Machine layout

Machine Construction
The TajmacZPS a.s. horizontal machining center H 40 continues to expand the line of horizontal machining centers. The model offered is a rigid and powerful machine for variety of application. The machine is suitable for complex precision machining process. Massive cast iron construction provides superior damping capacity. The customer has the ability to select SIEMENS SINUMERIK 840D or Heidenhain iTNC530, excellent state of the art CNC, useable for cutting and contouring, allowing processing time to be cat to the minimum and keep a part within specified accuracy. These CNCs offer optimum, complete digital solution with SIMODRIVE 611 D (digital). Linear Guide Ways Used on all axis are ball type, low friction, grease lubricated to guarantee long life. That lube system reduces maintenance headaches as well as it is an environmental friendly solution. Axes Drives The X,Y and Z axes are driven by high-performance Siemens environmentally sealed brushless motors with indirect feedback in the Standard version. Optional linear scales are also available on Trend and Contour version. The high pitch tensional preloaded ball screws are supported by pack of angular contact bearings, which completes very low friction motion system. Spindle Head and Drive The advanced spindle design provides high axial thrust capability, yet generates minimal heat. Spindle is driven by a belt transmission, which allows smooth torque transmission from reliable Siemens 12/18.5kW [16/24HP] spindle motor with 360deg. orientation as standard on all versions Automatic Tool Changer The standard 45-pocket automatic tool changer or 75 pockets optional is another advantage against competitors, and opens more tool flexibility to machine very complex parts or utilize tool life management for unattended operation. Automatic Pallet Changer The automatic pallet changer is efficiently integrated into the machine space. The switching device designed on the base of hydraulically powered rack-and-pinion moves two 400x400mm [15.75 x 15.75 inch] pallets from setup station located outside of work area back on table. The setup station allows to manually rotating the pallet, which permits quick and convenient setting of new work piece into the fixture or even use very popular clamping system Chick. Indexing rotary table The Standard model of the machine is equipped with 1 degree indexing rotary table. The method of using Hirth face gear for positioning and clamping has been proven as a reliable system for long lasting accuracy. Guarding The machine is fully enclosed. The machine enclosure and guarding complies with CE, and other safety standards requirements. The working area is accessible through the sliding door by the machine operator. Chip Conveyor Two auger style conveyors will effectively remove chips from working area to the back of the machine. Even there is only one machine or cell with multiple machines we can optionally add central chip conveyor to collect the chips into a drum. Coolant Unit The large coolant tank is designed to provide and collect enough capacity of coolant. One pump for flood coolant is on all versions. If the application requires cleaning up a large amount of chips (aluminum) we can provide as an option chip wash down system. A part cleaning is also available with upper rinse in the working area.

SPINDLE ASSEMBLY WITH COOLANT THROUGH THE SPINDLE CAPABILITY AND DUST SEAL

The Powerful HEIDENHAIN Contouring Control iTNC530

TNC contouring controls have been proving themselves in daily use on milling machines, drilling and boring machines, and machining centers. This success is due in part to its shop-oriented programmability, but also to its compatibility with the programs of its predecessor versions. The iTNC530 is also compatible in its operation and programming with its predecessor models. The machinist who has already worked with TNC does not have to relearn. On the iTNC 530 he immediately uses all of his previous experience with TNCs, programming and machining as before.
Heidenhain iTNC 530 Panel
The iTNC 530 features a new, more powerful processor architecture, to enable you to finish your jobs in the workshop even more quickly: With its sophisticated closed-loop control methods and short block processing times, the iTNC 530 mills your workpieces faster then ever. With the fast editor of the iTNC 530 you can edit and add to you existing programs in seconds. You can verify even complex programs quickly and simply with the iTNC 530 through its optimized graphic buildup. Over its Fast Ethernet data interface (100 megabaud) you can transfer long programs quickly from a remote programming station to the control. The iTNC 530 features a new, more powerful processor architecture, to enable you to finish your jobs in the workshop even more quickly: With its sophisticated closed-loop control methods and short block processing times, the iTNC 530 mills your workpieces faster then ever. With the fast editor of the iTNC 530 you can edit and add to you existing programs in seconds. You can verify even complex programs quickly and simply with the iTNC 530 through its optimized graphic buildup. Over its Fast Ethernet data interface (100 megabaud) you can transfer long programs quickly from a remote programming station to the control. The new iTNC 530 therefore combines modern technology with the well-known user friendliness of a TNC. Built for the workshop The machine operator can program his operations in dialog with the control. For simple work it is easy to operate the machine manually with the iTNC 530. Fast block-processing times and optimum motion control make the iTNC the perfect choice for HSC machining Automated manufacturing On machining centers the iTNC 530 manages tools and pallets. Over the data interfaces you can even interrogate operating conditions or operate the machine remotely.

