TOOLTRONIC makes milling-turning centre an all-rounder
Enhanced turning functions for standard machine tools
The Swiss milling and milling-turning centre manufacturer Reiden brought tool manufacturer MAPAL on board in order to meet a specific customer requirement. An actuating tool that meets high standards was required for the demanding internal machining of bores with variable shapes.
„Unsere Bearbeitungszentren sind auf höchste Flexibilität bei unterschiedlichen Aufgabenstellungen ausgelegt“, sagt Daniel Lustenberger, Leiter Marketing und Verkauf der Reiden Technik AG in Reiden in der Schweiz. Bei einem jetzt anstehenden Projekt habe der Kunde jedoch so spezielle Wünsche gehabt, dass Reiden diese mit den üblichen Bearbeitungsverfahren nur schwer oder gar nicht hätte darstellen können. Im Prinzip ging es darum, spezielle Innenkonturen mit Hinterschneidungen zu erzeugen. Solche Bearbeitungen erfordern den Einsatz von Aussteuerwerkzeugen, die eine zusätzliche interne Achse aufweisen, die seitlich ausgefahren werden kann. So können Anwender beispielsweise aus der Innenwand eines Zylinders eine Ringnut für eine Dichtung ausstechen.
„Bei Aussteuerwerkzeugen gibt es bewährte Ausführungen, die jeweils spezifische Besonderheiten aufweisen“, sagt Andreas Mollet, MAPAL Gebietsverkaufsleiter in der Schweiz. So gibt es beispielsweise Lösungen, die den Druck des axial über die Spindel zugeführten Kühlschmierstoffs auf einen Kolben nutzen, um den oder die Schieber auszufahren. Die Rückzugsbewegung erfolgt durch eine gespannte Feder, nachdem die Steuerung die Kühlschmierstoff abgeschaltet hat. Beide Bewegungen sind ungeregelt. Es erfolgt keine Rückmeldung, wenn die jeweilige Endlage erreicht ist. Deshalb müssen die Programmierer nach dem Befehl eine entsprechend lange Verweilzeit im NC-Programm vorsehen. Eine Alternative dazu sind Aussteuerwerkzeuge mit Zugstangenbetätigung. Die Zugstange durchläuft hierbei die Spindelachse. Die Maschinensteuerung steuert sie hydraulisch oder als zusätzliche NC-Achse an. Diese Zusatzausstattung erfordert jedoch ein Bearbeitungszentrum in Sonderausführung mit entsprechenden Einschränkungen bezüglich der Maschinenhersteller und der Wirtschaftlichkeit.
“As an alternative to classic actuating tools, we have developed TOOLTRONIC with complete NC connection”, explains Andreas Mollet. The unit, which is equipped with sensors and drives, is supplied with power via an inductive coupling unit on the lower side of the spindle and can transmit data bidirectionally. It represents a fully-fledged additional NC axis in the machine control. Functions of modern CNC control systems, such as indexing, interpolation of different axes or the correction of tool wear can therefore be fully utilized. The energy transmission enables high dynamics of the integrated drives. Bidirectional data transmission also opens up the possibility of new machining and control concepts. Thanks to integration into the machine control system, users can use TOOLTRONIC to create contours which are not radially symmetrical to the main axis of the bore or cylinder. Another advantage of the solution involves the many MAPAL mounting tools that can be used with TOOLTRONIC.
“The RX18 is an extremely robust and at the same time precise 5-axis milling machining centre that can be supplemented with a driven rotary table to become a milling-turning centre”, explains Daniel Lustenberger. Users clamp the spindle for turning operations. It then functions as a toolholder. The rotary table is 1,800 mm in diameter and reaches a maximum spindle speed of 250 rpm. This configuration enables turning operations up to a maximum workpiece diameter of 2,600 mm. This eliminates time-consuming workpiece changes between the lathe and milling machine. At the same time, machinists thus avoid the otherwise inevitable alignment deviations that occur during reclamping.
At the customer’s request, Reiden has supplemented the RX18 for use with TOOLTRONIC with an LAT facing head (linear actuating tool). The tool is mounted on a radially movable slide, which achieves a maximum stroke of 56 mm. This means it’s particularly suitable for applications requiring a large radial stroke.
A fully developed concept facilitates integration into the machine
“MAPAL TOOLTRONIC is a complete package with comprehensive documentation, whose fully developed concept made the successful integration into our machine tool considerably easier for us”, explains Daniel Lustenberger. This included mechanical and electronic connections to the spindle as well as space to house the TOOLTRONIC controller in the control cabinet. The modern Siemens controller of the Reiden RX18 made it possible to integrate the unit as its own axis. During mechanical integration, those responsible had to pay particular attention to making sure the tools could be exchanged in a straight-forward manner, as tool restrictions had to be taken into account in the inductive carrier below the spindle.
On the control side, the machine experts directly accessed the functions of the Siemens controller. The inductive carrier could be seamlessly integrated into the mechanics thanks to the integration into the controller. Furthermore, no difficulties arose in the control cabinet thanks to the small, compact control unit. “The TOOLTRONIC unit can be automatically changed from the magazine to the HSK A100 connection of the spindle like a normal tool”, explains Andreas Mollet.
“MAPAL gave us comprehensive advice before we chose the TOOLTRONIC”, explains Daniel Lustenberger. The subsequent cooperation between those responsible at Reiden and MAPAL from the fields of construction, electrical engineering and control technology went off without a hitch. MAPAL employees supported the commissioning of the system, so this process also ran smoothly, only taking three days. In the final machining tests, the system achieved the best results. “Thanks to this additional solution, we’re able to enhance our systems’ functions for our customers without impairing their versatility in the process”, Daniel Lustenberger sums up.
Simple, fast, safe and reliable – how the Swiss lathe manufacturer TORNOS is optimising the application performance of its multi-spindle lathe with the help of MAPAL hydraulic chucks.
