Perfect combination for structural parts – faster, better, lower cutting forces
F. Zimmerman GmbH relies on high volume milling cutters from MAPAL in combination with their machining centre FZH, which therefore raises performance to a whole new level.
The optimum machine tool + the optimum tool = the perfect combination. And that makes cost-effective processes and impressive machining results possible. One good example of this is the cooperation between the machine manufacturer, F. Zimmermann GmbH, and MAPAL. For demonstrations and machine acceptance tests, Zimmermann equips its new horizontal machining centre with milling cutters from MAPAL.
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.
The beginning: The milling tools used are not suitable for the machine's performance level
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.
From left: Steffen Nüssle, Sales Manager for Export and Head of Application Technology, Bernd Scheurenbrand, Application Engineer, both from Zimmermann, Norbert Meier, Sales, and Dietmar Maichel, Project Manager for 3D Milling, both from MAPAL.
Analysis of the machining directly in the horizontal machining centre.
The future: Zimmermann and MAPAL manufacture test components from composite materials
The Zimmermann machines are suitable not only for the machining of metals. “Many of our customers manufacture parts of composite materials,” says Steffen Nüssle. Zimmermann therefore also wants to mill trial parts of these materials using MAPAL tools. “We are optimistic that with the MAPAL milling cutters for composite machining, we will also find a new secret weapon to exploit the performance of our machines even better.” The corresponding plans are already in hand.
For finishing deep pockets and filigree structures in one go, Zimmermann relies on the solid carbide milling cutter SPM-Finish.
Key data of the tools used at Zimmermann:
Roughing – solution for diameter ranges above 25 mm SPM-Rough ISO shoulder milling cutter with indexable inserts
Diameter 40 mm
Feed rate 21 m/min
Material removal rate 6.9 l/min
10 percent lower cutting forces with the best surface finish compared with the milling cutters from competitors previously used.
Roughing – solution for diameter ranges up to 25 mm SPM-Rough solid carbide milling cutter with wave profile
Diameter 25 mm
Feed rate 13 m/min
Material removal rate 7.3 l/min
Cutting depth ap 37.5 mm, cutting width ae 15 mm
High material removal rates with the highest machining values.
Multi-stepped semi-finishing of thin-walled structures OptiMill-SPM solid carbide milling cutter
Diameter 16 mm
Feed rate 12 m/min
Projection length 66 mm
Extremely sturdy thanks to conical form
Time savings of over 40 percent are possible in combination with the 3-axis milling head.
Finishing of deep pockets and delicate structures in a single pass SPM-Finish solid carbide milling cutter
Diameter 12 mm
Feed rate 3 m/min
Best surface finish
Cutting depth ap 40 mm
Special finishing geometry
No vibrations
Perfect results even with large machining depths and practically complete wrapping of the milling cutter.
Four tools for roughing, semi-finishing and finishing are in use at Zimmermann.
About F. Zimmermann GmbH
F. Zimmermann GmbH from Neuhausen auf den Fildern is a world leading high-tech supplier of milling machines and solutions used in the automotive and aerospace industries and for special applications. The company founded by Friedrich Zimmermann in 1933 has 200 employees and branches in Germany, China and the USA.
From left to right: Dietmar Maichel, Project Manager of 3D Milling at MAPAL, and Steffen Nüssle, Sales Manager for Export and Head of Applications Technology at Zimmermann, in front of the new FZH horizontal machining centre.
