Perfect combination for structural parts – faster, better, lower cutting forces

F. Zimmermann GmbH developed its first horizontal machining centre specially for the machining of structural parts for the aerospace industry. The aluminium structural parts, such as wing parts and frame ribs, are generally milled from solid material – with up to 95 percent material removal. Fault-free machining with respect to dimensional accuracy and surface finish is crucial here. And the component structure that becomes more and more delicate with increasing material removal represents an additional challenge. In order to make the milling process as efficient as possible even in these areas, the new FZH machining centre offers maximum rigidity. For the core technology of the new 5 or 6-axis horizontal machining centre is a robust, water-cooled travelling column. Whereas conventional machine concepts suffer from lever-related deviations with increasing slide, the guide carriage distance of the new Zimmermann machine increases with increasing plunging depth into the material. That actually increases the rigidity. In order to achieve maximum efficiency, Zimmermann employs its own patented M3ABC 3-axis milling head in the machining centre. Particularly in the pocket corners of a workpiece, this milling head has to perform only very small swivel movements – allowing the feed rate to be kept more or less constant and hence the machining time to be significantly shortened. 

At an open house in June 2017, Zimmermann demonstrated its new machining centre with tools from competitors. These tools failed to meet the expectations, however, and were unable to exploit the performance of the machine. “Why not test the performance of the MAPAL tools?” thought the project managers at Zimmermann, as MAPAL was presenting its milling cutters for high-volume machining at the event. No sooner said than done. A short time later, representatives of the two companies carried out extensive milling trials with different tools together.