5-axis simultaneous milling shows great promise for the machining of sculptured surfaces and provides numerous benefits in terms of dimensional and shape accuracy and economic efficiency. Even today, practical utilisation of these high-tech machines is often thwarted by programming issues. Therefore HELLER has been performing highly complex 5-axis machining trials on sample workpieces in close co-operation with renowned CAD/CAM providers using new milling strategies, simulation and other optimisation tools. Highly complex operations usually imply time consuming programming in the CAM system. Although high functionality CAM systems are available, for instance, for peripheral milling or face milling of sculptured surfaces, the machines’ potential is often not fully utilised. Numerous CAD/CAM providers now offer an extensive range of automatic functions enabling faster programming.
This revolutionary development in the area of 5-axis milling takes account of the specific kinematics involved. Ingersoll will be presenting a high-feed cutter from the SP2L series to complement the SN2R and SM2R series with extremely soft cutting geometry. The launch of these new products also underlines what HELLER’s FT 4000 is all about: combining outstanding surface finish with highest cutting capacity. Instead of seeking to achieve theoretical or nonrecurring record values, the company aims to offer realistic and practice-oriented dynamic values, designed to guarantee longevity, high precision and availability. For decades, HELLER machines have been characterised by these qualities. Accordingly, the axis drives used for the F series have been amply dimensioned and the 5th axis provided by the tool forms the basis for achieving the necessary process reliability and high workpiece loads.
Universal, flexible and precise – what more could you want?
Combined, the new CAD/CAM systems, optimum tooling and the state-of-the-art 5-axis machining centre FT 4000 provide easy programming and excellent results at high process stability. With a workpiece load of up to 1,400kg and its spacious work area (800mm working range in X and Y axis and 1,000mm in Z direction), the FT 4000 has been practically tailored to the needs of tool and die manufacturing. Particularly since the universality and flexibility of the spindle technology are cutting edge. The Speed Cutting Universal SCU 63 swivel head with 40 kW and the Speed Cutting Tilt SCT 63 fork head, also with 40kW, are available for speed cutting. The Power Cutting Universal PCU 63 swivel head with 44kW and 242Nm is the most powerful 5-axis spindle with HSK 63 currently available on the market and an excellent choice for heavy-duty cutting applications. In terms of control, users also have the freedom of choice: whether they opt for Siemens Sinumerik 840Dsl or Heidenhain iTNC530, both types deliver all the performance they could wish for.