顶尖机床T系列的创新应用 (1).pdf

G环球瞭望LOBALOUTLOOK顶尖机床T系列的创新应用True greatness is T-shaped为了着眼于未来发展，美国制造商Metalex增购了斯达拉格的杜普莱恩T系列龙门加工中心，其可以灵活高效地对不同材料进行五轴高精度加工。编译/周淞美国Metalex制造有限公司和瑞士斯达拉格集团有着很多的共同点，这也成就了他们长期的合作伙伴关系：两者均是超大型铝合金、不锈钢和钛合金工件领域的专家，而这些工件常用于极富挑战性的应用。现在，这家建于俄亥俄州的制造厂有了进一步的发展计划，即在现有产线的基础上增购第四台斯达拉格机床一一新型杜普莱恩T系列六轴龙门加工中心。那么，Metalex对这台新机床有着怎样的期待和计划呢？来自俄亥俄州辛辛那提的Metalex和斯达拉格集团旗下比勒菲尔德工厂之间的合作曾因疫情原因一度停摆，而目前，最新型杜普莱恩T6080DTTT60HR100C龙门加工中心即将在Metalex先进的大型制造中心投入使用，该中心是Metalex在主厂之外为新生产系统扩建的一座巨大的建筑。这也是迄今为止杜普莱恩T产品系列中最大的工作台移动式龙门加工中心：它具有极佳的刚性结构和静压运行理念，非常适合对几何形状复杂且公差要求极其严格的超大型工件进行高精度加工。斯达拉格比勒菲尔德工厂的大型机床销图1 杜普莱恩T6080DTTT60HR100C龙门加工中心售总监HeikoQuack表示，这些机床可以灵活高效地对不同材料进行五轴高精度加工。84.第0 6 期数控机床市场环球瞭望GLOBALOUTLOOK成功通过客户的基准测试斯达拉格提供的产品正是这家美国客户所寻找的：Metalex需要的机床不仅要满足当前的生产要求，还要着眼未来发展。作为一家优质复杂工件的大型制造商，Metalex及其机械供应商必须要直面上述难题。目前已经有三台斯达拉格机床在Metalex工厂投入使用，但在经过密集的基准测试后，他们决定再增购一台杜普莱恩T系列龙门加工中心。促使Metalex作出这一决定的关键因素是强大的合作伙伴关系，这一点已由Metalex方面通过合约确认。这台新龙门加工中心有一个乙轴滑块进给铣削装置，并配有集成式C轴和各种铣削附件头。其中包括斯达拉格旗下多利斯产品系列中的两个转台和车刀座。这些部件在斯达拉格机床中已使用多年，并已向Metalex证明了它们的可靠性和生产能力。这可以说是最好的XXL型机床，工作区不同寻常的尺寸可以证明这一点（X:19,000mm，Y:9,000mm，Z:3,0 0 0 m m)，利用其巨大的可用空间，甚至可以通过单次装夹对超大型的工件进行加工。两个连续的万能叉式铣头可以实现高度灵活的五轴加工，对需要高达2,40 0 Nm铣削扭矩的重型加工来说这些主轴头是一个完美的选择。此外，它也可以与高转速的电主轴一起使用，可以随着铣削主轴的更换自动更换。为了进行更灵活的通用加工，Metalex还订购了一个5,50 0mm的连续活动横梁，作为第6 个轴(W)。配置双工作台以减少非生产时间根据销售总监Heiko Quack 的说法，这种XXL型机床的真正亮点是其专门设计的工作台配置：带两个6,0 0 0 mm8,000mm的超大工作台。“对于这两个工作台，操作人员可以完全分开操作。一个工作台在工作区域外进行预装夹或检测，同时，另一个进行加工。超长工件也可以在双工作台串联方式下进行加工，进而将工作台加长至1 8,0 0 0 mm。每个工作台还有一个集成转台（直径：6,0 0 0 mm)，通过1 1 1 kW的主驱动还可对重达2 0 0 吨的工件进行旋转加工。此外，转台也可以被用作C轴，tangDroop+ReinT图2 这台新龙门加工中心有一个Z轴滑块进给铣削装置，并配有集成式C轴和各种铣削附件头图3 龙门加工中心的超大工作台在铣削和钻孔时进行精确定位。HeikoQuack确信，这台机床具有独一无二的尺寸、配置和多功能性。高速铣削大型铝合金Metalex为机床订购的十一个附件头实现了机床的通用功能。但是，俄亥俄州工厂的日常工作证明，对于一个真正应对自如的制造商而言，这样做也是不够的。在调试机床的过程中，还收到了为一个航空航天客户铣削大型铝合金环的要求。所以，斯达拉格和Metalex集思广益，共同研究高速加工的可能性和可实现的最高生产率。测试成功后，斯达拉格及时交付并集成了一个用于五轴叉式铣头的新型电主轴（1 8,0 0 0 rpm),以便客户开始生产。“这个例子表明，如果一个制造商难以确切地定义产品规格，那就只能通过正确的机床理念和与机床供应商的密切合作积极第0 6 期数控机床市场85G环球瞭望LOBALOUTLOOK应对新的要求，”这位销售总监还强调说，“通过这根附加的主轴，该制造商可以大批量制造铝合金环，以提高生产率。”此外，当机床在原有的一个附件头更换系统和十二个附件头之外突然增加一个或多个附件头时，对生产率又会有什么影响呢？会导致非生产时间增加吗？斯达拉格在开发这套生产系统时就考虑到了这种情况。据HeikoQuack说，该加工中心配有一个电子系统来管理所有附件头，例如，可以弹出XY角度铣头，将其换成叉式铣头。所以，Metalex可以平时储备3 0 个附件头，并始终为加工提供所需的附件头。并且，这种投入正在得到回报，因为俄亥俄州的工厂正在讨论是否需要增加1 3 号和1 4号附件头。机械手确保快速更换刀具机械手换刀系统已经以闪电般的速度推出：大型制造商常常需要更大的空间，不仅用来放置各种刀具，还需要放置各种不同的刀具系统。目前，Metalex的这套生产系统可以使用与CAT60、C A T 50、C a p t o-C 8、H S K 1 0 0 或 HSK63刀柄适配的刀具，需要时，它可为各刀具提供相应的附件头。这种级别的项目代表了这家公司有史以来最大的一项投资。Metalex为这个先进的大型制造中心修建了最先进的厂房，其地基重达7,0 0 0吨，提供了良好的减震效果。因此，会有人提出疑问：这项投资花费了几百万美元，如此巨大的投资回报如何？当该机床在美国投入使用时，HeikoQuack听到了这样的回复：“我们已经看到，新型机床得到了很好的利用。”Metalex的首席执行官KevinKummerle有着相似的看法，他已在考虑追加投资。【英文如下】The long-term partnership between Usmanufacturer Metalex Manufacturing Inc ofOhio and the Starrag Group has resulted in theinstallation of the companys fourth Starragmachine,a large-capacity Droop+Rein T six-axisportal-type machining centre.The model T 6o 8o DT TT6o HR100 C hasX-,Y-and Z-axes of 19,000mm,9,000mm and3,ooomm,respectively,and to date it is the biggestportal-type machine made in the Droop+Rein Tline.With rigid construction and based onhydrostatic operating concepts,the machine isperfectly suited to high-precision/tight tolerancemachining of extremely large workpieces withcomplex geometries and,according to Starrag,itefficiently produces precise workpieces in variousmaterials using five axes.The machine has a Z-axis slide feed millingunit with integrated C-axis and a wide range ofmilling heads.It includes two rotary tables andturning toolholders(from the Dorries range).Metalex is a specialist in machining extremelylarge components in aluminium,stainless steeland titanium,for example,and the capacity ofthe new machine means that even very largeworkpieces can be machined in a