The F series: 5th axis in the tool for high-performance 5-sided and simultaneous 5-axis machining
5-axis machining on the F series
Machine concept
Only the perfect combination of strength and lightweight creates a machine design that guarantees the best surface quality and a long tool service life. As with all HELLER machines, the main components of our F-series 5 -axis machining centres were also computed by means of the FEM method. The result is a machine bed optimised for stiffness and a weight-reduced column – that's how we guarantee a high dynamic with perfect precision.
Cross-bed and travelling column in gated design
- high stability and damping in the flow of forces through topology-optimised structural components from cast iron
- thermo-symmetrical design and optimized flow of forces
- broad range of machining units in a robust design
- tool changer with two NC-axes for fast automatic tool change
- large range of tool magazines, chain or rack-type
- machines with integrated pallet changer (FP) and high payload for fast automatic pallet change
- machine variant with table loading (FT) available for selected sizes
5-axis kinematics with horizontal basic alignment and a 5th axis in the tool
- machine bed carries the X- and the Z-axis in a cross bed arrangement
- the machine column traverses in the X-direction and carries the machining unit
- machining unit traverses in the Y-direction, compactly integrated into the machine column in a stable manner
- rotary table traverses in the Z-direction and executes the feed movement
- NC rotary indexing table (B rotary axis) turns the workpiece continuously (360.000 x 0.001°)
- swivel head (C) or tilting head (A) – the 5th axis is in the tool (max. C 345.000 x 0.001°/ A 175.000 x 0.001°) (swivel range with optional swivel range expansion)
Roller bearing-mounted linear guides and stable YRT bearings in the rotary axes
- linear axes driven by roll guides with ball screws for high feed forces
- direct, absolute measuring systems (glass scales in linear axes) for optimised precision and low position tolerance
- rotary tables with large YRT bearings and automatic clamping for maximum stability and high tilting moments
- NC Rotary axis B executed as an NC-rotary feed table with gear drive for high circular milling torque and damping
Spindle units
Optimised process stability in 5-axis machining is also a question of the right spindle. The F-series 5-axis machining centres offer a choice of swivel heads and tilting heads. No matter whether heavy-duty machining of cast iron or steel or high-volume machining of light alloys – the F-series offers the ideal solution for your requirements.
Broad range of powerful 5-axis machining units
- machining units with two kinematic variants for the 5th axis in the tool: Swivel head or tilting head
- HSK-A 100 tool shank for maximum productivity and stability
- rigid cast iron guide slide with high dynamic stiffness and damping
- thermal stability and precision thanks to permanent cooling: Precision cooling unit and thermal growth compensation for the spindle
- automatic clamping of the 5th axis during machining with positioned rotary axes
Swivel head kinematics
- maximum performance in action thanks to stable swivel head kinematics
- compact design through 45° swivel head geometry
- high rigidity thanks to short distance between swivel head mounting and tool holding fixture
- swivel range between C +15° to C-190° (optionally expandable with swivel range expansion)
- energy and media routing integrated: no lines in the work area
Tilting head kinematics
- maximum flexibility with complex workpiece geometries
- simple programming and operation thanks to simple head geometry
- A-axis driven by two swivel motors and a braced power train
- swivel range between A +30° to A-120° (optionally expandable with swivel range expansion)
- energy and media routing integrated: no lines in the work area
4 powerful machining units
- torques of up to 1,146 Nm (S6 40 %)
- speeds of up to 12,500 rpm
- tool shank SK 50 / BT 50 available as alternative for machining unit PCU (PowerCuttingUniversal) and PCT (PowerCuttingTilt)
HELLER zero-spindle system for quick and easy spindle exchange
- spindle exchange without complex adjustments
- reduces the repair time
- cost-effective service solution
HELLER attachment head support (MSK)
- for use with adapter heads, e.g. angular heads
- enlarged location base with three-point location
- integrated torque absorption and media transfer
Swivel range extension
- swivel head from 205° to 345°
- tilting head from 150° to 175°
* not available for all machining units
Tool management
Especially in 5-axis machining, you work daily with a broad range of tools and large tool geometries. No problem for our F-series 5-axis machining centres: You can of course continue to be flexible in the use of your tool pool, and rely on short tool setting times, short downtimes and short idle times.
