GENERAL INFORMATION

Floor Type Boring and Milling Machines with horizontal spindle are intended for machining prismatic parts made of cast iron or steel and dimensions and weights within the machine processing capacity.

Such machines are also suitable for machining deep areas located inside the parts due to the cumulated ram (W axis) and boring spindle (Z axis) travels.

The operations available with these machines are: boring, milling, drilling, threading or tapping, flat or taper turning (with attached facing head), both in roughing and finishing modes.
The various special accessories available with such machines increase their machining capacity and productivity.

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Standard features

•  3D design for custom made machine tools;
•  Quality cast iron parts to avoid vibrations;
•  Hardened and ground ways, box or steel inserts;
•  Counter ways with anti friction material;
•  Ballscrews on all linear axis;
•  SKF, FAG high precision bearings;
•  Choice of Fanuc, Siemens, Heidenhain controls;
•  Heidenhain linear and rotary scales;
•  Automatic tool clamping;
•  Automatic lubrication system;
•  Coolant trough spindle;
•  Choice of hydraulic elements;
•  Fanuc, Siemens AC servomotors;
•  Fanuc, Siemens, Heidenhain PLC and electrics;
•  Motorized spindle with ZF gearbox and AC motors;
•  Telescopic cover for X, W axis of the heavy machine tools.

Optional features

•  Automatic tool changer 40/60 positions;
•  Facing head;
•  Vertical milling head;
•  Universal head;
•  Spindle bearing support;
•  Angle fixtures;
•  Chip conveyer;
•  2-axis CNC head;
•  CNC facing head.

Automatic Tool Changer

The mechanical arm is designed to clamp ISO 50 tools and the distance between two tool axes. The axial and spin movement of hand is provided by double action hydraulic cylinders.

Mechanical arm travels along on the rolling way, which is fixed on the column, and performs the change and carrying of tools between the tools-magazine and the machine spindle.

Mechanical arm consist of a levers mechanism for gripping the tools, an arm taking off and inserting the tools in the spindle taper or in the tool station in the magazine. The unit is completed with a 180° swiveling mechanism of the arm body supporting the tool grippers.

The 180° swiveling is performed by means of a pinion-rack mechanism, hydraulically driven by a hydraulic linear motor. The axial motion in and out is achieved by means of a linear hydraulic cylinder, placed inside the mechanical arm body.

On the upper and lower sides of the mechanical arm housing, there are attached the rolls to provide the movement along the rolling guide ways. Rolls are fixed by means of brackets supporting a free swiveling fork, so that the triangle profile roll follows the guide way track. The motion of the mechanical arm on the rolling – way, between the magazine and the machine spindle, is achieved by means of a rotating hydraulic motor. A chain and pinion mechanism moves the arm along its guide way.

All movements are hydraulic, by means of linear and rotary motors, and confirmed by inductive proximity switches, mechanically limited. The tool magazine is chain type, fastened on the column by a rigid welded structure support. It is positioned in vertical plane in the backside of the column. The chain is actuated by a variable speed feed motor through a planetary gear reducer (i=1:10) and a duplex worm reducer. The wormed gear is fastened to the chain gear.

Tools magazine is designed for the tools and tool holders stocking (50/60 – tools/tool holders) and to prepare the necessary tool for the next operation, thus shortening the operating time of the machine – tool.

Tool magazine consists of a links chain and of 50/60 tool holder supports. Tool holder supports are provided with a tool clamping system with balls and springs, a ranking number and an indexing system for placing the tool. Near the driving wheel, two proximity switches are provided to count tools in the magazine – A third proximity switch is placed on the tools-magazine support and is meant to show “O” position.

MACHINE STRUCTURE

Structurally, such a machine is designed with longitudinal moving column (X axis) and on the right side of the column (looking from the work piece side) and the headstock moving on the vertical direction (Y axis).

Inside the headstock the ram (Z axis) is moving in cross direction. Inside the ram the milling spindle is supported, having inside its bore the boring spindle that moves as W axis.

The main cinematic linkage consists of a gear box with two mechanical steps, connected to the spindle by a timing belt transmission. The gear box is driven by a stepless adjustable speed motor. The feed mechanisms are driven by stepless adjustable speed motors.

Each of the 4 moving axes of the machine and 2 axes of the rotary table has independent feed mechanisms and limit switches for travel limitation. The rotary motion coming from the feed boxes is transformed into translation motion by means of a preloaded ball screw-nut mechanism. The machine is endowed with auxiliary cinematic linkages that provide the locking of the movable assemblies as well as the tool clamping/unclamping.

The motion measurement of the movable assemblies is performed through linear scales and rotary encoders compatible with the electrical equipment. The machine controls are centralized on a control panel that may be of pendant or swiveling type. The machine is available for accommodating several special accessories that increase its machining capacity and productivity. The bed guide ways are protected by telescopic covers.

The bed is made of high quality cast iron and has a heavily ribbed structure. Its top surface features three guide ways for the column longitudinal motion (X axis). These guide ways are coated with hardened and ground steel plates (55 HRC and Ra=0.4). The bed is fixed to the foundation by means of leveling blocks and special foundation bolts. Oil collecting ducts are fixed to the bed, for collecting the hydrostatic lifting oil.

The column saddle is a cast iron component sustaining the column and headstock assemblies as well as other equipment and mechanisms. The column saddle moves along the bed hydrostatic guideways. The leading guide way is located in the front of the machine. The saddle contains the hydraulic installation ensuring the X axis hydrostatic lifting, the bearing and lubrication of the X axis feed reducer. To the saddle there are fixed the guide ways covers, the X axis cable carrier, the encoder of the X axis measurement system etc.

The column saddle feed motion is generated by an A.C. stepless servomotor and a planetary reducer /gearbox. The bed guide ways are protected with telescopic covers distributed on both sides of the column saddle.

The feed movements on all axes are driven by gears transmission via planetary speed reducers by servo motors with step less variation of the speed. The rotary motion coming from the feed box is transformed into translation motion by means of a preloaded ball screw-nut mechanism.

The double wall, ribbed cast iron column supports the headstock that travels along its two vertical guide ways (Y axis). The column guideways are provided with hardened and ground steel plate inserts. A counterweight, to balance the headstock, is guided inside the column.

The headstock is a heavily ribbed cast iron structure designed to withstand the extensive forces generated by the main motor. The headstock houses the spindle assembly and slides along the vertical guide ways of the column. The headstock guide ways are lined with anti-friction material. The spindle is driven by an A.C. stepless spindle motor through a precision ZF gear box, electrically shifted and a timing belt transmission that connects the ZF output shaft directly to the spindle.

The sleeve-type spindle assembly is composed of the milling spindle and boring spindle. Its bearings feature high precision angular grease lubricated ball bearings: four in the front and two in the rear. Cooling is achieved by a closed circuit oil refrigerating system inside the outer spindle sleeve.

The boring spindle is guided inside the milling spindle by nitrated bushings. The ISO 50 taper allows automatic clamping and unclamping by the mechanical-hydraulic system inside the boring spindle. Both its outer surface and the ISO 50 taper are nitrated. The rear side bearing consists of four radial-axial ball bearings, mounted within the special cast iron bearing of the ram. This one is actuated by the ball screw nut which creates the Z-axis feed motion.

Ram droop compensation is achieved through mechanical-hydraulic compensation. The main shaft is provided with internal coolant system of 20bar work pressure and 60 lpm flow.

The tool clamping/unclamping is located inside the boring spindle and the back bearing body. Tool clamping is mechanically performed by a disk springs package. Tool unclamping is achieved hydraulically.

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