GENERAL INFORMATION

Horizontal lathes, HL series, are designed to machine high complexity workpiece made of cast iron, steel or non­ferrous metals. Main machining operations are:

– internal and external turning

– front surface turning ­ drilling and boring (radial and axial),

– milling ­

– external grinding (using additional equipment).

Standard features

–  Set of tools for assembling operation
–  Set of levelling blocks for the bed
–  Accessories for:
•   milling
•   drilling or tapping the small hole or small screw (M4 to M20)
•   hydrostatic rolling
•   slotting
•   grinding

Special Accessories(optional at extra price)

•   Open C type steady with rollers and interchangeable pads.
•   Closed steady rests
•   All kinds of tool holders for VDI 3425 turret
•   External Grinding Device
•   Internal turning/boring bars.
•   Plate for headstock – SCA
•   Plate for tailstock – SCA
•   Universal bottom support for steady rest – 2 pcs.
•   Sword type tool holder with Capto C6 or according to the turret.
•   Chip conveyor.

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ASSEMBLIES

Such a horizontal lathe is composed of the following sub-assemblies:

• Bed assembly
• Headstock
• Tailstock
• Machining Unit
• Measurement system
• Electric equipment
• Lubrication units
• Hydraulic unit
• Coolant unit
• Telescopic covers
• Cable carriers
• Special accessories

MACHINE STRUCTURE

Structurally, such machines comprise a bed along which the carriage with the machining unit is sliding, between the headstock (located at one end of the bed) and the tailstock that slides along the bed, towards the end opposite to the headstock. The steady rests supporting the work piece slide along the bed guideways too.

–  Z axis: the carriage longitudinal motion along the bed guideways
–  X axis: the machining unit motion on the carriage guideways
–  Y axis: the machining unit motion in vertical plane
–  C axis: the headstock spindle rotation at low rpm rates for milling operations.

The bed assembly is a cast iron construction. The tailstock group is sliding along the bed back side guideways and the carriage/machining unit assembly slides along the bed front side guideways as well as on an additional way. This extra way is in fact a stiff construction located in front of the machine main bed, properly attached to the foundation. The guideways are coated with hardened (58HRC) steel plates, bolted and bond to the main structure.

All guideways are grinded.
–  Number of guiding ways: 3 (the guiding way at middle has 2 guiding sides)
–  Number of guiding ways for carriage: 2.
–  Number of guiding ways for steady rests and tailstock: 2

The headstock has an extremely rigid and robust cast iron and heat treaded structure. Inside it there are: the spindle, faceplate clamping system, rotary measuring systems for the main movement (spindle rotation).

The spindle is made of high quality forged steel, hardened and ground.

The spindle is borne on the front side by a big two-row cylindrical roller bearing, mounted on taper seats to enable their adjustment: these high precision roller bearings ensure a great efficiency and high accuracy of the machining at high speed. The rear bearing consists of a preloaded roller bearing, which is overtaking the radial loads and part of the thrust. The axial shaft is borne on a preloaded bearing.

On the spindle a faceplate with four independent jaws is mounted.

The spindle rotation consists of two modes:
–  For turning and grinding the cinematic linkage consists of main motor, double ZF gearbox and timing belt transmission.
–  For milling, the C-axis consists of a feed motor and direct belt transmission

The carriage consists of a longitudinal saddle sliding along the bed guideways as well as on the additional way. The guideway system is designed such as to pass through the headstock and reach the correct position with both sides of the milling turning/column. The saddle main guideway is coated with antifriction material and provided with roller packs.

The driving system of the saddle consists of a servo-motor, SPG gearboxes and a rack-pinion backlash-take mechanism, hydraulically preloaded. Along the guideways of the longitudinal saddle the cross slide is travelling. The cross slide guideways are coated with antifriction material and provided with roller packs. Its feed motion is performed by a servomotor, a ZF gearbox and a ball screw. On one side of the saddle, turning bars can be mounted for internal turning.

