MIKRONHSM 400, 400U600, 600U, 800

EN

2

MIKRON HSM 600, 600U, 800

High speed milling - Universal application in mould making.

MIKRON HSM 800

MIKRON HSM 600U

MIKRON HSM 600

GF AgieCharmilles makes no com-promisesHSM machines combine accuracy, ex-treme dynamics and high machiningspeeds with other important aspects,such as excellent chip removal, highflexibility, extraordinarily good ergo-nomics and possibility for automation.This makes HSM machines an idealmanufacturing facility for prototypeand mold making and also for work-shop.

3

Content Applications3-axis 45-axis 6

Highlights 8

Automation 10-15

Table variants3-axis 185-axis 20

Basic machine 22

Accuracy 23

High-tech spindles 24

Tool magazine 25

Chips and liquids 26

Success stories 27

Options 28

smart machine 29

About GF AgieCharmilles 30

MIKRON HSM 400, 400U

High speed milling in compact format.

MIKRON HSM 400U

MIKRON HSM 400

For years GF AgieCharmilles hassuccessfully set benchmarks in highspeed machining with the HSM family.This means workpiece accuracy,dynamics, ergonomics, automationand process safety as well as exem-plary accessibility of these portalmachines and their suitability for wetand dry machining.

The integrated pallet magazine for theunmanned operation is an importanthighlight.This generation of machines embo-dies the entire knowledge and yearsof experience of GF AgieCharmilles inhigh speed machining.

4

MIKRON HSM 400, 600, 800

HSC milling of a prototype moldinsert.

Applications3-axis

DieMIKRON HSM 800Alloyed tool steelTool and mold making• High surface quality• High contour accuracy• Machining out of entire pieces

Graphite electrode MIKRON HSM 400Graphite Mold making• High contour accuracy• Efficient graphite machining

Roll MIKRON HSM 600AluminiumMedical technology• Machining out of entire pieces• Machining with 4th axis• High contour accuracy

Watch components MIKRON HSM 400Different materialsWatch making industry/ micromechanics• High contour and position accuracy• High surface quality• Thin-walled and small geometries• Part-specific handling systems

5

6

Motorcycle part MIKRON HSM 600UAluminium production partMotor sport• Production part• High contour accuracy• 5-axis machining

Watch casing MIKRON HSM 400UDifferent materialsWatch making industry• Machining out of entire pieces• 5-axis simultaneous machining and

5-axis alternate machining• High surface quality

Casting moldMIKRON HSM 600UAlloyed tool steelTool and mold making• Machining out of entire pieces• High surface quality• 5-axis simultaneous machining

MIKRON HSM 400U, 600U

Efficient machining of an impeller in 5-axis simultaneous operation.

Applications5-axis

Dental bridges MIKRON HSM 400UTitaniumMedical technology• Machining of titanium alloys• 5-axis simultaneous machining• Complete machining in one clamp

ImpellerMIKRON HSM 400UAluminiumAutomobile industry• 5-axis simultaneous machining• High speed• Thin-walled geometries

7

8

Highlights Precision and quality for tool and mold making as well asparts production

Dynamic tool spindle with vector regulation and ceramic-hybrid bearings

Flexible automation

Effortlesscrane loading

Effortlesscrane loading

Machine base of polymer concretewith high damping characteristics

Trapezoidalwindow with a clear view of the machiningprocess

Direct drive round tilting table with integrated clamping system

GF AgieCharmilles machining centersare distinguished by extraordinaryergonomics. Compelling features ofMIKRON HSM include an unparalleledaccessibility regardless of therespective machine configuration.

Powerful machine control system

9

Ergonomics and process safetyNo compromises are made withregard to safety and accessibility.• Unaltered accessibility in every

configuration level thanks to theautomation through the portal

• Excellent view of the working area• Access from 3 sides by opening a

single smooth running door - alsofor crane loading

• Side window for optimum moni-toring of machining process

• Uninterrupted production thanks tothe pallet magazine

Clean cabins thanks to perfect chipmanagementMaximum attention was paid to thechip flow. Steeply inclined chromesteel plates in the working areafacilitate chip fall extremely well.• No chip accumulation• Easy cleaning• For dry, wet and minimum-quantity

cooling lubrication applications

Process optimisationVarious smart machine modulessupport an optimum process:More accuracy, enhanced surfacequality and contour accuracy alongwith improved safety, which isparticularly valued in unmannedoperation.

