5-axis machining center for highest precision and performance

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For the highest precision and performance in the manufacturing of small to medium batch sizes, Heller has expanded the latest generation of the F series. At AMB 2024, the company is presenting the new F 5000 size of the high-performance 5-axis machining centers (BAZ).

In fall 2023, Heller launched the F 6000, the first 5-axis machining center of its new, modularly designed F-series (X/Y/Z: 1000 × 1000 × 1400 mm). About six months later, another model, the F 5000, is available with a working area of 800 × 850 × 1100 mm (X/Y/Z) and a reduced footprint. The pallet size of 630 × 630 mm and a maximum payload of 2000 kg for the F 5000 match those of the F 6000, as do the travel speeds and other performance data. This is because both new F-machines utilize key components such as spindles, heads, and tables from the same modular system.

Among the highlights of the new generation of five-axis machining centers, optimized for maximum flexibility and precision, are the fundamentally revised swivel heads and the motor spindles integrated within them, developed and built by Heller. These spindles are standardly equipped with an HSK-A 100 interface and can now optionally be equipped with an HSK-A 63 interface. The dynamic swivel head, with its fifth axis, ensures maximum performance in machining. Its drive impresses with precision based on a backlash-free drive concept. Additional useful features include an integrated work light and a remaining travel distance display, which are part of the Setup Assist function.

Heller provides various spindles depending on the requirements: The Speed Cutting Unit (SCU) achieves speeds of 15,000 rpm in conjunction with the HSK-A 100 tool shank. Alternatively, Heller offers the Dynamic Cutting Unit (DCU) designed for universal use, which provides 400 Nm and 12,000 rpm. When combined with HSK-A 63, these achieve speeds of up to 18,000 rpm. For heavy-duty machining, the Power Cutting Unit (PCU) is also available, featuring a geared spindle and 1146 Nm of torque at 8000 rpm.

Another core element of the F series is the revised drive concept of the linear axes, featuring two ball screw drives in the Z-axis and a significantly reinforced X-axis. Dr.-Ing. Manuel Gerst, Head of Development at Heller Group, explains: "We offer increased dynamics in the linear axes for both the F 5000 and F 6000. At the same time, we have further reduced position tolerances in the Pro package. The new standard is now at 5 microns. Similarly, the tolerances of the rotary axes B and C have also been reduced and are now standard at 7 arcseconds. Overall, this allows us to achieve new benchmarks in terms of accuracy and machining time on the workpiece."

The machines of the new F series from Heller are also distinguished in terms of operability. For instance, the easy access to the work area and the LED light integrated in the head simplify the operation of the machine. The new setup assistant actively supports the operator in setting up machining processes and prevents collisions between machine components and tools.

The standard use of the new generation of Siemens Sinumerik One controls, combined with the comfortable main operating unit in a console design with a 24-inch large touch screen, also provides an optimal workspace. Of course, the user can directly and effortlessly transfer existing NC programs from the Heller F and C machines with Sinumerik 840D sl.

To increase process reliability, Heller developers ensured free chip fall under the spindle and effective chip disposal. Steep stainless steel covers and a wide chip conveyor contribute to this.

With the new machine setup—and specifically through the direct rear chip disposal system—the footprint of the F series has become significantly smaller. The width is now approximately 3700 mm. Despite a high tool capacity, both machines remain particularly compact in combination with the new Heller tool rack systems. These systems are—regardless of their storage capacity—almost two meters slimmer than previously available variants. This advantage is particularly beneficial in the automation of multiple machining centers, as space where three machines previously fit can now accommodate four machines in a row.

The different expansion stages vary only in length. The racks designed for HSK-A-100 tools with storage capacities of 200, 260, and 340 tools are no longer than 7000 mm. For HSK-A-63 tools, there are 489 storage slots available.

The compact size is crucially determined by the space-saving tool arrangement, which allows for high packing density. Thanks to the integrated preferred position module, the times for tool provisioning in practical use are significantly reduced.

