the MAXXMILL 500. The machines are completely developed and produced in central Europe in cooperation with European brand manufacturers that meet the highest standards in terms of quality, productivity and efficiency.

MAXXMILL 500 is therefore the ideal vertical milling center for the 5-sided machining of workpieces in low or medium quantities. This makes it particularly suitable for contract manufacturers, industrial enterprises such as automotive supply companies that are involved in general mechanical production, and higher-level training institutions.

The new HYPERTURN 45 is distinguished by even greater dynamics and technical sophistication, and therefore impresses users with the additional options for machining workpieces and increasing productivity. For example, extremely ‘HYPERTURN-like’, there is now a Y axis with a 70 mm travel in the upper slide system and a Z2 axis in the lower slide system. As with the HYPERTURN 645/665, the main and counter spindles are equipped with integrated water-cooled spindle motors with high drive power of 15 kW, a maximum speed of 7,000 rpm and an even higher torque of 90 Nm. The counter spindle’s nose is also larger: With A2-5, the counter spindle can be used to remove bar stock parts with a diameter of up to 45 mm.

Thanks to the latest Siemens control and drive system, the Sinumerik 840D-sl (solution line), programming the machine is quick and easy. The fold-out PC keyboard is an ergonomic plus, especially if the machine is regularly programmed.

Naturally, the EMCO commitment of ‘Made in the Heart of Europe’ also applies to the HYPERTURN 45. The machines are completely developed and produced in central Europe in cooperation with European brand manufacturers that meet the highest standards in terms of quality, productivity and efficiency.

The HYPERTURN 45 is characterized by its great flexibility and can therefore be used in the widest range of sectors for the broadest production requirements: From general mechanical engineering, job shops and the automotive supply industry, where production tends to involve large quantities, through to precision trades such as dental technology or the jewelry industry.

Fascinating machining examples from the power engineering, medical technology, drive technology and automation sectors will prove the many uses of the EMCO machines:

• The HYPERTURN 45 promises the highest productivity and dynamics: High-performance main and counter spindle, two tool systems, stable Y-axis, water-cooled spindle motors, dynamic digital drives, a thermo-symmetrical machine construction and compact dimensions. 
• In line with the motto ‘Save time, money, and room’, EMCO offers its customers a new, flexible vertical CNC milling machine for 5-side-machining in the form of the new MAXXMILL 500. In just one operation, complex workpieces with an edge length of 500 x 500 x 500 mm can be efficiently and precisely machined. The compact machine structure and excellent value for money also make possible further advantageous savings.
• Small, compact, powerful and flexible! The new vertical CNC machining center EMCOMILL E350 with a travel in X of 350 mm convinces with its small foot print, its powerful performance data, its flexible applicabilities and its very attractive price-performance ratio.
  Due to the solid machine construction and the strong technical data, the machine is perfectly suited for steel machining. The EMCOMILL E350 is equipped with a powerful direct-drive main spindle (10,000 rpm, 7 kW, 41 Nm), a high feed rate coupled with immense feed power, a fixed 20-tool magazine, a fast two-arm changer. Small workpieces in small to medium lot sizes can be produced easily by the standard 3 axes machining center.

• When conventional machines reach their limits and CNC machines are too complex, EMCO cycle-controlled lathes provide an economic alternative. Whether for one-off or small series production, simple or complex workpieces, EMCO cycle-controlled lathes impress with their high cutting performance and maximum precision, especially the new cycle-controlled lathe EMCOMAT E200 and the cycle-controlled milling machines EMCOMAT FB450 and 600 L. All of these are equipped with EMCO Easy Cycle control systems characterized by their advanced user-friendliness.  No CNC knowledge is necessary. Programming is carried out via the user interface and a graphic simulation of the workpiece.

Additionally to the novelties, the visitors of the EMCO booth are shown a selection of Big CNC machines and Industrial Training machines.  

Das Detailprogramm finden Sie anbei - siehe rechts oben.

