High Performance 5-Axis Machining CenterECOSPEED, ECOSPEED FDörries Scharmann

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Products:

Dörries Vertical Turning Machines Vertical Machining Centers

Droop+Rein Portal Machining Centers High Speed Machining Centers

Scharmann Horizontal Machining Centers Boring Mills

Mecof Horizontal and Vertical High Speed Milling Centers

Berthiez Vertical Turning Machines Vertical Grinding Machines

DS Aircraft Machining Centers

Service

Headquarters:

Dörries Scharmann Technologie GmbHHugo-Junkers-Straße 12-32D-41236 Mönchengladbach-RheydtTel. +49/2166/454-0Fax +49/2166/454-300www.ds-technologie.deinformation@ds-technologie.de

Sites, Subsidiaries and Service Centers:

Dörries Scharmann Technologie GmbHProduct line Droop+ReinHofkamp 2, D-33719 BielefeldTel. +49/521/5804-0, Fax +49/521/178006

Dörries Scharmann Technologie Service Center GmbH & Co. KGAm Sülzenbrückener Weg 14, D-99334 IchtershausenTel. +49/36202/77980, Fax +49/36202/779829

Dörries Scharmann Technologie GmbHService Center SouthWannetal 47b, D-88131 LindauTel. +49/2166/454-700, Fax +49/2166/454-701

Dörries Scharmann Technologie GmbHBeijing OfficeRoom 704, Kun Tai Building, No. 10 Chao Wai Da Jie, Chaoyang District, 100020 Beijing, PR ChinaTel. +86/10/65995556, Fax +86/10/65995559

Dörries Scharmann Technologie GmbHMoscow Officeul. Tverskaya 16/2, Building 1, 7. Floor, RUS-125009 MoscowTel. +7/495/737-4981, Fax +7/495/737-6588

DS Technology (USA), Inc.7861 Palace Drive, Cincinnati, OH 45249, USATel. +1/513/247-2590, Fax +1/513/247-2599

DS Technology (UK) Ltd.43/45 Phoenix Park, Avenue Close, Nechells, Birmingham B7 4NU, United KingdomTel. +44/121/3593637, Fax +44/121/3591868

Berthiez SAS5, rue Barrouin, F-42029 St. Etienne Cédex 1Tel. +33/4/77923992, Fax +33/4/77923993 www.berthiez.fr, sales@berthiez.fr

Mecof SrlVia Molino 2, I-15070 Belforte Monferrato, ALTel. +39/0143/8201, Fax +39/0143/823088 www.mecof.it, info@mecof.it

is it your business?

…digital standard?

Wing and body components for c iv i l and mil itary aircraft

2 3

The ultimate goal of the industry is to pro-

duce ever more increasing lighter weight

structural parts with increasing inherent

strength. Previous methods of joining a

number of profiled parts together, has largely

been replaced by machining larger structures

from aluminium billets. Thinner wall sections

and more complex contours in five axis pro-

vide for this possibility to decrease weight

and increase strength.

It is inevitable that as designers make more

use of the modern 3D CAD tools 5 axis

applications will increase.

To achieve this goal the only real solution

can be provided by high speed machining

where the distortion forces of the tool on

the component are largely eliminated.

This in turn means that a much higher accu-

racy and higher surface quality is demanded

not only from the linear axis but also from

the rotary axis.

To meet these demands the machine’s linear

axis, has to provide a highly dynamic extre-

mely stiff construction.

In the case of complex contours and radii

this can not be provided by the conventional

rotary drives of Fork or Swivel heads.

How close can you get to the …

The typical gantry type profiler as designed

in the 1970’s has largely remained unchan-

ged until today. The high mass of the bridge

or cross rail renders it totally unsuitable for

any high speed process.

I f you are using these solutions

then its l ikely you are not very c lose at

al l .

The Fork Head with its open design concept

lacks the stiffness required coupled with

rotational bearings, a relatively long swivel

length and mechanical geometric alignment

makes it unsuitable for real accurate high

speed application.

The Swivel Head with its closed design is a

much more stiff solution and goes some way

in the trend of high speed machining but still

suffers from some of the previously menti-

oned difficulties, it is however, also suited

for the machining of titanium and steel.

20 years and 180 rotary axis type heads shows us that

these head types are not a high speed

solution.

