Modular Machining Center handles complex workpieces.
December 23, 2008 -
Featuring 800 x 800 mm pallet clamping surface with max workpiece weight of 2,000 kg, 5-axis Model STC 800 provides X,Y,Z axis travels of 1,650 x 1,200 x 1,300 mm. Rapid traverse rates are 60 m/min for X, Y, and Z; 12 rpm in A-axis; and 60 rpm in B-axis. Dynamic drives with digital control and regulating system feature 3-phase servo motors; pretensioned, ground, and backlash-free ball screws; and absolute optical measuring systems on all 5 axes.
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Original Press release
StarragHeckert Inc.,
Skyport Business Park
Hebron, KY, 41048
USA
New 5-Axis STC 800 Tackles Challenges with Precision & Power
With the introduction of the STC 800, StarragHeckert once again lives up to its reputation as technology leader in the field of 5-axis machining technology. It was our aim to develop a modular machining center, which can be flexibly configured to meet the different requirements of new production concepts.
The machine offers maximum stability and performance while also featuring a very compact design. These are crucial requirements to produce highly complex pieces in aluminum, steel, titanium and other difficult-to-machine materials.
With uncompromising technology, the STC 800 takes on a variety of challenging machining solutions - especially in the fields of aircraft and engine construction, steam and gas turbine construction as well as production engineering and mechanical engineering.
When completely machining today's impellers and blisks made of difficult-to- machine materials, precision and high flexibility are essential. By virtue of decades of experience in the 5-axis machining of flow surfaces we have the necessary expertise to support you in every respect.
The STC 800 is perfectly suited for the machining of complex workpieces, because the machining is done simultaneously in five axes and at any required angle. The machine allows the use of vertical milling heads, overlong tools and bridge-mounted tools with large diameters. Rotating axes and tilt heads work very precisely and deliver economical machining from five sides in one or several setups.
If operations in the high-tech sector want to be successful today, they need to provide a high amount of flexibility. Production cycles are growing shorter and an ever-increasing amount of component variants has to be produced. This is where the STC 800 offers particular advantages as it was specially designed to accommodate the continuously changing demands of production technology. Thanks to its modular machine concept, it is able to meet all technical requirements very flexibly.
The STC 800 has an extremely rigid frame structure which has been calculated and optimized by using FEA (finite element analysis). This is one of the reasons why it has excellent static and dynamic characteristics and offers outstanding process stability. Even under extreme cutting conditions, such as when machining difficult-to-machine materials, the drive power can be exploited to the full. The stable, low vibration machining guarantees long tool life which directly results in increased productivity and profitability.
A wide selection of high-performance spindles for diferent speed ranges, torques and powers is available. This allows the use of the very latest tools. Non-productive times can be reduced thanks to fast rapid traverse rates, and the modularly expandable tool and workpiece handling has been thoroughly tested in the automotive industry.
To minimize downtime, StarragHeckert has developed the graphic-aided diagnostic system SAM. The Software allows users to locate the root causes of errors almost instantly and diagnostic messages help to eliminate these errors.
Axis drives and guides. Highly dynamic drives with digital control and regulating system features high feed forces for heavy-duty cutting, low-maintenance three-phase servo motors, pretensioned, ground and backlash-free ball screws and absolute optical measuring systems on all five axes. Further, drives and guides are outside the range of operation. Large dimensioned, stiff, precision linear guides with recirculating roller packs complement pretensioned guide carriages that guarantee high machining quality and long-term accuracy.
Table. Pallet clamping surface is 800 x 800 mm with a maximum workpiece weight of 2,000 kg. X-axis travel is 1,650 mm, Y-axis travel, 1,200 mm and Z-axis, 1,300 mm. Swing diameter is 1,400 mm. Travel is endless on the CNC rotary table B-axis. The B-axis is the fourth simultaneous axis and handles pallet interface with clamping cones and features concentric, water-cooled direct drive, high driving torque and fast table rotation. The A-axis milling spindle is the fifth simultaneously controlled CNC axis. The A-axis features a travel of -100°/+ 60°, stable roller bearings on both sides, high positioning accuracy through direct optical distance measuring and low-wear worm drive. High driving torque, hydraulic axis clamping and heavy-duty cutting are also performance features.
Rapid traverse rates are 60 m/min (X, Y, and Z), 12 rpm in the A-axis and 60 rpm in the B-axis.