Stability and dampingPrimary prerequisites for maximumprecision and best workpiece surfacequality include damping and stabilityof the components:• Highly stable portal construction• Monolithic design• Machine base of mineral cast with

high damping characteristics (8-10x better than grey cast iron)

• Improved workpiece surfaces andtool service life increased up to 30%

Machine control systemPowerful latest generation contourcontrol system. Heidenhain iTNC 530is a versatile and flexible workshop-oriented control system that meets allrequirements.• Efficient workshop programming or

external machine-independent pro-gram creation

• Parallel programming, free contourprogramming, user-definable sub-programs

• Quick processing thanks to a shortset processing time

• Swivelling of machining level • 3D tool correction• The best control system for 5-axis

simultaneous machining

10

....Dank Automatisierung noch produktiver

The linear type magazine - the universalautomation for heavy workpieces.

Automation withlinear type magazine

MIKRON HSM 600

(max. load capacity 800 kg)

GF AgieCharmilles Size 600 x 600 mm

4x

Universal automation for heavy work-pieces.

• Linear 4x storage• Up to 1000 kg load capacity

MIKRON HSM 800

(max. load capacity 1,000 kg)

GF AgieCharmilles Size 800 x 600 mm

4x

Producing more parts in shorter time at lower cost.

OperationServicing

Advantages of automation• Highest productivity and efficiency are achieved in combination with auto-

mation technology. The combination considerably enhances the economicutilisation of the machine.

• Auxiliary processing times can be reduced to a minimum. While one workpiece is being machined the others can be mounted.

• Shorter production times increase productivity and lower production costs.• Simultaneous machining operations are carried out without interruptions in

multiple shift operations

For maximum possible efficiency, GF AgieCharmilles has developed itsown pallet magazines.

The linear type magazine can beloaded during operation and operatedvery easily via CNC control system.This ensures automated production.

Universal automation for heavy work-pieces. Pallets weighing up to 1000 kgcan be loaded in the magazine.

11

12

MIKRON HSM 400UMIKRON HSM 400, 600U

System 3RMacro Magnum

18xErowaITS 148

20xSystem 3RMacro

48x

Ergonomic loading and unloading of disc type magazine.

....Dank Automatisierung noch produktiverAutomation withdisc type magazine

Producing more parts in shorter time at lower cost.

System 3RGPS 240 x 240 mm

10xSystem 3RDynafix 280 x 280 mm

7xErowaUCP 320 x 320 mm

7x

OperationServicing

For maximum possible efficiency GF AgieCharmilles has developed itsown pallet magazines.

The disc type magazine can be loadedduring operation and operated veryeasily via CNC control system. Thisensures automated production.

A fully integrated automation solutionfor the prevalent industry standards.Pallets weighing up to 90 kg can beloaded in the magazine.

System 3RDynafix 350 x 350 mm

7x

A pallet magazine to be proud ofAutomated production is ensured inMIKRON HSM machines by cost-ef-fective integration of pallet magazine.Together with the modular tool maga-zine it serves as a compact millingcenter for a high production and flexi-ble manufacturing cell.• System 3R (Macro Magnum, GPS,

Dynafix) or Erowa (ITS 148, UPC)version.

• Repeated machining operations areexecuted without interruptions inmultiple shift operations

• Increases the economic viability ofthe machine with a correspondinglyhigher profit

We recommend: SIGMA FMC (FlexibleManufacturing Cell) and RNS (RemoteNotification System). These and othersmart machine modules guaranteestill more flexibility and processsafety in high-quality component pro-duction.

13

14

....Dank Automatisierung noch produktiverRobot Interface forautomation systems

Producing more parts in shorter time at lower cost.

Workpiece-side automation of MIKRON HSM through a robot solution.