The competition is organized and hosted every year by the Salzburg Chamber of Commerce and is a valuable opportunity for apprentices to directly compare the knowledge and skills they have learned from their companies among trainees of their own age. This event is also an excellent opportunity for training companies to measure the quality of their apprenticeship training courses.  This year’s result reflects EMCO’s ongoing commitment to the development of its trainees and the optimization of its apprenticeship course. EMCO will continue to make every effort to provide its apprentices with the best possible training program.

Along with EMCO’s managing directors, the whole EMCO team would like to congratulate Andreas Wiesner on his outstanding achievement!

The visitors were introduced to the new products (HYPERTURN 45, MAXXMILL 500, EMCOMAT E200, and EMCOMAT FB-450 and -600 L) and had the opportunity to discuss the latest trends in the world of machining with research and development managers. Fascinating machining examples from the power engineering, medical technology, drive technology and automation sectors highlighted the many uses of the EMCO machines.

In case you missed the chance to be won over by the new products on site, the following brief profiles give them the opportunity to make a first impression:

• The HYPERTURN 45 promises the highest productivity and dynamics: High-performance main and counter spindle, two tool systems, stable Y-axis, water-cooled spindle motors, dynamic digital drives, a thermo-symmetrical machine construction and compact dimensions.

• In line with the motto ‘Save time, money, and room’, EMCO offers its customers a new, flexible vertical CNC milling machine for 5-side-machining in the form of the new MAXXMILL 500. In just one operation, complex workpieces with an edge length of 500 x 500 x 500 mm can be efficiently and precisely machined. The compact machine structure and excellent value for money also make possible further advantageous savings.

• When conventional machines reach their limits and CNC machines are too complex, EMCO cycle-controlled lathes provide an economic alternative. Whether for one-off or small series production, simple or complex workpieces, EMCO cycle-controlled lathes impress with their high cutting performance and maximum precision, especially the new cycle-controlled lathe EMCOMAT E200 and the cycle-controlled milling machines EMCOMAT FB450 and 600 L. All of these are equipped with EMCO Easy Cycle control systems characterized by their advanced user-friendliness.  No CNC knowledge is necessary. Programming is carried out via the user interface and a graphic simulation of the workpiece.

The technology day takes place at June 26 from 9:00 a.m. to 4:00 p.m. at the show room at the headquarters of the EMCO Group in Hallein.
Please register at emco2606@emco.at.

The EMCO team looks forward to spending an exciting day with you.

The unique interchangeable control concept

With its globally unique interchangeable control concept, EMCO Industrial Training teaches trainees to use up to eight different industry-standard control units. This is a significant advantage, not just for future specialists, but also for employers. As well as opening up a wide range of professional opportunities and career prospects for CNC technicians, it creates a pool of expertly trained staff that companies can draw upon regardless of the machines and control systems used.

The conversion to another control system is carried out within y minute by calling up the respective software and by simply replacing the control specific module.

Ideal for training on the latest machining technology

The Concept MILL 250 is typically aimed at industrial training establishments with production applications, manufacturing businesses with apprentices and trainees, factories, watchmakers and jewellery manufacturers, and both beginners and advanced trainees with more demanding requirements. It is ideal for machining steel and aluminum.

Sophisticated technology for industrial machining

The refined machine design ensures perfect training conditions for industrial machining: With a powerful direct-drive main spindle (10,000 rpm and 7 kW), a high feed rate coupled with immense power, a fixed 20-tool magazine, a fast two-arm changer, and the EMCO WinNC control unit, the Concept MILL 250 can be used not only for CNC milling training, but also, depending on the precise user requirements, as a fully-functioning production machine. For training at highest level.

As well as programming with different control units, users are trained in future machining technology trends. These include selecting the right cutting parameters, such as depth, feed rate, and rotational speed, taking into account optimum chip formation and the surface to be achieved. The upshot is that EMCO Industrial Training has set another clear milestone towards a soundly-based industrial training regime in machining.