Motor spindles. Concentrically mounted, water-cooled high-performance synchronous /asynchronous motors (motor spindle 1: 60 kW, 81.6 hp, 15,000 rpm; motor spindle 2: 70 kW, 93.9 hp 24,000 rpm) feature oil-air lubrication directly through the outer ring (direct lubrication system), variable hydraulic bearing pretensioning, vector control with constant torque up to corner speed, thereafter constant power. An internal coolant supply is standard and sensors for bearing temperature, thermal spindle growth with compensation and in-process vibration monitoring.
Gear-driven spindles. Drive is via two-step gearbox and achieves a maximum of 8,000 rpm from a 37 kW, 49.6 hp motor and torque of 940 Nm. Large dimensioned precision hybrid bearings, oil-air lubrication and internal coolant supply are standard.
Tool handling. There are a variety of tool management approaches: a chain magazine with 60 and 80 pockets, a tower magazine with up to 240 tools for ISO 50 and HSK-100 tapers and a chain line magazine with up to 240 tools for HSK-A63. Magazine loading takes place without interruption of the machining process. Fast tool change is made possible by a twin arm tool changer. Options include tool breakage detection via laser within the working area and tool coding.
Chip removal. Safe and quick chip removal through a wide chip conveyor in traverse bed. The STC 800 offers integrated washing system with workpiece/pallet shower and is highly suitable for wet and dry machining.
Coolant supply. Vacuum fleece band filters or alternatively a low-maintenance backflush turbo filter and internal cooling, programmable in 10 bar steps to 70 bar. Coolant temperature regulation is optional.
Workpiece handling. Rotating load/unload pallet station featuring 4 x 90° indexing and optional hydraulic or vacuum coupling device with a maximum of 6 connections. Quick pallet change via lift-rotate system.
Control and system capability. State-of-the-art process control and monitoring via Sinumeric CNC 840 D with integrated PLC provides contour fidelity during high-speed machining through look-ahead feature and dynamic preselection. Drive parameter adjustment depending on machining complexity and material, etc., and graphical diagnostic system "SAM", remote service and control cabinet with air conditioning unit.
System extension and system capability. Future configurations of the STC 800 include expansion to a machining cell with linear or circular pallet pool; linking of several machines with single or multi-story linear pool, including all system control software.
StarragHeckert provides individually adapted solutions for specific production requirements. Our experienced team of technical experts will help you to set new production milestones. Ranging from the calculation of the production time, the choice of the optimal tool to complete programming and production of pilot runs in our Center of Production Excellence. We will support you in every respect to ensure a trouble-free start of production.
Of course, we are also ready to prove and document the capabilities of the STC 800 by trial machining. Productivity, precision, flexibility and reliability are more than just catchwords for StarragHeckert.
We only judge new technological solutions by the benefits they bring you as their user in practice, and this over the course of many years. Therefore, we do not rely solely on revolution but rather on well-targeted evolution when we develop new solutions.
For more information, contact StarragHeckert Inc., Skyport Business Park, 2379 Progress Drive, Hebron, KY 41048 USA. (859)534-5201 (v), (859) 534-5212 (f), ussales@starragheckert.com
STC 800, a dynamic 5-axis machining center offers a new dimension in flexibility and capability, working some of the most difficult materials - aluminum, titanium and nickel-based alloys.
StarragHeckert AG
StarragHeckert has confirmed its position as market leader in the machine tool market with its machining centers. They combine successful, tried and tested features with the latest findings and innovative ideas. They are fully equipped to further increase the metal cutting capacity and reduce non-productive downtime.
StarragHeckert globally provides a comprehensive range of technologically advanced precision milling machines, as well as productivity enhancing software and engineering solutions, engineering and process optimization projects and a wide range of special tools for customers in the aerospace, energy, transport and precision machine industry. The company brings to bear a nearly 150 year old heritage of technological innovation to help its customers to be more productive, efficient, precise and innovative. StarragHeckert includes production plants in Rorschacherberg, Switzerland (Starrag); Chemnitz, Germany (Heckert); Geneva, Switzerland (SIP) and Haddenham, UK (TTL), as well as sales and service companies in China (Beijing and Shanghai); USA (Hebron, KY, Dallas TX and Laguna Hills, CA); France, the UK and Russia.
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