www.alzmetall.com Machining CenterGS 600

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ALZMETALL - COMPANY INTRODUCTION

is a company with an international reputation and global activities. For more than six decades we have been the leader in technology for drilling, milling and casting.

ALZMETALL products have proven themselves in general machining applications, in the automotive industry, in mould and die business, at the aircraft industry, as well as in many mid-size mechanical engineering enterprises. Our experience is based on over 200.000 machines supplied.

We focus on precision, performance and Quality for all our products. With our own foundry we do not only produce gray cast iron and spheroidal grey cast iron for our own machines, but also are supplier to the machine tool manufacturers and customers worldwide.

Our open company culture encourages innovation and performance by a continuous innovation towards High Tech and customer benefit for added value. Developing the GS-series, we offer highly dynamic and extremely rigid machining centers according to our pretensions: „we drive productivity“.

How to find us

Premises

Airport München“Franz Josef Strauß”

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Highlights

• ALZMETALL-Gantry-Concept (AGK)• Grey Cast Iron and Spheroidal Graphite Cast Iron• Monobloc Travel-System-Carriage with incorporat-

ed Box-in-Box-System • 4-fold Linear Guidance for Travel-System-Carriage

and Z-Axis with integrated Motor-Spindle• 3-fold Torque-Drives for Swivel-Axis (A-Axis) and

Rotary-Axis (C-Axis) at GS 600/5-T und GS 600/5-FDT

• Hybrid-Machining-Applications such as: Drilling/Mill-ing/Turning and Grinding at one Clamping-Set-Up

• Up to 750 kg workpiece weight including Clamping-Set-Up-Device at GS 600E/3 (Static Table)

• Up to 500 kg workpiece weight including Clamping-Set-Up-Device at 5-Axis Machines

Focus on operators needs

• Access to Machine-Table ergonomically configured at working height

• Workpiece loading by front, side and from top access. Crane loading possible

• Mist extraction directly at Machine-Table• Steeply sloping chip tunnel straight below

Machine-Table

User benefits

Streamlined Force-Circuit between workpiece and Cutting-Tool in addition to geometrical and symmet-rical configuration of the Carriage-Travel-System.

 Performing• Thermal consistency at Tool Center Point (TCP)

at X-Y- level without additional Axis compensa-tion

• Significant reduction of Cutting-Tool costs  Optimum• Contour consistency at highest path velocity• Lifetime of Motor-Spindle

 Guaranteed• High-grade Parallel-Path-Precision through two

Servo-Drives at each X- and Y-Axis• Considerably reduced Total Cost of Ownership

(TCO) over lifetime period of Machining Center

Machining Center with options: chip conveyor, cooling unit and coolant filter. These options are either to be installed along the right - or left side of the Machining Center.

AT A GLANCE

5-Axis Machining Center GS 600/5-T

• Working-Space flushing with coolant (option)• Automatic Access-Door feature open/close (option)• Access to all maintenance units at working height

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FEM generated Structural Model - Point of force-input at TCP and simultaneously at Machine-Table

ALZMETALL - THE CONCEPT

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FEM generated Structural Model - Point of force-input at TCP and simultaneously at Machine-Table

Multi-Elements-Simulation

During the development process the Finite-Elements-Meth-od was already applied by building the structure of the machine, patterned from the 3D-Volume–Model born from CAD to simulate vibration characteristics. Thus enabling engineers to determine the optimal dynamic rigidity of the machine under terms and conditions of the daily use at the shop floor.

Development

The „Finite-Elements-Method“ was applied to obtain the desired static and dynamic characteristics of each individ-ual part of the machine and to investigate the collective rigidity of the Machining Center.

Modal-Analysis

Results gained by the Multi-Elements-Simulation of entire machine structure and design had to be confirmed at the prototype of the GS-Machining Center by using the Mod-al-Analysis. The experimental Modal-Analysis procedure is being used to realize and demonstrate the quality of the dy-namic machine characteristics under production conditions.

