New HyperMach(TM) GTi Series 5-Axis Titanium Aerospace Profilers Introduced for IMTS

2010-06-04

Covered by four patents, high-performance horizontal design delivers superior stiffness for aggressive hard-metal machining

MAG introduces the HyperMach(TM) GTi series 5-axis titanium aerospace profiler at IMTS for efficient processing of large parts such as spars, bulkheads and door edge frames, or nested part groups. MAG will showcase a new HyperMach H4000 GTi at the show with hard-metal cutting demonstrations using a new 5-axis HSK100A 6000 rpm/850 Nm high-torque geared spindle. Part of the larger HyperMach horizontal family of machines, the GTi series is covered by four key patents related to efficient, accurate machining.

Developed for high-output machining of large monolithic titanium aerospace parts, the 5-axis HyperMach GTi series turns the typical profiler concept on its side in a fixed-column, traveling table arrangement. The modular machine design is available with part capacities from 2 x 4 m (6.6 x 13.1 ft) to 2 x 8 m (6.6 x 26.3 ft). Unlike others' T-type machine designs, which lose up to 80 percent of their stiffness and require frequent re-alignment to maintain accuracy, the HyperMach GTi's patented structural link provides lock-up between the column and X-axis table base to provide extreme stiffness for aggressive cuts at the upper limits of the workzone. This four-point column link provides closed-loop stability, controlling machine geometry changes caused by thermal growth and maximizing structural stiffness for heavy machining. The added stiffness enables the HyperMach to consistently produce higher quality and more accurate parts, while allowing heavy cuts at any position in the workzone to reduce cycle times and achieve the lowest cost-per-piece production.

The X-axis table/pallet receiver delivers feed rates up to 50 m/min (2000 inches per minute), while the Y-axis reaches vertical speeds up to 35 m/min (1378 ipm) to minimize parasitic time out of the cut. Water-cooled servomotors are used on X,Y and Z axes of GTi series machines to eliminate thermal influence of the motors on positioning accuracy and to maximize performance for high acceleration/deceleration and feed rates. The spindle carrier rotates at 60 degrees/sec (10 rpm) in A and C axes, powered by worm/wheel drives. Scale/encoder feedback on all five axes provides accuracy well beyond the capabilities of other horizontal machines on the market, and MAG's optional Volumetric Error Compensation package can enhance the machine's volumetric performance by 50 percent or more. GTi series machines come standard with a 72-tool magazine, which is field expandable to 110 or 142 tools.

HyperMach GTi series machines can be configured to meet the layout and work flow requirements of most plants. All HyperMach H-Series machines feature a full-portal, open-center design, allowing chips to fall through to a high-volume conveyor to avoid chip re-cutting and the need for a blow-off attendant. Programmable, variable high-pressure through-spindle and external coolant system is a standard feature. Pallet load can be from the right or left side, and the chip conveyor can be configured to discharge in either direction. Installation is on a flat floor, which reduces the cost and time required for installation by avoiding the need for pits and multi-step foundations. This makes future reconfiguration of the plant layout easy. Combined with MAG's CINCRON® cell automation modules, the GTi series design allows virtually an infinite number of material handling and cell configurations for extremely flexible multi-machine and multi-pallet part manufacturing.

The four patents covering the HyperMach machine design include one for the rigid four-column lockup between the column and table base, which provides consistent stiffness and improved accuracy throughout the work zone. A second patent covers the "flight deck" ergonomics of the operator station. Its layout permits visual monitoring of the machine's HMI, the work zone, the tool change process, tool in the ready position, the tool magazine itself, and utilities panel, as well as immediate physical access to the work zone. A third patent covers maintenance and reliability issues - motors and drives are on the exterior of the machine, away from workzone contamination, and critical drive components, such as ways, bearing, ballscrews and scales, can be accessed and serviced from the exterior of the machine. A fourth patent covers the pallet handling system, which allows a pallet to be loaded from either or both sides of the machine without any modification to the system, permitting a wide variety of work handling configurations without modification to the machine.

MAG is a leading machine tool and systems company serving the durable goods industry worldwide with complete manufacturing solutions. With a strong foundation based upon renowned brands such as Cincinnati, Cross Hüller, Fadal, Giddings & Lewis, Hüller Hille, Witzig & Frank, Hessapp, Ex-Cell-O, Honsberg and Boehringer, MAG is recognized as the preeminent provider of tailored production solutions based on state-of-the-art technology. Key markets served include aerospace, automotive and truck, heavy equipment, oil and gas, rail, solar energy, wind turbine production and general machining.

With manufacturing and support operations strategically located worldwide, MAG offers comprehensive lines of equipment and technologies including process development, automated assembly, turning, milling, automotive powertrain production, composites processing, maintenance, automation and software, and core components.