MIKRON HSM 400U Robot Integrated withthe fully integrated FANUC robot. Loading and unloading from rear sidethrough the portal.

Thanks to the standardised robotinterface MIKRON HSM can be usedin robot systems of well-known pro-viders.

Whether it is an integrated robot or a WorkMaster by System 3R, the ergo-nomics of the machine is alwaysguaranteed.

These machines can be easily alsointegrated in a total system. Again,the accessibility is not affected.

15

Achieve more...

MIKRONHSM 400, 400U600, 600U, 800

18

Table variants3-axis

Process-oriented workpiece clamping - the integrated automation interface.

MIKRON HSM 400 interior MIKRON HSM 800 interior

Table with integrated chuck of type System 3R Dynafix

Pallet 800 x 600 mm

Table with integrated chuck of type System 3R GPS 240

Pallet 600 x 600 mm

Table with integrated chuck of type Erowa UPC

Chuck for pallets in MIKRON HSM 600/800

Origin clamping systemIn place of T-slot tables, origin clam-ping systems are used for clamping ofstandard or normal pallets. As stan-dard it includes clamping of workpie-ces while machining.

Clamping systems of the companies"System 3R" and "Erowa" are used onMIKRON HSM-400 machines.

On MIKRON HSM 600/800 near-stan-dard pallets are in 600 x 600 mm orrespective 800 x 600 mm size.

MIKRON HSM 400Up to 200 kg load capacity

MIKRON HSM 600/800Up to 800/1000 kg load capacity

19

Pallet table MIKRON HSM 600

20

Table variants5-axis

HSC simultaneous machining with quick turning.

The excellent dynamics of roundtilting tables with MIKRON HSM 400Uand MIKRON HSM 600U direct driveallows HSC simultaneous machiningin all 5 axes - a product of GF Agie-Charmilles:

• Extremely fast: turning and swivel-ling movements up to 250/min

• Extremely precise and flexible:integrated origin clamping system

• Highly dynamic during turning andswivelling thanks to the directdrives

• Extremely stable: hydraulicclamping in turning and swivellingaxis

• Ergonomic and clean: withouttroublesome edges for best accessand optimum chip fall

• All feed motors are liquid-cooled• Direct measuring system

MIKRON HSM 400UUp to 25 kg load capacity

MIKRON HSM 600UUp to 120 kg load capacity

Round tilting table with pallet chuckSystem 3R Macro Magnum Ø 156 mm

Round tilting table with pallet chuckSystem 3R GPS, 240 x 240 mm

Round tilting table with pallet chuck Erowa ITS Ø 148

Round tilting table with pallet chuckSystem 3R Dynafix 280 x 280 mm

During pallet change Round tilting table with pallet chuckSystem 3R Dynafix 280 x 280 mm

Round tilting tableMIKRON HSM 400U

21

22

Basic machine Sophisticated polymer concrete basic design for maximum rigidity.

Polymer cast machine baseThe single unit portal constructionimpresses with its high rigidity andcompact look.No loss of stability since there are nojoining points due to the monoblockprinciple.

Cross slideThe cross slide is most weight-optimised and well ribbed to meethighly dynamic requirements.

Polymer concreteStriking features of polymer concreteinclude high thermal resistance andoutstanding damping characteristics.It is not susceptible to oil or coolinglubricants and does not undergo anaging process.

Pyramid-shaped designThe pyramid-shaped arrangementadditionally ensures more stabilityand rigidity.

Closed structureThe O-shaped portal is extremelysuitable for integrated automationsolutions.

Up to 6 times better damping charac-teristics than grey cast iron.

3

�m

1

0

-1

-2

-30 0.2 0.4 0.6 s 1.0 0 0.2 0.4 0.6 s 1.0

Zeit Zeit

Grey cast iron Polymer concreteAm

plitu

de

Accuracy Maximum accuracy through direct positioning measuringsystems, cooled drives and other features.