The design of this machine adheres, of course, to EMCO's commitment of "Made in the heart of Europe" and "Design to cost"

With the EMCOMILL E-series, EMCO expands its ample product range and thus offers an even more matching structure: the new machine generation is a counterpart in milling to the successful EMCOTURN E25/E45/E65 lathe series. Therefore, EMCOMILL E-series is the very recent proof for the persistent application of the "Design to Cost“ approach: offering the highest possible benefit at the lowest cost to the customers. All components that contribute to performance, precision and long duration of the machines are optimized, focussing at the same time on main functions for the customer.

This can be seen not only in the definitely simpler operability of the machines, but above all with regard to price as well.

However, the customer need not dispense with quality - quite to the contrary: The development and the production of the machines is carried out according to the EMCO philosophy "Made in the Heart of Europe“, i.e. exclusively in Central Europe in cooperation with European brand producers who comply with top standards regarding quality, productivity and economy.

EMCOMILL E1200, E900 and E600 are the promising results of a successful cooperative effort between EMCO and its Italian subsidiary, FAMUP, and is enormously attractive particularly for general machining as well as tool and prototype construction.

Mechanical Engineering without Compromises

EMCOMILL E1200 is designed as a very compact universal 3-axes machine for general machining. The machine base, the support and all three slides are of massive cast design and form the basis for the robust machine structure. The excellent damping properties of the cast material result in high surface qualities with ample cutting values. 

The caged ball guides with their parts that provide high support and stiffness values make the slides traverse precisely and without jerking.

The tool magazine is designed as a very quick 2-arm magazine as a standard. Tool changing times of 1.6 seconds facilitate more than quick change to other tools and thus ensure production that saves time and costs.

Concept of Modular Structure

The highly proven modular concept facilitates a perfect adjustment of the machine to the customer's requirements also in the EMCOMILL E1200.

The main modules are spindle variants, tool magazine, controls, chip removal, coolant supply, rotary table/4th axis.

Naturally, EMCO offers to the customer a standard selection of options for the new machine series: measuring sensor for tool or workpiece measurement, hand wheel, band filter, alarm lamp, blow-out device, chip flushing, automatic door system.

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:

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

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. In the QuickMill version, the upper turret is equipped with a B axis which allows the upper turret to swivel to any position within a 45º arc, thus continuously supporting the lower tool system. In addition, it is characterized by extremely short tool-change times (0.2 seconds).

An even much higher milling performance can be achieved with the PowerMill: here a milling spindle with hollow-shaft motor replaces the top turret. The PowerMill is provided with a 24-tool or 28-tool magazine with Capto-C4-adapters. The result: an unbeatable and complete synthesis of turning and milling technology. This machine version is especially suitable for complete machining complex workpieces that require extensive milling due to its high degree of flexibility and high metal-cutting capacity.

The HYPERTURN 665 MCPlus 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.

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 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 welded-steel construction is filled with HYDROPOL®, an extremely high-quality and vibration-damping material made of special concrete and steel. 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 machine’s basic equipment.

Y axis:

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. Its travel of +/- 50 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.

B axis “PowerMill” version:

The B axis “PowerMill” version includes a powerful milling spindle with a 24-tool and 48-tool magazine. In combination with the lower 12-tool turret it is therefore possible to precisely manufacture complex machined parts.

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 665 MC Plus comes equipped with two tool systems – one each on the top and bottom. The tool system on top is fitted with a 12-station turret with 12 driven tools. The lower tool system is equipped with a VDI quick-change system with an EMCO adjustment plate. EMCO's tool alignment system optimizes the VDI quick-change system. Alignment is no longer required. Short switching times accelerate processes. All tool holders are fitted 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.

Flexible automation systems:

The HYPERTURN offers an entire range of automation possibilities to facilitate efficient production e.g.: automatic bar loading, counter spindle unloading for long parts and a loading gantry. In addition, it is possible to cut back on personnel due to the integrated monitoring system.

