Mag’s HyperMach H12000 is all about horizontal five-axis contouring

  • 15-Sep-2009 10:08 EDT

The new models for aluminum machining offer an expanded choice of 30,000-rpm 60-kW or new 100-kW HSK63A motorized spindles, or 20,000-rpm 85-kW HSK100A motorized spindle.

Mag brings the efficiencies of horizontal five-axis contouring (no chip attendant, blow-off, or recutting) to long aerospace parts up to 12 x 2 m with the introduction of the H12000 HyperMach processing cell. The largest of three new models in the HyperMach H-Series—which includes the H6000, H8000, and H12000—the H12000 allows efficient part loading for machining of wing spars, ribs, fuselage frames, and floor components, or nested part groups.

Joining the original HyperMach H4000, the new models for aluminum machining offer an expanded choice of 30,000 rpm 60-kW or new 100-kW HSK63A motorized spindles, or 20,000-rpm 85-kW HSK100A motorized spindle. The powerful high-speed spindles deliver metal-removal rates of 8066.5 cm3/min on aluminum plate or forgings. New GTi titanium models in the H-Series offer a choice of two geared, high-torque HSK100A spindles delivering 850 or 1050 N•m torque at 6000 or 4800 rpm.

All HyperMach H-Series machines feature a full-portal, open-center design, and what Mag considers industry-best horizontal machining productivity. Cutting operations are totally enclosed, with chip fall-through to a high-volume conveyor, avoiding chip recutting and the need for a chip blow-off attendant. Full-portal closed-loop construction maximizes stiffness and ensures consistent cutting performance at any position of the pallet and spindle, while eliminating thermal drift and periodic realignment between column and pallet table.

Scale/encoder feedback on all five axes enables extreme accuracy beyond the capabilities of other horizontal machines currently on the market, according to Mag. The 4-, 6-, and 8-m machine models use a fixed-column, traveling-table/pallet design, while the 12-m model uses a traveling-column, stationary-pallet receiver. All H-Series machines are cell-ready for integration in multiple-machine, pallet-pool systems using Mag CINCRON cell modules.

The HyperMach H-Series uses proven elements from Mag's advanced line of HyperMach vertical profilers, only in different orientation. “The larger range of the new models increases the machining capacity and cost-reduction efficiencies for longer aerospace parts that would normally be processed by vertical machines,” said Mag Aerospace Senior Product Manager Randy Von Moll.

Water-cooled servomotors are used on all five axes to eliminate thermal influence of the motors and maximize performance for high acceleration/deceleration and feed rates. The X-axis table/pallet receiver and the Y and Z axes are capable of speeds up to 50 m/min, while the spindle carrier rotates at 150°/s (25 rpm) in A and C axes powered by direct drive permanent magnet torque motors—no gears, belts, or mechanical drive elements to wear or replace. The H-series comes standard with a 96-tool automatic tool changer (HSK63A), field-expandable to 190-tool capacity.

H-Series machines can be set up for pallet load from the right or left side with chip conveyor discharge configured in either direction, enabling best-fit to shop layout and work flow. A compact design allows a larger machining envelope with a smaller footprint than competitive machines.

A centrally located operator station gives the full view of machining area, automatic tool changer, tool storage, and critical utilities/services cabinet. The operator can check, load, and exchange tools without walking around to the opposite side of the machine. Flat floor installation reduces cost and installation time and avoids pits and multistep foundations, allowing easy reconfiguration of the plant layout. CINCRON Cell Automation Modules allow near-infinite material handling and cell configurations for multimachine, pallet-pool processing and highest production efficiency.

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