23

Position measuring systemsAs standard all MIKRON HSMmachines are equipped with directposition measuring systems.• Long time accuracy• No negative effects of drive train

Water-cooledAll water sources in MIKRON HSMmachines are as standard water-cooled.• Drives• Tool spindle• Switch cabinet

Touch probeA compact and extremely accuratetouch probe is available as a standardoption.• Easy set-up• In process calibration• Measurement in the machine

Laser measuring systemAn accurate and reliable tool measu-rement is absolutely necessary for agood process and accurate work-pieces.Due to this laser measuring system isincluded in MIKRON HSM machinesas standard equipment.• Tool measuring at nominal speed• Wear/crack monitoring• Measuring molding tools

Quality controlBefore delivery every MIKRON HSMmachine is tested in our air-condi-tioned assembly shop among otherthings with laser measuring systemfor accuracy and quality.

LightsourceLED

Scanningreticle

Referencemark

Photo-voltaiccells

Condenserlens

Glassscale

Gratingperiod

24

High-tech spindle

Constant machining in HSC area:Core components of high-tech motor spindles.

Tool spindles for demandingmachining jobsWhichever machine configuration youselect, with a MIKRON HSM machineyou get one of the most modern toolsavailible with the latest spindle tech-nology.

The facts• Vector control for full torque in

deepest area• Highly stable ceramic hybrid

spindle bearing• Spindle jacket cooling by means of

a controlled cooling circuit forconstant temperatures duringentire working hours

• Oil-air lubrication system with usedoil suction

• Integrated "smart machine"sensors

Advantages• Precise high performance - con-

ventional, universal as well as HSCmachining

• Shorter acceleration phases• High torque at lower speeds• Thread cutting without compen-

sating chuck

The scope of delivery includes smartmachine module APS (Advanced Pro-cessing System) for reliable recordingand display of vibrations duringmilling process.

24'000 min-1 30'000 min-1 36'000 min-1 42'000 min-1 54'000 min-1

HSM 400 • • •HSM 400U • • •HSM 600 • • • • •HSM 600U • • • • •HSM 800 • • • • •

Since 1995 Step-Tec has developed,produced, sold and repaired motorspindles for leading manufacturers ofmachining centers for milling anddrilling applications. Step-Tec is able to manufacture fastrunning and precise heavy-dutyspindles with an integrated motor.Thanks to these spindles machininghours are reduced drastically withoptimum quality.

Toolmagazine

No restriction to the work area.

Tool automation in every configuration level• Single or double row tool magazine• Reliable "Pick-and-Place" system• Loading control through light beam• Capacity up to 68 tools• Tool lengths up to 210 mm• Tool diameter up to Ø 75 mm• Tool weight up to 3 kg

Operator friendly tool loadingProductivity and process safety areensured thanks to side tool loading• Simultaneous machining and

loading • Easy loading control though large

glass pane• Ergonomic access

25

Available sizes:HSK-E32 : 20; 40 toolsHSK-E40 : 16; 36; 68 toolsHSK-E50 : 15; 30; 60 toolsHSK-E63 : 30; 50 tools

Double row HSK-E40 magazine witha capacity of 68 tools.

26

Chips andliquids

Well conceived working areafor optimum chip fall.

Chip removalChip removal lies at the core of everymachining center. This process shouldbe as automated as possible andshould take place without much inter-vention from the operator. A goodconcept is the key to success.

Clean working areaMIKRON HSM machines have thesteepest possible inner casing. Thischrome steel casing facilitatesoptimum chip fall and cleaning.

Cooling lubricant through the spindle(IKZ)In this option the percentage purity ofthe cooling lubricant is of considera-ble importance. A filter is thereforeabsolutely essential.

With a well conceived combination ofan efficient chip conveyor and filteringunit, nothing stands in the way of ma-chining with through-spindle cooling.

Handling of chips and liquidsChip form and quantity as well asliquids determine the chip mana-gement.The options range from coolinglubricant tank with chip tray...

to the variants with standard chipconveyor...

and further up to the solution with achip conveyor for increased demandsor without filter unit.

27

Success stories Results with GF AgieCharmilles

MEDICAL TECHNOLOGY

Innovative SpinalTechnologies (IST)Milled and electrical discharge machinedimplants make backs mobile again

Spine implants and associated sur-gical instruments tested in its ownoperating theater makes the Innova-tive Spinal Technologies (IST) theworld leader in minimum invasivespinal surgery products. The companywith its head-office in Massachusettsdevelops, designs and produces pro-totypes for all products on its own.Key technologies used here are elect-rical discharge machining and 5-axismilling.