Chain-type tool magazine for fast tool provisioning
- 3 chain-type magazines with up to 150 pockets to choose from
- rigid tool holder mounted on both sides of a double chain for high chain traversing dynamic
- tool setting station with optimum accessibility for ergonomic and fast tool setting
- integrated tool provisioning station for provisioning of the follow-on tool during machining and short tool-to-tool times
- tool shank in closed holders: protects against contamination and optimum hold during positioning
- tool provisioning during machining for short tool-to-tool times
Options
- convenient operating panel at workpiece loading station
- setting during machining
- tool coding with RFID chip
- tool shank cleaning, incl. cartridge flushing and drying
- HELLER TRP (Tool Requirement Planning) for automatic creation of loading and unloading lists
- tool break monitoring during machining
Rack-type tool magazine with high storage capacity
- 2 rack-type magazines with up to 425 pockets to choose from
- tool handling with highly dynamic loader for fast tool provisioning
- tool setting station with integrated rotary station with multiple tool pockets for setting during machining
- convenient operating panel at workpiece loading station
Options
- automatic rotary station
- tool coding with RFID chip
- tool shank cleaning with brush and flushing option
- HELLER TRP (Tool Requirement Planning) for automatic creation of loading and unloading lists
- tool break monitoring during machining
Fast tool change for short chip-to-chip times
- two NC-axes with lifting/swivelling principle for a high dynamic and continuous precision
- stable double gripper for secure hold with high tool weights and tool moments of weight
Workpiece management
You can of course configure the F-series 5-axis machining centre to suit your particular requirements: As a workshop machine with large work area, ideally suited for single part production or as a production machine with pallet changer and the corresponding automation solution for series production.
Pallet changers are optimal for series production
- automatic pallet changer with lifting/swivelling principle (FP 16000 with sliding/swivel principle)
- high maximum payload through robust, hydraulic drive
- optimised force application to machine pallets due to the fork shape of the lifting/swivelling traverse
- continuously high changeover accuracy through robust aligning elements and extensive blow-out of the function surfaces
- hydraulic pallet clamping for secure hold, even with high process forces
- HF machine pallets with DIN hole pattern and standardised aligning elements for fast mounting of clamping fixtures
Setting and loading during machining
- manual or automated loading by robot or pallet
- large smooth-running door to optimise access for loading and setting by crane or handling systems
- workpiece setting station, lockable at 90° indexing with foot unlocking mechanism, unrestricted manual rotation
- operating elements, as well as media guns within reach, integrated into the machine enclosure
Options
- integrated media interface for hydraulic workpiece clamping (60 / 200 bar)
- additional pneumatic functions: location check and unclamping check via media interface
- active operator support through automatic functions: automatic setting station door, automatically rotating NC setting station, automatic setting and de-setting sequence
- machine pallets in DIN T-slot design
Table loading for workshop use
- workpiece loaded directly onto the machine table in the work area
- optimum accessibility to the workpiece thanks to integrated platform and low "loading edge"
- large, divided work area door opens wide to the work area for simple setting and crane loading of large components
- round machine table with large clamping surface and DIN hole pattern
- main operating unit designed as a console with 24" multi-touch screen, can be swivelled between operating station and workpiece setting station
- media guns integrated into the machine enclosure
NC rotary indexing table as standard
- rotary tables with gear drive for high circular milling torques and damping (FP/FT 16000 with direct drive)
- large YRT bearing for maximum stability and high tilting moments
- automatic hydraulic rotary table clamping for high tangential torques
- compact design for optimum effect in the flow of forces and absorption of cutting forces
Options
- integrated media interface for hydraulic workpiece clamping (60 / 200 bar)
- additional pneumatic functions: Location check and unclamping check via media interface
- automatic setting station door
Automation
Automation solutions from HELLER are individual concepts that we develop specifically for your production facility. We analyse your requirement and devise a solution that allows you to work to your maximum capacity. We use standardised solutions wherever possible. The F-series 5-axis machining centres are prepared for pallet and workpiece automation.