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 Data:

Versions:

· HT 645 MC plus (TC): with counter spindle, without driven tools

· HT 645 MC plus (TCM): with counter spindle, driven tools

· HT 645 MC plus (Y): with counter spindle, driven tools and Y axis

· HT 645 MC plus (QuickMill): with counter spindle, driven tools and with Y-B axis

· HT 665 MC plus (TC): with counter spindle, without driven tools

· HT 665 MC plus (TCM): with counter spindle, driven tools

· HT 665 MC plus (Y): with counter spindle, driven tools and Y axis

· HT 665 MC plus (QuickMill): with counter spindle, driven tools and with Y-B axis

· HT 665 MC plus (PowerMill): with counter spindle, driven tools and with Y-B axis

Tailored automation

A swing loader is included for automatic loading and feeding out of the machined parts. This extremely compact and integrated loader is controlled via the machine control. Two linear axes with high feed rates and an additional B axis in the swivel head, guarantee short loading times and fast setup. As a result, preformed raw parts can also be inserted position-oriented into the clamping device. The gantry loader transports the finished workpieces from the machine and places them on an accumulating conveyor.  

EMCO has two different versions of bar loaders on offer for bar work: a classic 3-meter loader (EMCO TOP LOAD 8-65/3300) and the EMCO short bar loader LM1200 for limited floor space. 

Depending on the make, the MAXXTURN 65 forms the basis for efficient machining of precision and machined parts. The range of manufactured workpieces ranges from hydraulic / pneumatic components, to machines as well as engine and automotive parts, all the way to components from the field of biomedical engineering or the fields of materials and bulk material handling. Friction and antifriction bearing parts are just a few more examples of the nearly endless possibilities.

The highlights of the MAXXTURN series

One of the characteristics which distinguishes the entire MAXXTURN line is that the Y axis is integrated in the body of the machine. This ensures maximum stability, as well as utmost precision of all parts manufactured. The extremely wide distances between the guides make for stable turning and offer the operator additional possibilities for complete machining.

The compact counter spindle is an additional highlight, taking over workpieces position-oriented and with utmost precision for machining the reverse side. This avoids having to clamp workpieces a second time, thereby avoiding wait time, which in turn increases productivity and makes for shorter part delivery periods.

The tool turret with single-motor engineering offers space for 12 VDI30 tool holders. Each station can accept driven tools. A servo motor powers the driven tools and the swivel movement, respectively. The tool holders, equipped with EMCO joggling plates, allow easy tool insertion with repeatable accuracy without the need for time-consuming adjustments.

In the course of modular assembly customers can choose between a SIEMENS (incl. ShopTurn dialogue interface) and a FANUC control interface (incl. Manual-Guide-i control interface).

Technical details/ Concept of the machine:

Machine base:

The 40° inclined bed is the core of the machine. The very rigid and compact welded-steel construction provides an extremely solid basis for a precise as well as economic production. The advantages of steel, in comparison to machine casting, are on the one hand its higher rigidity and on the other hand the superior thermal behavior of the lathes during warm-up. For optimum damping of the vibrations and resonances which naturally occur during machining, the machine base of the MAXXTURN 65 is filled with special vibration-damping material. A perfect turning finish and true running accuracy are the result.

Reinforcing materials provide additional rigidity in zones that are often subject to intense stress.

The MAXXTURN 65 is equipped with roller guides which are free from wear and bedded without play. They are delivered with highest possible prestress and are bolted onto high-precision, ground bearing pads. Perfect guidance qualities without any stick-slip effect guarantee best surface qualities for all machined parts. Covers along the guides, as well as additional telescope covers made of stainless steel increase operational safety and durability. 

Main spindle:

The high driving power of the spindle combined with optimal torque curve ensures economic efficiency in cutting steel, as well as high-speed cutting of aluminum. The main spindle guarantees a bar capacity of up to 65 mm and is supported with extra large precision bearings.  These allow for a wide range of speeds with extremely good running truth. A symmetrical headstock with fitted cooling fins ensures optimum thermostability. 