Swivel Head

Typical wing and

body components

from billet or plateFork Head

Required rotational speed of the C-Axis at a 6° angle

radius [mm]feed [m/min]

spee

d C-

Axis

[rp

m]

40

20

0 10080

6040

200

0

100

200

300

400

500

600

700

800

Fork and Swivel Head - Disadvantages:

Positioning velocity, Angular acceleration,

Weight, Stiffness, Accuracy, Swivel length,

Geometric alignment, Complexity, Slip Rings,

Rotary couplings

vertical beam

A new approach……for real

Production gains

5A new generation completely

optimised by FEA

applied force: Fx = 1kN

Deflection ∆x = 18 µm

Stiffness kxx = 55 N/µm

applied force: Fy = 1kN

Deflection ∆y = 20 µm

Stiffness kyy = 50 N/µm

applied force: Fz = 1kN

Deflection ∆z = 1 µm

Stiffness kzz = 250 N/µm

Optimisation of machine column

Task:

– Optimisation of wall thickness

regarding thickness and mass

– Easier assembly

Result:

– Stiffness increased 20 % with

same mass

Static deformation (x-direction)

Applied force: Fx = 10 kN

max. deformation: ∆x = 47.6 µm

Stiffness: Kxx = 210 N/µm

WHY THE NEED

nEfficiency is the most critical and important

driver in manufacturing industry today. As

business becomes evermore competitive and

cost conscious, the factor of efficiency will

become increasingly critical.

nECOSPEED was specifically designed,

exclusively for the purpose of high speed

machining of structural aircraft components

from aluminium alloy plate or billet type

materials.

nECOSPEED was specifically designed to use

conventional well proven machine tool

technology.

nECOSPEED uses components that are mainly

proprietary parts, which can be bought from

suppliers shelves.

nECOSPEED has a machine stiffness that

equals or betters standard machining centre

designs.

nECOSPEED has first class ‘’maintainability’’

features.

nECOSPEED with it’s Z-3 head being

configured through linear axes only, carries

none of the compromises and performance

weaknesses associated with rotary axes.

nECOSPEED is the most efficient machine

tool on the market today for producing alu-

minium aerospace type components.

nECOSPEED makes traditional Profiler almost

obsolete for this type of application. As time

passes, this efficiency and technological gap

will widen. In a few years time, companies

using traditional equipment in this field will

become uncompetitive.

nECOSPEED in terms of cost, represents an

economic solution. Although single unit

prices may be higher than a conventional

Profiler, less machines are required for a

given output. Fewer operating personnel are

also required to run the machines.

nECOSPEED provides previously unknown

surface qualities rendering deburring and

fettling to a minimum requirement.

nECOSPEED offers the production of multiple

parts or part sets from a single billet giving

considerable time savings.

nECOSPEED is capable of increasing its levels

of performance still further in the future, as

motor spindle development provides faster

and more powerful units these will be easily

incorporated into the existing design.

4The KEY - El imination of rotary axis

n Offers possible platform orientations up

to +/- 40° within a Z-stroke up to 370 mm

n Offers angular velocities and accelerations

of the platform of 15 U/min and 685°/s2

nPositioning speed of 80°/sec around the

tool tip is available in every space angle

n Has a low mass, which leads to lower

acceleration forces in X-and Y-directions

n Offers a max. Z-stroke of 670 mm

With the aforementioned in mind Dörries

Scharmann Technologie has developed a

3 axis head concept of extremely stiff design

that takes account of all of the previous

mentioned difficulties to meet the highly

accurate contouring and radii requirements

including the higher surface quality demands,

by eliminating the need for rotary motions.

Continuous motion through standard

elements

proven technology

Comfortable component handling, (horizontal loading,

vertical transfer and machining)

Layout showing rail guided vehicle, pallet

buffer stations and load/unload station

7High Performance 5 axis Machining Center ECOSPEED

6

no risk solution

Complete machine with covers showing

optimised chip evacuation with no traps.

Complete machine without covers

showing gantry axis drives.

Column group with extreme low mass

and highest stiffness incorporating all

drives for every axis.

Headstock with complete freedom of move-

ment without slip rings or rotary couplings.

Automatically exchangeable angle heads

(option).Pallet for component mounting prepared for

automatic vacuum connection (option).

Example layout of

two machine system

Static table group showing pallet

transfer drive, location and clamping

We are designing and manufacturing

customer specific machines and variants of

ECOSPEED.

If you have any additional requests please

contact us.

5 axis machining example

98

ECOSPEED FECOSPEED F was designed for machi-

ning smaller structural Aircraft parts.

Table sizes from 1,500 x 2,500 mm to

2,000 x 3,000 mm offer you a range

below ECOSPEED with the same tech-

nical advantages.

Configuration

n Stationary column, moveable table

group

n Horizontal motor spindle, vertical

component

n 5-axis machining capability by

Sprint Z3-head

n Rotatable load / unload station with

2 pallets horizontal loading – vertical

machining

n Stand alone machine extendable to

FMS

Advantages

n Dramatic productivity increase

n Highest chip removal rate

n Extreme high accuracy

n Highest acceleration / deceleration in

all axis

n Eliminate fettling, polishing, deburing

n Improved chip management (free chip

flow)

n Advantageous price / performance ratio

ECOSPEED F X-axis drives with master

slave concept

Electronically pre-loaded X-axis drive

n Double pinion, electronically

pre-loaded by 2 drives

Advantages

n backlash elimination

n High stiffness

n High positioning accuracy

n Easy maintenance by reduced number

of elements

ECOSPEED F pallet changer

(horizontal loading, vertical machining)

completely independent of machine

eliminating interference to work spindle

when loading components

Oil mist extraction data

capacity 2,400 m3/h

air exchange > 1/min

coolant contents in cleaned air 10 mg/m3

The angular milling head ensures

full 5 sided machining.