Storage of machine pallets and automated setting of one or multiple machines
- standardised linear storage systems with up to 15 storage locations depending on type and size (optional)
- standardised machine interface available for numerous machine sizes (option)
- everything from a single source: complete solution for short installation time and commissioning
- optimal capacity utilisation with continuous pallet feed to one or multiple machines
- consequently, increased cost efficiency and more flexibility in the production facility
- specific advantages for production tasks with a large part mix and series production with small batch sizes
Options
- standardised host computer interface for optimal connection to the host computer
- high number of functions and options for automated production control
- media interface for hydraulic workpiece clamping
Automatic loading and unloading of workpieces
- workpiece handling by robot relieves the operator
- ideal solution for series production
- machining centre works to capacity thanks to continuous material feed
- standardised machine interface for robot loading onto the setting station (option)
Options
- media interface for hydraulic workpiece clamping
- location check and unclamp check
Supply and disposal
Our F-series 5-axis machining centres offer extremely fast and effective chip disposal. The work area of these machining centres is designed such that chips are prevented from accumulating and are quickly transported out of the machine. Individually matched to your operating process, you select the best conveyor and coolant methods to suit you. Precision and process guaranteed!
Central media supply area at the rear of the machine
- simple maintenance with optimum accessibility, all supply units at a glance
- compressed air and flushing gun integrated into the machine enclosure at the workpiece setting station
- centralised oil/air lubrication for the key components
- sealed air and selective blow-out of interfaces for permanently smooth machine operation
- media interface for hydraulic workpiece clamping at 60 bar or 200 bar (option)
Effective cooling lubricant supply and filtering
- coolant units: paper band filter or vacuum rotation filter with high tank volume optionally available
- internal coolant supply (IKZ) through the tool at high pressure 50 bar (option: 70 bar)
- internal coolant supply with up to 7 pressure stages freely programmable via the NC program
- external tool cooling with flushing nozzles integrated into the spindle
- integrated work area flushing with adjustable nozzles for optimal work area flushing and workpiece cooling
Options
- coolant cooler or coolant temperature control for high thermal stability and precision
- automatic filling of the coolant unit
- oil skimmer for removing foreign oil from the cooling lubricant tank by oil separation
Fast chip removal from the work area
- chip disposal using spiral conveyors and a cross-conveyor
- chip conveyor as either scraper conveyor or hinged conveyor, depending on the application (option)
- steep side walls and bellow covers with self-cleaning effect prevent chip deposits
- work area flushing and work area shower support fast chip disposal for machines with coolant units
- optional: exhaust unit for exhausting cutting fluid mist from the work area
Operation and maintenance
When you work with HELLER F-series machines, just how much machine construction has gone into these 5-axis machining centres will be tangible. No matter whether on the workpiece setting station, during tool loading, programming or maintenance – your comfort and safety and, above all, the productivity of your manufacturing facility is paramount at all times.