The final test of the Modal-Analysis accomplished at ALZMETALL verified the high degree of performance of the dynamic requirements in reality. Thus the ALZMETALL GS-Series offers comparable Best-in-Class conditions for high dynamic machining applications.

RESEARCH AND DEVELOPMENT

Development by using Finite-Elements-Method (FEM)

X

YZ

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BASIC DESIGN

Rigidity, Dynamic and Thermal Symmetry „that‘s it what counts“

Extreme rigid, Integral-Basic-Body prepared for:• Frame Side Walls as carrier for both Y-Axis (Y- and V-Axis) • NC – Swivel- and Rotary-Table (A- and C- Axis) or Static-Table• Disc-Tool-Magazine for 40 Tool Positions, alternative twin Disc-Tool-Magazine for [76] Tool-Positions.

Rack-Type Tool-Magazine for [224] Tool Positions [Option].

All statically stressed Basic-Machine-Parts made from EN-GJL 300 (GG 30) and all dynamically stressed Basic-Machine-Parts and components made from EN-GJS 600 (GGG 60).

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• Y- and V-Axis Frame Side Walls as static basic structure. On top mounted Travel-System-Carriage with integrated Z-Axis Monobloc

• Dynamically stressed Basic-Machine-Parts and components made from EN-GJS 600 (GGG60)

• Both Linear-Axis X and Y 4-fold guided, Z-Axis 8-fold guided

TRAVEL - SYSTEM - CARRIAGE

Z-Axis sliding tube

Travel-System-Carriage

Monobloc

Ballscrew 2-fold, Y-Axis

Linear Guidance SystemsLinear-Encoder

Ballscrew

Servo-Drive Z-Axis

Servodrive X-Axis

2-fold Servodrives Y-Axis

4-fold Linear Guidance Systems

• Linear-Axis Y driven by two Ballscrews and two Servo-Drives. X- and Z-Axis each driven by one Ballscrew and one Servo-Drive.

 Excellent Axis dynamics  Cutting edge Parallel-Path-Precision  Thermal stability due to geometrical symmetry with Thermo-Symmetric Motor-Spindle

Design Characteristics

Box-in-Box-System:

Y

Z

X

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TRAVEL - SYSTEM - CARRIAGE

• Small lever arms through Z-Axis Monobloc design

 Increase of stiffness and thus gain of Stability of overall framework

ÂMaximized cutting capacity

• Thermo-Symmetric• Narrow and direct Force-Circuit

 Thermal stability  High grade stability and stiffness with coexistent weight-optimized Axes-Elements

Force Transmission - Symetry

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NC - SWIVEL - AND - ROTARY - TABLE (SDK)

Torque-Motor sectional viewTorque-Motor

Torque-Motor

Swivel- (A-Axis) and Rotary- (C-Axis) Unit GS 600E/5

Rotary-Table DIA. 320 mm (Standard)

Rotary-Table 400 x 400 mm [Option]

Servo-Drive with gear

Counter-Bearing with clamping

Highly self-locking Gear-Motor

GS 600/5 -T and GS 600/5 -FDT

• Direct Rotary Drives (Torque-Motors) for high dynamic and oscillating machining – maintenance free –

• Two internal Torque-Motors at each Frame side wall as NC-Swivel-Axis (A-Axis) – patented-

• NC-Rotary-Table (C-Axis) equipped with Torque-Motor

 Highest swivel and rotational speed  Higher accuracies – no mechanical backlash  Elimination of friction at Drive-Components ÂWear – and maintenance free delivers reduced Total Cost of Ownership (TCO) over lifetime period of Machining Center

• A-Axes Servo-Drive with DC coupled preloaded gear. Counter-Bearing with hydraulic clamping

• C-Axes Compact-Unit with Servo-Drive and integrated gear

 High grade torsion stiffness  Fast rotary motion of gear through capacious gear transmission at short positional movements of the Axes

 No single-edged wear

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A-AxisC-A

xis

min

. 150

/m

ax. 5

50 m

m

100

mm

500

mm

350

mm

ø 800

mm

ø 640 mm

Machining Space

• Maximum utilization of Machining Space• C-Axis DIA. 640 mm• A-Axis DIA. 800 mm • Swivel range ± 140°• Table Load max. 500 kg• Stainless steel Machining Space cover [Option]