The milling unit consists of the housing fitted with the spindle system and its drive system. The complete milling unit has two fixed positions on the saddle.Spindle main rotation is provided by a ZF gearbox and a timing belt transmission.
The milling unit centre can receive the following attachments: vertical milling head, universal milling head, with manual or (on special request) automatic (hydraulic) indexing.

Instead of this machining unit, a 12 position turret may be mounted. This will be fixed on the cross slide by means of a rotating indexed column that has a vertical slide which can move up and down.

The tailstock group has an extremely rigid and robust structure, of modern design. It includes:
–  the shaft, fitted with a big rotary bushing for the stock: a roller bearing of high load, overtaking the radial fore loads;
–  a roller bearing with ellipse – shaped rolls that overtakes the radial and axial loads at the rear end of the bushing; an ulterior two rows ball bearing overtakes the axial load;
–  binding on stock;
–  automatic locking/unlocking of the tail stock group on the bed guideways;
–  an elastic device, including a set of disk springs that is incorporated to the tailstock shaft and automatically overtakes the elongation of the workpiece during machining;
–  measurement system for the axial loads;
–  motorization of the entire tailstock group by means of an electrical independent motor;

The spindle of tailstock can receive different faceplates on its live centre.

The guiding way system of the Z, X and Y axes consists of hardened and ground guideways, automatically lubricated.

Each axis, except for the tailstock, has its own Heidenhain linear or rotary measuring system.

The lubrication of shaft bearings inside the headstock and tailstock is performed by the continuous lubrication units mounted on each subassembly. Its components are REXROTH and HYDAC made.

The guideways are intermittently lubricated with oil. The lubrication is controlled by the CNC system. The lubrication unit is Willy VOGEL. Milling Spindle bearings are lubricated with life lasting grease, as well as the ball screws bearings.

Through the cable carriers, of closed type, the power and control cables are drawn between the electrical cabinets placed on the ground and the electric equipment on the machine. The hydraulic ducts of the coolant unit and the lubrication ducts are also drawn through carriers. All cable carriers are available for additional cables with approximately 20% space.

The hydraulic unit is fitted with Rexroth, Atos, Vickers, and/or Parker components, as per the customer’s request.

It provides the following functions:
–  Spindle clamping
–  Tailstock un-clamping
–  Indexing – Un-indexing bolt on the Tailstock
–  Swivelling Slide clamping

The electric installation is made up of:
• Electric cabinet placed on the floor;
• Electric installation on the machine;
• Choice of CNC equipment: SIEMENS 840D ,Fanuc 31imB
• Choice of Motors and PLC : Siemens/Fanuc made
• Conventional apparatus (contactors, circuit breakers, fuses) Siemens/GE made
• Control panel and electronic hand-wheel
• Measuring scales for the travels of the movable elements – HEIDENHAIN made
• The electric equipment ensures the functioning, diagnosis of the machine, monitoring functions, part programming and the interfacing of the operator with the machine.
• The execution of the electric cabinets, connection boxes and wiring on the machine are according to the related international standards;
• The motors for spindle driving and feed driving are AC type with stepless adjustable speed (SIEMENS/Fanuc made);
• The electric equipment on the machine includes general purpose AC motors, electric wiring on the machine, connection boxes, actuators and control elements, encoders.
• The electric cabinets include general purpose apparatus, AC drives and the decentralized peripherals of the CNC equipment. The connecting cables between machine and cabinets are protected in metallic hoses, cable carriers and channels.
• Machines are CE marked

Three-phase AC: 380±10V%, 50±1 Hz;
Single-phase AC: 220±10V%, 50±1 Hz.

The machine is designed according to ISO230/1.
Geometric accuracy is according to ISO1708
Positioning deviation is according to VDI 3441, ISO230/2
–  reference travel for X and Z axes: = 1000 mm
–  positioning uncertainty: P= µm
–  average positioning dispersions: P = µm
–  average reversal error: U = 15 µm
–  positioning error P = 8 µm
–  the positioning precision at Z direction whole travel P =0.05mm, repeat positioning precision PS=0.01 mm
–  the positioning precision at X direction whole travel P=0.01mm, repeat positioning precision PS=0.008mm

The orientation accuracy of C axis is ±5″.

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