Optimal accessibility to all work areas for simple operation and maintenance
- operating comfort and ergonomic design increase productivity
- spatial separation between operating and maintenance areas
- robust operating elements for tough everyday production conditions
- smooth-running doors and easily removal metal enclosure elements
Maximum operating comfort during setting and production
- ergonomically arranged operating elements and control screens
- swivelling main operating unit with clamping function optimally integrated into the machine enclosure
- good view into the work area thanks to large safety screen
- smooth-running work area door with linear guide opens the work area roof in the operating area
- operating modes 2 and 3 included in standard scope of supply
Options
- handheld operating unit
- screen blow-off device for a clear view when machining with cutting fluid
- main operating unit in console design with 24" multi-touch screen and HELLER Operation Interface
Setting and loading during machining thanks to the pallet changer
- large smooth-running door to optimise access for loading and setting by crane or handling systems
- workpiece setting station, lockable at 90° indexing with foot unlocking mechanism, unrestricted manual rotation
- operating elements, as well as media guns within reach, integrated into the machine enclosure
Options
- automatically actuated setting station door
- automatically rotating NC setting station
- software options: Automatic setting and de-setting sequence
Optimal accessibility for fast tool setting
- ergonomically arranged operating elements
- insertion location at optimum height and with integrated unclamping function for simple handling
- tool setting at the magazine when spindle is running
Options
- convenient operating panel at workpiece loading station
- setting during machining
- tool coding with RFID chip
- HELLER TRP (Tool Requirement Planning) for automatic creation of loading and unloading lists
Central supply area at the rear of the machine
- simple maintenance: All supply units at a glance with good accessibility
- smooth-running doors and easily removal metal enclosure elements
- simple and direct access to the control cabinet
- quick-response HELLER spare part service
Options
- maintenance manager for maintenance planning and operator support on the machine itself
- HELLER TPS (Total Productive Services) – Service Agreements for inspection, service and maintenance measures
Control
Speed is always of the essence during the daily working routine. The Siemens SINUMERIK 840D sl, a state-of-the-art high-performance controller with HELLER Operation Interface, makes your work easy through efficient support: with intuitive operation, simple programming, cycle support and all important information at a glance.
Siemens SINUMERIK 840D sl
- high-performance control for machining centres that have to meet the highest requirements when it comes to performance and machining precision
- digital drive technology and state-of-the-art system architecture
- SINUMERIK Operate user interface for efficient machine operation
- HELLER Operation Interface for more comfortable operation (as standard for machines with table loading, optional for machines with pallet changer)
- optimally integrated and adapted specifically to the requirements of HELLER machining centres with the MDynamics 5-axis technology package
- standard for machines with table loading (optionally available with pallet changer)
- main operating unit designed as a console for optimum operating comfort on machines with Siemens control systems
- 24" screen and multi-touch function, optimum for displaying documents and drawings
- HELLER Operation Interface with 4 function areas for extra information at a glance
- practical Xtends HELLER expansions and additional functions
- machine control panel with pushbuttons and 3 overrides for optimum control in all operating situations
- handheld operating unit
- convenient operating panel at workpiece loading station
- HELLER Remote Diagnostic Services (RDS)
- pallet management system for multiple setups
- alternative strategy
- order management
- automatic setting and de-setting sequence
Technical data
| Product selection | FP 10000 | FP 14000 | FP 16000 | FT 16000 | ||
|
Positioning range
X/Y/Z | mm | 1,600/1,400/1,600 | 2,400/1,600/1,600 | 2,400/1,600/1,600 | 2,400/1,600/1,600 | |
|
Rapid traverse speed
X/Y/Z | m/min | 45 | 41/45/45 | 41/45/45 | 41/45/45 | |
|
Acceleration
X/Y/Z | m/s² | 4/4(3)2)/4 | 3 | 3/3/2 | 3/3/2 | |
|
Positioning tolerance Tp / At1) X/Y/Z | VDI/DGQ 3441 / ISO 230 | mm | 0.008 | 0.008 | 0.008 | 0.008 | |
|
Tool shank
SK/BT for selected units available as alternative | Size | HSK-A 100 | HSK-A 100 | HSK-A 100 | HSK-A 100 | |
|
Chip-to-chip time
t₂,₃ | VDI 2852 | s | 7.1 | 8.5 | 8.5 | 8.5 | |
|
Clamping surface
Nominal size | mm | 1,000 x 1,000 | 1,000 x 1,000 | 1,250 x 1,600 | Ø 1,300 | |
|
Workpiece dimension
Diameter x height | mm | Ø 1,400 x 1,600 | Ø 1,400 x 1,800 | Ø 2,000 x 1,725 | Ø 2,500 x 1,725 | |
| Clamping load | kg | 4,000 | 4,000 | 8,000 | 8,000 | |
|
Machine control
Siemens SINUMERIK 840D sl | Siemens | Siemens | Siemens | Siemens |
( ) = optional values
- = not available
1) = position uncertainty
2) = in conjunction with tilting head
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