single setting.5-axis machining is enabled by twocontinuous universal fork-type milling heads withup to 2,4ooNm of milling torque.The machine canalso be used with motorised milling spindles athigh speeds,which can be changed automatically.And,for even more flexible,universal work,thereis a 5,5oomm continuous mobile crossbar as thesixth axis(W).The two tables of 6,ooomm by 8,ooommallow one to be used for set-up or inspectionoutside the work area while the other is beingused for machining.Extra-long workpieces canbe machined in a coupled tandem formation-which extends the tables to 18,ooomm.Each tablealso has an integrated rotary table of 6,ooommdiameter which,thanks to the 11ikW main drive,also enables rotary machining of componentsweighing up to 20o tons.The rotary tables can alsobe used as a C-axis for precision positioning whenmilling and drilling.86第0 6 期娄数控机床市场环球望GLOBALOUTLOOKIn addition to utilising all types of machiningprocesses,the company is also investing in newproduction processes such as metal 3D printingand is developing a Smart Factory where futuremachinery and sensors will feed data directly intothe industrial internet of things to analyse datausing AI and machine learning.Indeed,with Smart Factories in mind,Starrag has implemented several digital solutionson its machines.First,there is an interface toenable Metalex to connect the machines toits production monitoring system.Data fromthe machine is constantly being collected andprocessed-for example,the run times of NCprograms can be monitored and evaluated,orWhile the 11 machining heads createuniversal functionality for Metalex,there is also anintegrated motorised 18,ooorpm spindle for the5-axis fork type milling head,initially being usedfor milling large aluminium rings for an aerospacecustomer.The extra spindle allows Metalex toincrease productivity by a significant amount whenmachining this ring.The machine has an electronic system formanaging the machining heads;an X-Y angularmilling head can be ejected to swap with a forktype milling head,for example,so Metalex caneffectively keep 30 machining heads to hand.With over 4oo tools served by a robot toolchange system,the machine allows the use of toolswith CAT 60,CAT 50,Capto-C8,HSK 100 or HSK63 holders.Metalex was founded in 1971 and hasgrown to become one of the leading high-techmanufacturers in the US,employing 130 staff inthree factories which produce primarily extra-large components from challenging materials suchas titanium,Inconel,nickel aluminium bronze andstainless steel.Customers include large clients insectors such as aerospace,energy,defence andpower generation.tool costs can be clearly assigned to individualmachining operations.Starrag also took the digital fingerprintof the machine after it was put into operation,documenting its condition on delivery usingvarious measurements and analyses.By repeatingthese automatically and digitally evaluating thisfingerprint,the user can carry out preventivemaintenance on the machine and ultimatelyanticipate maintenance needs throughout itslifespan.Metalexs latest investment arose after thecompany was on the hunt for a machine that wouldsatisfy not only its current production needs butalso likely future demands.Although the companyalready has three Starrag machines,it decided onthe Droop+Rein after an intensive benchmarkingprocess.A key factor in the decision was the strongpartnership between Metalex and Starrag.Costing several million dollars,the machinerepresents the largest single investment in thecompanys history and Metalex constructeda state-of-the-art production building-withextremely low-vibration foundations weighing7,ooo tons-specifically for it in its Center forAdvanced Large Manufacturing.t第0 6 期数控机床市场87.