Tailstock:

On the MAXXTURN 65 with tailstock, the tailstock is set up on the linear roller slide and can be positioned automatically within a range of 500 mm. The rolling centre with MK4 shaft is directly integrated into the tailstock and can be removed using a pressure wedge.

Counter spindle:

On the MAXXTURN 65 S, which is equipped with a counter spindle, the counter spindle headstock is placed on a separate linear roller slide and can be positioned within a range of 580 mm. A stroke-monitored parts ejector, flushed with coolant, ensures safe removal of the finished parts.

Tool holder:

The tool holder consists of a 12-position VDI30 radial turret with single-motor engineering and quick-change system. All 12 stations can accept driven tool holders. A servo motor powers the driven tools and the swivel movement, respectively. The machine operator may adjust the slewing speed at any time, using a feed-override switch. The turret can be used on both spindles and switches with direction logic. This means that it always takes the shortest way when swiveling to the next tool. The tool holders, equipped with the EMCO joggling plate and DIN 5480 coupling, allow easy tool insertion with repeatable accuracy without time-consuming adjustments.

C axis/main spindle (model-specific):

The C axis is part of the machine’s standard equipment. The spindle can be positioned with a resolution of 0.001°. Since an integrated spindle motor is used, instead of a belt drive, the C axis is perfectly suited for precise contour milling.

Y axis (model-specific):

The Y axis is integrated in the standard build of the machine and is positioned at an angle of 90° in relation to the X axis. Extremely short protruding lengths are the basis for solid lathing and drilling operations, as well as for milling without receiving imprecise contours.

Feed drive:

Highly dynamic three-phase drives in all linear axes, with preloaded circulating ball spindles, provide high feed forces and positioning with repeatable accuracy.

Measure system:

Incremental measure systems in the feed motor are integrated in all linear axes. Positioning variation according to VDI3441 in X/Y/Z: 0.0035/0.0035/0.004 mm

Clamping unit:

The clamping unit is a hydraulic clamping system with a bar capacity of up to ø 65 mm, including a programmable chuck stroke monitor and direct measure system. Time-consuming adjustments with the tools are thereby substituted by a simple training in Teach-In-Mode.

Lubrication:

The MAXXTURN 65 uses an automatic centralized lubrication system with lubricant-saving impulse lubrication due to its integrated pressure and quantity monitoring.

Coolant device:

A central coolant supply through the VDI interface at the turret and through the tool holder ensures optimal cooling and lubrication during the machining process. An additional coolant pipe has been installed to clean the clamping devices and the work area.

Hydraulic system:

The hydraulic system is a high-pressure compact hydraulic system with a pump and a fine filter in the head pipe, with which the chucking pressure can be more finely adjusted, which is an absolut must for clamping sensitive work-pieces in the main and the counter spindle.  Thanks to its compact construction it only has a small footprint.

Casing:

The casing of the machine is completely closed. Its door is monitored with safety switches to prevent operator injury and features a sizeable viewing window made of laminated safety glass. 

Finished parts pick-up unit (optional):

The pneumatically operated pick-up unit removes finished parts from the main or the counter spindle. The parts are gently transported into a finished parts container outside of the work area. Max. length of finished parts: 175 mm; max. ø 65 mm; Max. weight: 4.5 kg

Technical Data:

Versions:

 · Choice of control: Fanuc or Siemens

 · MT 65 MY: Tailstock version with driven tools and Y axis

 · MT 65 S: Counter spindle version without driven tools

 · MT 65 SM: Counter spindle version with driven tools

 · MT 65 SMY: Counter spindle version with driven tools and Y axis

Tailored automation

A swing loader is included for automatic loading and feeding out of the machined parts. This extremely compact and integrated loader is controlled via the machine control. The exceptional combination of a swivel movement and a linear movement, driven by servomotors, guarantees simple and fast setup. As a result, preformed raw parts can also be inserted position-oriented into the clamping device. After machining has been completed the finished parts are transported out of the machine via the parts catcher. 

EMCO has two different versions of bar loaders on offer for bar work: a classic 3-meter loader (EMCO TOP LOAD 8-45/3300) and the EMCO short bar loader LM800 for limited floor space. 