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The preferred placement module also offers space for tools up to 800 mm in length with selected sizes in combination with HSK-A 100. Simple manual loading of the tools is achieved using an integrated rotary lock. This allows up to seven HSK-A-100 or nine HSK-A-63 tools to be set up during the main operation time. Additionally, Heller has designed the racks with optimal ergonomics in mind, ensuring that they can always be loaded using a crane.

Particularly for industries such as aerospace, the additional expansion of the spindle range is likely to be of interest. In addition to the proven variant with an HSK-A-100 interface, the F 5000 and F 6000 can now also be equipped with motor spindles that feature an HSK-A-63 interface. High speeds up to 18,000 rpm combined with short ramp-up times make them ideal for applications in light metal machining—such as for complexly designed, integral components for airplanes, machines, or vehicles.

Later this year, there will also be an expansion in terms of kinematics. As an alternative to swivel kinematics, tilt kinematics will also be available starting in the fall. In this context, the range of work units will be expanded by four new fork head variants. Following the modular concept, Heller continues to rely on in-house developed motor spindle variants. These offer torque up to 400 Nm in combination with HSK-A 100, and in the variants with HSK-A 63, focus on speed up to 18,000 rpm.

Compared to swivel heads, fork heads offer a significant increase in flexibility for five-axis machining. For instance, the tilt kinematics allow the execution of undercuts and back cuts. Development director Manuel Gerst explains: "Especially for the production of integral components, which are frequently required in the aerospace industry, it is crucial that the machines used can also machine at negative angles. With swivel heads, this is not mechanically possible. We designed the new fork heads specifically for such applications. Particularly with the HSK-A-63 interface and a fast spindle, they are ideally suited for these tasks."

The 5-axis machining center F 5000, like the F 6000, comes standard as a version with an automatic pallet changer (APC). This is also the first automation stage of the machine.

Additionally, Heller will offer the machine variant Flex without the integrated pallet changer. This modification will make the F 5000 and F 6000 about one meter shorter. "The Flex variant particularly shows its strengths in an externally automated system network. When combined with linear and rotary storage systems, this significantly increases machine utilization time, while offering greater flexibility regarding workpiece size and payload," says Manuel Gerst. The advantages of the Flex variant come into play especially with workpieces that have long run times, as the slightly longer workpiece exchange times compared to the APC variant are negligible in this context.

The Flex variant is offered in conjunction with external automation. A Heller rotary storage (RSP) can be attached, as well as a standardized linear storage system. Additionally, the APC variants also allow for expanded automation. For those who are not ready to commit to such an automation system immediately, Heller offers the "Automation-ready" option. This means that the standardized pallet automation systems can also be retrofitted quickly and easily at a later time.

The machines of the F series are equipped with an optional mill-turn function, suitable for combined milling and turning tasks. The centerpiece is the high-torque rotary table DDT (Direct Drive Turning), which achieves speeds of up to 700 rpm. This allows, in addition to the conventional milling and drilling operations, the machining of external and internal contours longitudinally or on a plane, as well as various grooves and notches in a single setup. Even external and internal threads can be produced. This eliminates the need to transfer to separate turning machines, which increases accuracy on the workpiece and significantly reduces turnaround times, especially in series production.

Under the motto "Passion for Production," Gebr. Heller Maschinenfabrik GmbH will present its latest 360° solutions for the manufacturing of tomorrow at AMB 2024 in Hall 10, Booth A31. Among the highlights is the latest generation 5-axis machining center F 5000, known for its high precision and performance in the production of small to medium batch sizes. Combined with a newly developed tool rack magazine, the F 5000 remains particularly slim even with high tool capacity. Additionally, the machine manufacturer will showcase the 5-axis machining center HF 3500, automated with a Heller robot cell. The flexible workpiece automation is particularly suitable for serial production with medium and high batch sizes. A variety of services and future-oriented technology and digitalization solutions will also enhance the trade show appearance.

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