Specifications Components MC 422 main computer CC 422 controller unit TE 420 keyboard unit TFT color flat-panel display with soft keys: BF 120 with 10.4 inches Hard disk 6Gbyte To 0.1 m for linear axes To 0.0001 for angular axes Straight line: in 4 axes Straight line: in 5 axes (export permit required)
software option 2

Program memory Input resolution and display step Interpolation

Circle: in 2 axes in 3 axes with tilted working plane Circle: in 3 axes with tilted working plane
software option 1

Helix: Combination of circular and linear motion Spline: Execution of splines (3rd degree polynomials)
software option 2

Block processing time (3-D straight line without radius compensation) Axis feedback control

3.6 ms Option: 0.5 ms

software option 2

Position loop resolution: Signal period of the position encoder/1024 Cycle time of position controller: 1.8 ms Cycle time of speed controller: 600 s Cycle time of current controller: minimum 100 s Linear and nonlinear axis error, backlash, reversal spikes during circular movements, thermal expansion Stick-slip friction One each RS-232-C / V.24 and RS-422 / V.11 max. 115 Kb/s Expanded data interface with LSV2 protocol for remote operation of the iTNC 530 through the data interface with the HEIDENHAIN software TNCremo Fast Ethernet interface 100BaseT

Error compensation

Data interfaces

User Functions Brief description Basic version: 3 axes plus spindle 4 th NC axis plus auxiliary axis, Digital current and speed control HEIDENHAIN conversational and as per ISO Nominal positions for straight lines and circular arcs in Cartesian or polar coordinates Dimensions absolute or incremental Display and entry in mm or inches Display of handwheel traverse when machining with handwheel superimposition Tool radius in the working plane and tool length Radius-compensated contour look ahead for up to 99 blocks (M120) Three-dimensional tool radius compensation for changing tool data without having to recalculate an existing program Several tool tables with any number of tools Cutting data tables for automatic calculation of spindle speeds and feed rates from tool-specific data (cutting speed, feed per tooth) Relative to the path of the tool center Relative to the tools cutting edge Creating programs with graphic support while another program is being run Motion control with minimum jerk 3-D tool compensation through surface normal vectors Tool Center Point Management (TCPM): Using the electronic handwheel to change the angle of the swivel head during program run without affecting the position of the tool point Keeping the tool normal to the contour Tool radius compensation normal to the direction of traverse and tool Spline interpolation Programming of cylindrical contours as if in two axes Feed rate in mm/min Line segment Chamfer Circular arc Circle center Circle radius Tangentially connecting circular arc Corner rounding Via straight line: tangential or perpendicular Via circular arc FK free contour programming in HEIDENHAIN plain language with graphic support for workpiece drawings not dimensioned for NC Subprograms Program section repeats Calling any program as subprogram Cycles for drilling, peck drilling, reaming, boring, counterboring, conventional and rigid tapping Cycles for milling inside and outside threads Roughing and finishing rectangular and circular pockets Cycles for clearing level and inclined surfaces Cycles for milling straight and circular slots Circular and linear point patterns Contour pockets also with contour-parallel machining Contour train OEM cycles (special cycles developed by the machine tool builder) can also be integrated

Programming Position data

Tool compensation

Tool tables Cutting data tables Constant contouring speed Parallel operation 3-D machining

Machining with rotary tables Contour elements

Contour approach and departure FK free contour programming Program jumps

Fixed cycles

Coordinate transformations

Datum shift, rotation, mirror image Scaling factor (axis-specific) Tilting the working plane
software option 1

Q parameters (Programming with variables)

Mathematical functions =, +, , *, /, sin , cos , angle of sin and cos , a, Logical comparisons (=, = /, <, >) Parentheses n n tan , arcus sin, arcus cos, arcus tan, a , e , In, log, absolute value of a number, constant , negation, truncation of digits before or after the decimal point Functions for calculation of circles

Programming aids

Pocket calculator Context-sensitive help function for error messages Graphical support for programming cycles Comment blocks in the NC program Actual positions can be transferred directly into the NC program Graphic simulation before a program run, even while another program is running Plan view / projection in 3 planes / 3-D view Detail enlargement In the Programming and Editing mode of operation, the contour of the NC blocks is drawn on screen while they are being entered (2-D pencil-trace graphics), even while another program is running Graphic simulation during real-time machining Plan view / projection in 3 planes / 3-D view Calculation of machining time in the Test Run operating mode Display of the current machining time in the program run modes Mid-program startup in any block in the program, returning the tool to the calculated nominal position to continue machining Program interruption, contour departure and reapproach Several datum tables Pallet tables (with as many entries as desired for the selection of pallets, NC programs and datums) can be machined workpiece by workpiece or tool by tool Touch probe calibration Compensation of workpiece misalignment, manual or automatic Datum setting, manual or automatic Workpiece measurement, automatic Cycles for automatic tool measurement

Actual position capture Verification graphics (Display modes) Programming graphics

Program run graphics (Display modes) Machining time Returning to the contour

Datum tables Pallet tables Touch probe cycles

Software Option 1 Machining with a rotary table Coordinate transformations Interpolation Software Option 2 3-D machining Motion control with minimum jerk 3-D tool compensation through surface normal vectors Tool Center Point Management (TCPM): Using the electronic handwheel to change the angle of the swivel head during program run without affecting the position of the tool point Tool radius compensation normal to the direction of traverse and tool Spline interpolation Straight line: in 5 axes (export permit required) Spline: Execution of splines (3rd degree polynomials) 0.5 ms Programming of cylindrical contours as if in two axes Tilting the working plane Circle: in 3 axes with tilted working plane