Depending on the make, the MAXXTURN 45 forms the basis for efficient machining of precision and machined parts. The range of manufactured workpieces ranges from hydraulic / pneumatic components, to machines as well as engine and automotive parts, all the way to components from the field of biomedical engineering or the fields of materials and bulk material handling. Friction and antifriction bearing parts are just a few more examples of the nearly endless possibilities.

The highlights of the MAXXTURN series

One of the characteristics which distinguishes the entire MAXXTURN line is that the Y axis is integrated in the body of the machine. This ensures maximum stability, as well as utmost precision of all parts manufactured. The extremely wide distances between the guides make for stable turning and offer the operator additional possibilities for complete machining.

The compact counter spindle is an additional highlight, taking over workpieces position-oriented and with utmost precision for machining the reverse side. This avoids having to clamp workpieces a second time, thereby avoiding wait time, which in turn increases productivity and makes for shorter part delivery periods.

The tool turret with single-motor engineering offers space for 12 VDI25 tool holders. Each station can accept driven tools. A servo motor powers the driven tools and the swivel movement, respectively. The tool holders, equipped with EMCO joggling plates, allow easy tool insertion with repeatable accuracy without the need for time-consuming adjustments.

In the course of modular assembly customers can choose between a SIEMENS (incl. ShopTurn dialogue interface) and a FANUC control interface (incl. Manual-Guide-i control interface).

Technical details/ Concept of the machine:

Machine base:

The 72° inclined bed is the core of the machine. The very rigid and compact welded-steel construction provides an extremely solid basis for a precise as well as economic production. The advantages of steel, in comparison to machine casting, are on the one hand its higher rigidity and on the other hand the superior thermal behavior of the lathes during warm-up. For optimum damping of the vibrations and resonances which naturally occur during machining, the machine base of the MAXXTURN 45 is filled with special vibration-damping material. A perfect turning finish and true running accuracy are the result.

Reinforcing materials provide additional rigidity in zones that are often subject to intense stress.

The MAXXTURN 45 is equipped with roller guides which are free from wear and bedded without play. They are delivered with highest possible pre-stress and are bolted onto high-precision, ground bearing pads. Perfect guidance qualities without any stick-slip effect guarantee best surface qualities for all machined parts. Covers along the guides, as well as additional telescope covers made of stainless steel increase operational safety and durability. 

Main spindle:

The high driving power of the spindle combined with optimal torque curve ensures economic efficiency in cutting steel, as well as high-speed cutting of aluminum. The main spindle guarantees a bar capacity of up to 45 mm and is supported with extra large precision bearings.  These allow for a wide range of speeds with extremely good running truth. A symmetrical headstock with fitted cooling fins ensures optimum thermostability. 

Tailstock:

On the MAXXTURN 45 with tailstock, the tailstock is set up on the linear roller slide and can be positioned automatically within a range of 510 mm. The rolling centre with MK4 shaft is directly integrated into the tailstock and can be removed using a pressure wedge.

Counter spindle:

On the MAXXTURN 45 S, which is equipped with a counter spindle, the counter spindle headstock is placed on a separate linear roller slide and can be positioned within a range of 510 mm. A stroke-monitored parts ejector, flushed with coolant, ensures safe removal of the finished parts.

Tool holder:

The tool holder consists of a 12-position VDI25 radial turret with single-motor engineering and quick-change system. All 12 stations can accept driven tool holders. A servo motor powers the driven tools and the swivel movement, respectively. The machine operator may adjust the slewing speed at any time, using a feed-override switch. The turret can be used on both spindles and switches with direction logic. This means that it always takes the shortest way when swiveling to the next tool. The tool holders, equipped with the EMCO joggling plate and DIN 5480 coupling, allow easy tool insertion with repeatable accuracy without time-consuming adjustments.

