Automation, connectivity, combined machine power

At EMO 2021, Stand D09 in Hall 4, WFL Millturn Technologies presents the new M20 MILLTURN complete machining center for the first time. Alongside gear skiving technology, there is clear trend toward automation and the integration of sensors. The latest solutions from WFL range from smart software to screw programming through to intelligent tools and clamping devices.

The aim when developing the M20 was to introduce a particularly robust machine with the highest possible long-term accuracy. The machine frame is made from spheroidal graphite iron, ensuring optimal stability plus outstanding damping properties. This also means heavy roughing cuts can be made without compromise.

The continuous toughened-glass front features an integrated performance data display and a touch panel for conveniently operating the tool magazine from the front of the machine. The working area is perfectly illuminated thanks to ultra-efficient and bright LED lights. A clearly visible LED strip at the bottom of the sliding door displays the machine status.

The M20 is available with a tailstock or counter spindle and features dynamic and powerful drives. The turning-boring-milling unit with integrated spindle motor and a B-axis with torque motor are entirely new features. The turning output of up to 44kW means even hard-to-machine materials can be handled with ease. The milling spindle with up to 25kW and 20,000rpm is ideally equipped for all machining tasks. There’s the option of using HSK 63 or Capto C6 tool systems.

The individual tool holder with B-axis on the lower slide is a highlight. The upper and lower system can be used simultaneously, and both systems are supplied by a reliable and dynamic tool changer from a shared magazine. This allows even complex components to be machined with optimal efficiency.

The tool can be moved up to 100mm below the turning center, so drill patterns with diameters of up to 200mm can be produced on the face with a high level of precision and without turning the C-axis.

Another key benefit of the machine is easily integrating a wide range of automation options, including articulated robots, gantry loaders, or an integrated production cell with the associated peripheral equipment. The newly integrated production cell intCELL is fitted on the right-hand side of the machine. The workpieces are supplied on a strip accumulator.

Furthermore, it’s also possible to automatically switch the tool to the lower individual tool holder with B-axis. With the integrated loading concept, WFL has reduced the space requirement by 50% in comparison to a conventional production cell.

The M20’s integrated loading feature is designed for chuck parts with a diameter of up to 300mm and a workpiece weight of 15kg. For shaft parts, a workpiece diameter of 100mm and a workpiece length of 300mm is possible.

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The new M50-G MILLTURN generation, with greater axis distance and improved performance, is another highlight of the trade fair. The optional center distance of 6,000mm enables efficient machining of long shaft parts. The machine’s existing potential is fully utilized in increased drive power, combined with the HSK-A100 or Capto C8 tool accommodation. The turning diameter is available up to 670mm. A separate pick-up magazine is also available for very long and/or heavy tools. Workpieces with a length of 1,600mm can be automatically inserted and changed. The standard disc magazine can be expanded to up to 200 positions.

The ICOtronic tool, which is fitted with sensors, provides information on the machining process as close as possible to the cutting edge.

The automatically loading ultrasound measuring probe enables a fully automated measuring process. The large measuring range (1.5mm to 30mm) offers further benefits. Ultrasound measuring is extremely well suited for calculating the hole run-out and diameter of very deep holes.

The new operational data acquisition system myWFL Cockpit displays machine and program states according to chronological order, productivity, and technical availability. You can view this on a web browser via the control system, either on a PC or a mobile device. This means that the user can always be well-informed about their machine productivity.

myWFL Cockpit integrates energy usage measurement via myWFL Energy which displays the current power and energy consumption data and that of each workpiece.

Another highlight of myWFL is the integrated Condition Monitoring cycle. When the cycle is running, the friction values of the axes and spindles, as well as the temperature in the milling spindle housing and the vibration or the rolling bearing condition value of the front milling spindle bearing are continuously recorded and stored on the control system. Using Condition Monitoring Viewer, it is possible to select the data of the various Condition Monitoring runs on the control system, graphically overlay them and analyze them according to time. This allows for the early detection of possible malfunctions and minimizes unplanned downtimes.