Interpolation Block processing time

H 40 Trend
Machine configuration
Heidenhain iTNC 530 Siemens Simodrive 611 digital 45 tool pockets CAT40 automatic tool changer Scale feedback Flood coolant Machine enclosure Full protection (fence) guarding of tool magazine and other moving items on the machine All electrical devices complies with CE, or are UL /CSA approved or listed Fluorescent work light Auger style chip conveyers 10000 RPM spindle 2-pallets 400 mm x 400 mm [15.75 x 15.75 inch] Full contouring rotary table Chip pan Tool air blast CTS Prep Lift-up chip conveyor

ROTARY TABLE WITH PALLET Pallet size Max. pallet load Max. workpiece dimension (dia.x height) Number of pallets Min. pallet indexing angle Pallet change time TRAVELS X axis Y axis Z axis B axis PERFORMANCE Cutting feed rate (X/Y/Z) Rapid feed rate (X/Y/Z) Acceleration Accuracy*, positioning P Accuracy*, repeatability PS max Accuracy*, positioning P (linear scales) Accuracy*, repeatability PS max (linear scales) Pallet changing repeatability B-AXIS (Rotary table) Max. radial force (Z-axis) Max. permissible torque for milling Max. permissible torque when clamped B-axis angular repeatability Max .Speed ( B axis ) Max. run out of central hole Max. run out of on Dia. 340mm Max. run out of table surface on Dia 340mm SPINDLE Main motor Max torque (continues/peak) Spindle speed Spindle taper Spindle center to pallet Spindle end to pallet center Power transfer TOOLING ATC, number of tools Max. tool diameter Without adjacent tools Max. tool length Max tool weight Tool change time GENERAL INFORMATION Machine width x depth Machine height Machine weight Air pressure requirement Power requirements Coolant capacity 4377mm x 2570mm [144.5 x 8 5.2] 2625 mm [8 7.4] 9,000 kg {19,850 lbs] 0.6 0,8 Mpa [87 116 PSI] 480V 60Hz/3-phase 450 liters [120 Gall] 400 mm x 400 mm [15.75 x 15.75 inch] 300 kg [660lbs] 600 mm x 600 mm [23.62 x 23.62 inch] 2 continuous 10 sec 560 mm [22 inch] 510 mm [20 inch] 560 mm [22 inch] 360 Deg. 1 15,000 mm/min. [1 590IPM] 40 m/min [1572 IPM] 2 5.0 m/s [1/2G] 0.016 mm [0.0006 inch] VDI/DGQ 3341 0.008 mm [0.0003 inch] VDI/DGQ 3341 0.012 mm [0.0005 inch] VDI/DGQ 3341 0.006 mm [0.00025 inch] VDI/DGQ 3341 X,Z: 0,01, Y 0,05 [X,Z: 0.0004, Y 0.0020 inch] 6000 N [1350 lb] 1200 Nm [270 lbf] 2700 Nm /R=300mm [600lbf / 12inch] 8 arc seconds 16 RPM 0.010mm [0.0004 inch] 0.010mm [0.0004 inch] 0.020mm [0.0008 inch] 12 / 18,5 kW [16 / 24 HP] 92 / 141 Nm [68 / 104 lbf-ft] 10 000 RPM ISO 40, (CAT 40, BT40) 80 - 590 mm [3.15 23.23 inch] 130-690mm [5.11 27.16 inch] Belt transmission 45 tools 85 mm [3.34 inch] 125 mm [4.92 inch] 300 mm [11.81 inch] 7 kg [15.5 lbs] 5 seconds

Power and Torque Diagrams ISO (METRIC) UNITS 12,0 Max. Output Power [kW] 91,7 MaximumTorque [Nm] 1250,0 Max. Spindle Speed [RPM] ENGLISH UNITS 16,1 Max. Output Power [HP] 67,6 MaximumTorque [lb-ft]

Cont. Output Power [kW] Torque at Rated Speed [Nm] Rated Speed [RPM] Cont. Output Power [HP] Torque at Rated Speed [lb-ft]

15,0 Peak Output Power [kW] 114,6 Peak Torque [Nm] 10000,0 Motor Max. Speed [RPM] 20,1 Peak Output Power [HP] 84,5 Peak Torque [Lb-ft]

18,5 141,3 8000,0 24,8 104,2

Spindle 10000 RPM Power Characteristics Siemens motor 1PH7 133-2ND02-OC2A0

30 Power (kW) 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 Speed (rpm)

Peak (S6-40%) Intermittent (S6-60%) Continuous S1

Spindle 10000 RPM Torque Characteristics Siemens motor 1PH7 133-2ND02-OC2A0

160 Torque (Nm)

Peak (S6-40%)
140

Intermittent (S6-60%)
120

100

Continuous S1

80

60

40

20

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

7000

7500

8000

8500

9000

9500

10000

Speed (rpm)