C axis/main spindle (model-specific):

The C axis is part of the machine’s standard equipment. The spindle can be positioned with a resolution of 0.001°. A directly attached no-contact rotary encoder without a belt drive guarantees the precision of the C axis as well as precise contour milling. In addition, the main spindle can be clipped into the right position for drilling and milling operations using a spindle brake.

Y axis (model-specific):

The Y axis is integrated in the standard build of the machine and is positioned at an angle of 90° in relation to the X axis. Extremely short protruding lengths are the basis for solid lathing and drilling operations, as well as for milling without receiving imprecise contours.

Feed drive:

Highly dynamic three-phase drives in all linear axes, with preloaded circulating ball spindles, provide high feed forces and positioning with repeatable accuracy.

Measure system:

Incremental measure systems in the feed motor are integrated in all linear axes. Positioning variation according to VDI3441 in X/Y/Z: 0.0035/0.003/0.004 mm

Clamping unit:

The clamping unit is a hydraulic clamping system with a bar capacity of up to ø 45 mm, including a programmable chuck stroke monitor and direct measure system. Time-consuming adjustments with the tools are thereby substituted by a simple training in Teach-In-Mode.

Lubrication:

The MAXXTURN 45 uses an automatic centralized lubrication system with lubricant-saving impulse lubrication due to its integrated pressure and quantity monitoring.

Coolant device:

A central coolant supply through the VDI interface at the turret and through the tool holder ensures optimal cooling and lubrication during the machining process. An additional coolant pipe has been installed to clean the clamping devices and the work area.

Hydraulic system:

The hydraulic system is a high-pressure compact hydraulic system with a pump and a fine filter in the head pipe, with which the chucking pressure can be more finely adjusted, which is an absolut must for clamping sensitive work-pieces in the main and the counter spindle.  Thanks to its compact construction it only has a small footprint.

Casing:

The casing of the machine is completely closed. Its door is monitored with safety switches to prevent operator injury and features a sizeable viewing window made of laminated safety glass. 

Finished parts pick-up unit (optional):

The pneumatically operated pick-up unit removes finished parts from the main or the counter spindle. The parts are gently transported into a finished parts container outside of the work area. Max. length of finished parts: 120 mm; max. ø 45 mm; Max. weight: 2 kg

Technical Data:

Versions:

· Choice of control: Fanuc or Siemens

· MT 45 MY: Tailstock version with driven tools and Y axis

· MT 45 S: Counter spindle version without driven tools

· MT 45 SM: Counter spindle version with driven tools

· MT 45 SMY: Counter spindle version with driven tools and Y axis

One of the machines highlights is its new compact counter spindle. It is able to take over workpieces position-oriented and with utmost precision for machining the reverse side. This makes a second clamping step unnecessary and avoids wait time, which in turn increases productivity and makes for shorter part delivery periods.

Additional outstanding technical features are for example:

 -       The MAXXTURN 25 can be configured either with tailstock or counter spindle or alternatively with or without Y-axis

-       The turret with hydraulic lock offers space for up to twelve VDI16 tool holders.

-        With a total of 36 switch positions, the number of cutting edges may be increased up to 42.

-        The driven tools and the c-axis are already included in the standard model.

-        Like in all bigger models of the same range, the y-axis of the MAXXTURN 25 is fully integrated in the body of the machine, ensuring maximum stability as well as utmost precision of all parts manufactured.

-        The extremely wide distances between the guides make for stable turning and even offer the user additional possibilities for complete machining.

In the course of modular assembly customers can choose between a SIEMENS control interface (including the popular ShopTurn dialogue interface) or a FANUC control interface (featuring the equally popular Manual-Guide-i interface).

Technical details/Concept of the machine:

Machine base:

The core of the machine is the 60° inclined bed. The extremely rigid and compact cast-iron design provides the basis for this robust and precise lathe. Heavy duty reinforcing ribs provide additional rigidity in zones that are subject to intense stress. All guides are crafted as preloaded cross-roller guideways. They are screwed onto bearing surfaces that have been precisely ground, with additional wedges that brace them against a plane of reference which is also ground. Covers along the guides as well as additional telescope covers made of stainless steel increase operational safety and durability.