WORKPIECE DIMENSIONS - MACHINING SPACE

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 All components at one cabinet  At ground level ergonomic access  Easy to maintain  Integrated cooling unit for Motor-Spindle at GS 600E

SUPPLY - MAINTENANCE - SERVICING

Switchboard cabinet Pneumatic-System

Lubrication

Hydraulic-SystemCooling unit for Motor-Spindle

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OPTIONS

Table-Set 1) 2)

Clamping surface mm 555 x 320T-slots acc. DIN 650 5 x 14 H12Configuration parallel in X-directionDistance mm 63Table Load max. kg 500Notice Rotary-Table ø 320 mm

Rotary-Table C-Axis 1) 2)

Clamping surface mm 400 x 400T-slots acc. DIN 650 5 x 14 H12Configuration parallelRPM max. 100 1) 1200 2)

Table Load max. kg 500Distance T-slots mm 63

Rotary-Table C-Axis with NPS 1) 2) 3)

Clamping surface mm 400 x 400T-slots withoutConfiguration NPS 4 x 90 °RPM max. 100 1) 1200 2)

Table Load max. kg 500

Clamping surface mm 600 x 630T-slots acc. DIN 650 9 x 14 H12Configuration parallel in X-directionDistance T-slots mm 63Table Load max. kg 750

1) GS 600/5-T2) GS 600/5-FDT

3) NPS = Nullpunkt Spannsys-tem

Further executions on demand

GS 600E/3 3-Axis-Machine with Static Table

400 mm400 mm

400 mm

200 mm

200 mm

400 mm

630 mm

600 mm

Static Table

ø 320 mm

555 mm

320 mm

NC - Swivel - (A-Axis) and Rotary-Tables (C-Axis)

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400 mm

400 mm

CNC-Contr o ls

Heidenhain TNC 640 (standard) Heidenhain iTNC 530 HSCI

KINEMATIK Gauging

Accuracy check and compensation - KinematicsOpt., Heidenhain - C 996, Siemens

3D-Touch Probes

Infrared transmission

- TS 640, Heidenhain- TS 740, Heidenhain - IRP 25.41, m&h Inprocess- OMP 60, Renishaw- TC 50, Blum

CNC-Contr o ls

Siemens SINUMERIK 840 D sl

Electrical Handwheels

- HR 510, Heidenhain- HR 520, Heidenhain- Mini-Handwheel, Siemens

Multiple-Media-Couplingfor Rotary-Table

4-fold on selection air and/or fluids

OPTIONS

320 mm

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Tool-Magazines

Twin-Disc-Tool Magazine for 76 Tool PositionsTool-Magazines

Rack-Type Magazines with 224 Tool positions

Production Package

On selection A, B, C with Scratch-Type-Convey-or, Hinge-Type-Conveyor, Magnetic-Conveyor

Production Package

Coolant Cleaning Unit with Metal-Edge-Filter or Compact-Paper-Filter

Camera and Screen

Camera mounted at Machining Space with trans-mission to external flat screen or Video-Server for process-set-ups and process-controls

OPTIONS

Tool Setting System

Laser System for Tool Setting and Breakage Detection on selection including mechanical Touch Trigger Probes LTS 35.65, m&h, (without mech. Touch Trigger Probes) LC NT, Blum, (without mech. Touch Trigger Probes) TC 76, Blum, (with mech. Touch Trigger Probes)

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Services

Machining Center Installation, Set-Up, Production Assistance and Maintenance

Mist Extraction Unit

Attached to Machine-Basic-Body

OPTIONS

[ ] Options

• Rotary-Table (C-Axis) various configurations• Mutiple-Media-Coupling for Rotary-Table (C-Axis)• Motor-Spindles RPM-Range 30.000 RPM/42.000 RPM• Disc-Tool Magazine up to 76 Tool Positions• Tool Magazine Rack-Type up to 224 Tool Positions• Chip Conveyor: Scratch-Type-, Hinge-Type-,