High Performance5 axis Machining Center ECOSPEED F

Uni directional moments, rapid traverse

Opposing moments pre-loaded area,

feed mode

Uni directional moments, rapid traverse

comparison

Siemens Sinumerik 840 D

1

75

24,000

50

272

34

10 11Performance analys is

Year of construction

Producer

Spindle power

Spindle speed

Feedrate

Acceleration

* year of Retrofit

FPV 2,500/25

Performance characteristics

1975 - 2000

(5-axis machining)

1987*

Droop + Rein

30

12

8

0.2

1998*

Droop + Rein

40

24

20

1.5

2000

DST

75

24

50

10.0

Control

No. of spindles

Power

Speed

max. Feed

time for 8 components

time for 1 component

Bosch CC

4

33

6,000

10

480

60

Time comparison

vertical beam (see page 2)

(kW)

rpm. * 1,000

m/min.

min.

min.

Technical data ECOSPEED

factsX-axis

Y-axis

Z-axis

Angle orientation

Z-stroke at ± 40°

Pallet size in X-axis

Pallet size in Y-axis

Tool magazine

Coolant

Chip evacuation

Process control

Oil mist extraction unit

CNC Control

Video

Acc./Dec. in X

Acc./Dec. in Y

Acc./Dec. in Z

Rapid traverse in X

Rapid traverse in Y

Rapid traverse in Z

High rotary positioning velocity

High rotary acceleration

Spindles

3,800 - 6,300 mm

2,500 mm

670 mm

± 40°

370 mm

3,500 - 6,000 mm

2,000 mm

38, 57, 93, 129 tools / HSK-A 63/80

Minimum Quantity Lubrication /

Flood and Through Tool Coolant

Hinged belt conveyor

Extraction volume 100,000 cm3/min

Component probing, Tool life

management, Tool length control,

Tool measuring, Tool coding,

Tool balancing / Pre-setting,

Post processor

Basic machine capacity 2,400 m3/h

Siemens SINUMERIK 840 D

Video monitoring inside machine housing

9.81 m/sec2

9.81 m/sec2

9.81 m/sec2

50 m/min

50 m/min

50 m/min

80°/sec

≥ 685°/sec2

(eg. 115 ms to full speed)

80 kW, 46 Nm, 30,000 rpm

120 kW, 83 Nm, 30,000 rpm

and more

3,300 - 15,800 mm

2,500 mm

670 mm

± 40°

370 mm

7,000 * 15,000 mm

1,500 * 2,500 mm

min. 125 tools / HSK-A 63/80

Minimum Quantity Lubrication /

Flood and Through Tool Coolant

Hinged belt conveyor

Extraction volume 100,000 cm3/min

Component probing, Tool life

management, Tool length control,

Tool measuring, Tool coding,

Tool balancing / Pre-setting,

Post processor

Basic machine capacity 2,400 m3/h

Siemens SINUMERIK 840 D

Video monitoring inside machine housing

9.81 m/sec2

9.81 m/sec2

9.81 m/sec2

65 m/min

50 m/min

50 m/min

80°/sec

≥ 685°/sec2

(eg. 115 ms to full speed)

80 kW, 46 Nm, 30,000 rpm

120 kW, 83 Nm, 30,000 rpm

and more

ECOSPEED FECOSPEED

1975

Droop + Rein

20

4

4

0.1

Unit FPA 2,500/24 FPA 3,000/33 ECOSPEED

(kW)

rpm. * 1,000

m/min.

m/s2

Unit Droop + Rein FBV 3,200 ECOSPEED

Performance characteristics 1975 - 2000

(Efficiency)Performance characteristics 1975 - 2000

(Technology Development)

FPV 2,500/251975

FPA 2,500/241987*

FPA1998*

ECOSPEED2000

800

700

600

500

400

300

200

100

0

FPV 2,500/251975

FPA 2,500/241987*

FPA1998*

ECOSPEED2000

80

70

60

50

40

30

20

10

0

Spindle Power (kW)Spindle Speed (rpm.*1,000)Feedrate (m/min)Acceleration (m/s2)

Material removal rate (dm3/h)Part production time (h), based on five different EUROFIGHTER parts

X-axis

Y-axis

Z-axis

A/B-axis

up to 3,000 mm

above 3,000 mm up to 8,000 mm

above 8,000 mm

2,500 mm

670 mm

+/- 40°

Positional accuracy according

VDI/DGQ 3441

Axis Working Area

10 µm

+ 1.5 µm/1,000 mm

+ 2.0 µm/1,000 mm

10 µm

8 µm

10 arc. sec.

P

5 µm

+ 0.5 µm/1,000 mm

+ 1.0 µm/1,000 mm

5 µm

4 µm

5 arc. sec.

Ps