Main spindle:

The high driving power of the spindle combined with optimal torque curve ensures economic efficiency in cutting steel, as well as high-speed cutting of aluminum. The main spindle which is pivoted with a sizeable precision bearing allows for a wide range of speeds with extremely good running truth. A nearly symmetrical headstock with a large cooling surface ensures optimal thermostability.

Tailstock:

On the MAXXTURN 25 with tailstock, the tailstock is set up on the linear roller slide and can be positioned automatically within a range of 360 mm. The rolling centre with MK3 shaft is directly integrated into the tailstock and can be removed using a pressure wedge.

Counter spindle:

On the MAXXTURN 25 S, which is equipped with a counter spindle, the counter spindle headstock is placed on a separate linear roller slide and can be positioned within a range of 360 mm. A stroke-monitored parts ejector, flushed with coolant, ensures safe removal of the finished parts.

Tool holder:

The tool holder consists of a 12-position VDI16 disc turret with 36 indexed positions and servo technology. A servo motor powers the driven tools and the swivel movement, respectively. The machine operator may adjust the slewing speed at any time, using a feed-override switch. The turret switches with direction logic. This means that it always takes the shortest way when swiveling to the next tool. Tool holders complying with VDI 69 880 allow easy tool insertion with repeatable accuracy without time-consuming adjustments. 

C axis/main spindle (model-specific):

The C axis is part of the machine’s standard equipment. The spindle can be positioned with a resolution of 0.001°. A directly attached rotary encoder, which is no-contact and without a belt drive ensures the precision of the c-axis as well as precise contour milling. In addition, the main spindle can be clipped into the right position for drilling and milling operations using a spindle brake.

Y axis (model-specific): 

The Y axis is integrated in the standard build of the machine and is positioned at an angle of 45° in relation to the x-axis. Extremely short protruding lengths are the basis for solid lathing and drilling operations as well as for milling without receiving imprecise contours. 

Feed drive:

Highly dynamic three-phase drives in all linear axes with preloaded circulating ball spindles provide high feed forces and positioning with repeatable accuracy. 

Measure system:

Incremental measure systems in the feed motor are integrated in all linear axes. Positioning variation according to VDI3441 in X/Y/Z:  0.0035/0.003/0.004 mm 

Clamping unit:

The clamping unit is a hydraulic clamping system with a bar capacity of up to ø 25 mm including chuck stroke monitor. Either a pull-back or push-back collet chuck may be attached to the main spindle as well as a 3-jaw power-operated lathe chuck. The counter spindle provides space for a pull-back or push-back collet chuck. 

Lubrication:

The MAXXTURN 25 uses an automatic centralized lubrication system with lubricant-saving impulse lubrication due to its integrated pressure and quantity monitoring. 

Coolant device:

A central coolant supply through the VDI interface at the turret and through the tool holder ensures optimal cooling and lubrication during the machining process. An additional coolant pipe is installed to clean the clamping devices and the work area.

Hydraulic system:

The hydraulic system is a high-pressure compact hydraulic system with a pump and a fine filter in the head pipe, with which the chucking pressure can be more finely adjusted, a precondition for clamping sensitive work-pieces in the main and the counter spindle. Thanks to its compact construction it only has a small footprint.

Casing:

The casing of the machine is completely closed. Its door is monitored with safety switches to prevent operator injury and features a sizeable viewing window made of laminated safety glass.  

Finished parts pick-up unit (optional):

The pneumatically operated pick-up unit removes finished parts from the main or the counter spindle. Thus, the parts are gently put into a finished parts container outside the work area. Max. length of finished parts: 120 mm, max. ø 25.5 mm; max. weight: 0.5 kg

Technical core data:

Models:

Selection of controls: Fanuc or Siemens

· MAXXTURN 25 MY: Tailstock version with driven tools and Y axis

· MAXXTURN 25 SM: Counter spindle version with driven tools

· MAXXTURN 25 SMY: Counter spindle version with driven tools and Y axis