Magnetic-Conveyar 1) • High pressure Coolant Units up to 150 bar 1) • Electrical Handwheels• 3D-Touch Probes• Automatic Workpiece-Changing-System• Tool Setting and Detection Systems• Workpiece-Pallet-Changing-System• Robot-Systems• Custom-Made Solutions• Services

1) Optional placement along the right- or left side of the Machining Center

Services NC-Program-Training, Operator-Training for Heiden-hain and Siemens

Machining Center Acceptance Workpiece according to ALZMETALL-Standard, on selection Customer-Workpiece (option)

Remote Diagnosis, Remote Maintenance

and for NC-Programming-Support

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Type GS 600E/3 GS 600E/5 GS 600/5-T GS 600/5-FDT

Working RangeTraverse Path 460 / 600 / 400 mmStatic TableDistance Spindle - Static-Table min./max. 100/500 mmClamping Surface (w x d) 600/630 mm9 T-Slots acc. DIN 650 at X-Direction 14H12 x 63 mmMachine-Table Load 750 kgNC-Swivel-and Rotary-TableDistance Spindle - Table min/max. 150/550 mm

Drives at Swivel- and Rotary-Axis conventional indirect Torque direct

Swivel Range of A-Axis ± 140 ° ± 140 °Swivel Speed at A-Axis 30 min-1 90 min-1

C-Axis Rotation 360 ° endlessC-Axis RPM max. 50 min-1 100 min-1 2700 min-1

Diameter Machine-Table C-Axis Ø 320 mm Ø 320, [400 x 400] mmT-Slots acc. DIN 650 14H12Star-Shaped Configuration 4 x 90 ° 4 x 90 ° [ 5 x parallel|, Distance 63 mm]Machine-Table Center Bore Ø 50 H7 mmTable Load max. 500 kgC-Axis Rotary-Diameter at A-Axis Center Ø 640 mmA-Axis Swivel Diameter (Swing) at X-Axis Center Ø 800 mm

Distance A-Axis-Center to Rotary-Table 100 mmFeed-Drive-System X-, Y-, Z-AxisDigital AC-Servo-Motors, maintenance freeMax. Rapid Travel X-, Y-, Z-Axis at TCP 30 [60] m/min 60 m/minFeeding Force X-, Y-, Z-Axis at CDF 40% 4 - 4 - 5 kNMotor-Spindle-DriveHigh Frequency Motor-Spindle Cutting-Tool Interface HSK-A63 HSK-T63Motor-Spindle-Power at CDF 25% 26 [16] [44] [17] kW 13 [24] kWVariable Speed Range max. 18.000 [10.000] [30.000] [42.000] min-1 10.000 [18.000] min-1

Motor-Spindle Torque at CDF 25% 116 Nm [102] [40] [11] Nm 80 [92] NmTool-Magazines Tool positions, Type 40 Disc, [76 Twin-Disc] [224 Rack-Type]Max. Tool Diameter, Chain fully loaded 80 mmMax. Tool Diameter, Chain neighbour posi-tions unloaded 130 mm

Max. Tool Length 300 mm [150 at upper Disc]Max. Tool Weight 4 kg [10 kg at Rack-Type]Tool-Change-Cycle (approx.) 2 sChip-to-Chip Cycle 4,5 sLinear Encoders X-, Y-, Z-Axis indirekt absolut, directPositional Tolerance TP acc. DIN/ISO 230-2 (VDI/DGQ 3441) ≤ 0,007 mm

Angle Encoder System A-, and C-Axis direktMachine Weight excl. Options 6800 kg

CNC-Controls Heidenhain TNC 640, [Heidenhain iTNC 530 HSCI], [Siemens 840 D sl]

Heidenhain TNC 640 [Siemens 840 D sl]

[Option]

TECHNICAL DATA

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TECHNICAL DATA MOTOR - SPINDLES RPM - Power - Table

16P S6/25%

Md S6/25%

1.500 10.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

14

11

70

90102

Md

(Nm

)

P (k

W)

GS 600E/3, GS 600E/5, GS 600/5-T

[RPM max. = 10.000 min -1] Option

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24

P S6/25%

P S6/25%

Md S6/25%

Md S6/25%

2.100

2.500

18.000 n (min -1)

18.000 n (min -1)

P S6/40%

P S6/40%

Md S6/40%

Md S6/40%

P S1

P S1

Md S1

Md S1

22

22

17

17

70

65

100

84

116

92

Md

(Nm

)

Md

(Nm

)

P (k

W)

P (k

W)

GS 600E/3, GS 600E/5, GS 600/5-T

GS 600/5-FDT

RPMmax. = 18.000 min -1 (Standard)

[RPMmax. = 18.000 min -1 Hirth-Gear-Indexing for turning Operation] Option

13P S6/25%

Md S6/25%

1.500 10.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

11,59

7

7383

Md

(Nm

)

P (k

W)

GS 600/5-FDT

RPM max. = 10.000 min -1

Hirth-Gear-Indexing for turning Operation (Standard)

17P S6/25%

Md S6/25%

15.000 42.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

13

10

6,4

8,311

Md

(Nm

)

P (k

W)

GS 600E/3, GS 600E/5, GS 600/5-T

[RPM max. = 42.000 min -1] Option

44P S6/25%

Md S6/25%

7.200 30.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

40

30

28

3640

Md

(Nm

)

P (k

W)

GS 600E/3, GS 600E/5, GS 600/5-T

[RPM max. = 30.000 min -1 ] Option

18

appr

ox. 2

.300

mm

max

. 2.8

00 m

m

incl. Options A) und B) approx. 3.250 mm

Coolant Unit

Inductor Unit

approx. 1.900 mm

appr

ox. 3

.150

mm

incl

. Opt

ions

E) ,

appr

ox. 4

.010

mm

appr

ox. 6

00 m

m

R 1.150

approx. 1.350 mm

A)B)

E)

F)

C)D)

GS 600

MACHINING CENTER DIMENSIONS

Machining Center (Single Unit) - Transport Dimensions) GS 600

• Width approx. 1.900 mm• Depth approx. 3.750 [4210] mm• Height approx. 2.370 mm

Options

A) Chip ConveyorB) Chip TrolleyC) High pressure Coolant UnitD) Coolant cleaning systemE) Rack-Type Tool-MagazineF) Mist Extraction Unit

Please observe: Options A, B, C, D and E are either to be installed along the right- or left side of the Machining Center!The cooling unit and the inductor unit are variable placeable!

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MACHINING CENTER DIMENSIONS

Machining Center (Single Unit) - Transport Dimensions) GS 600

• Width approx. 1.900 mm• Depth approx. 3.750 [4210] mm• Height approx. 2.370 mm

AUTOMATION SOLUTIONS

PowerCell Robot-Loading-System and Zero Point Tooling System with 24 workpiece-pallets

Robot-Loading-System for workpiece-pallets with external Rack-Type-System

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ALZMETALL Werkzeugmaschinenfabrik und Gießerei Friedrich GmbH & Co. KGPostfach/P.O. Box 1169D-83350 Altenmarkt/Alz · GermanyHarald-Friedrich-Straße 2-8D-83352 Altenmarkt/Alz · Germany Tel./Phone +49 86 21 88-0Fax +49 86 21 88-213E-Mail: info@alzmetall.comInternet: www.alzmetall.com

Also contact us for further Machining Centers of the CS-Series, Drilling Machines-Series and Custom made Cast-Iron-Products.

• GS 800/3• GS 800/5-T• GS 800/5-FDT

• GS 1000/3• GS 1000/5• GS 1000/5-T

• GS 1000/5-FDT• GX 1000/5-AF• GX 1000/5-LOB

• GS 1400/3• GS 1400/5-T• GS 1400/5-FDT• GX 1400/5-AF

• CS 600• CS 1200• CS 1200 P

PRODUCT RANGE - PLEASE CONTACT US

Machining Centers

Machining Centers Machining Centers

Machining Centers

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