"MIKRON HSM 400U exactly matchesthe requirement profile of our pro-duction unit. For electrical dischargemachining also we have invested in GF AgieCharmilles machines. Wethus get excellent one-stop serviceand advice".

Jeff KazmierskiProduction manager - ISTInnovative Spinal Technologies

MOULD PRODUCTION

Krones

Pulse generator forinnovations in milling

With the production of stretch-blowmolding tools Krones AG offers itscustomers the service for producingPET bottles. For accurately detailedreproduction of customer design, theBavarian company employs the latestGF AgieCharmilles HSM machines.

"Since1999 we have purchased 20high-speed machining centres fromGF AgieCharmilles. Several timesduring this period Krones gave animpetus for new developments,which are successfully implementedtoday in MIKRON models".

Georg HofmeisterProduction team manager FE 1Blow moulding by Krones AG

AUTOMOBILE INDUSTRY

Great Lakes Mold

Unique with unmanned milling jobs

Great Lakes Mold in the US state ofMichigan makes complete injectionmolding tools for automobile, electro-nics and medical industry compo-nents. The company also supplies toolelements such as mold inserts, sli-des, ejectors and repair parts. Forthis, Great Lakes Mold uses HSC andEDM machining processes as keytechnologies in tool production.

"I know of no other milling machine,which could carry out our certainmachining jobs in unmanned opera-tion better than MIKRON HSM 800".

Ron KrissVice-President, Great Lake Moldsand Engineering

28

Options Customised equipment

Other options:

• T-slot table• Minimum-quantity lubrication• Minimum-quantity lubrication easy to dose via NC program• Rotating window• Internal coolant supply

Standard chip conveyor Cooling lubricant filtration forthrough-spindle cooling

Coolant tankMIKRON HSM 400

Touch probe Mobile handwheelSignal lamp smart machine modules(see www.gfac.com)

Operating mode 3 and 4

Chip conveyor / chip tray

Coolant tankMIKRON HSM 600/800

Chip conveyor for bringing out large chip volume

29

smart machine The new dimension in modern production

Bringing intelligence into the millingprocess is the intended aim of "smartmachine". This includes a range of modules thatare collectively referred to under thegeneric term "smart machine" andthat fulfil various functions. In order tomake the milling process "intelligent",various requirements have to be im-plemented. First of all, establishing comprehen-sive communication between man andmachine, which makes precise infor-mation that the operator requires toassess the milling process available tohim. Secondly, supporting the opera-tor in the optimisation of the process,which considerably improves the per-formance. Thirdly, the machine opti-mises the milling process, whichimproves the process safety and thequality of the workpiece - above all inunmanned operation.

The facts• Greater accuracy in shorter machi-

ning times• Increase in the workpiece surface

quality as well as the surface andshape accuracy

• Recognition of critical machiningstrategies

• Improvement in the process safety• Reduction of the hourly rate due to

longer service life• Higher availability• Better operating comfort• Considerable increase in reliability

in unmanned operation

smart machine construction kitsystemEach of the modules fulfils a specifictask. Just like in a construction kit,the user can select the modules thatseem to him to be the best option forimproving his process.

Your benefit Producing the workpieces in a pro-cess-secure and precise manner,increasing the reliability in unmannedoperation, increasing the service lifeof the machine and significantly redu-cing production costs.

The smart machine is constantlybeing developed further.

The currently available modules canbe found at www.gfac.com

30

About GF AgieCharmilles

Milling

EDM

Automation

Spindle

Service

High-Speed and High-Performance Milling Centers

In terms of cutting speed, HSM centers are 10 times faster thanconventional milling machines. Greater accuracy and a better surfacefinish are also achieved. This means that even tempered materials canbe machined to a condition where they are largely ready to use. Oneessential advantage of HSM is that with systematic integration, theprocess chain can be significantly shortened. HSM has developedalongside EDM into one of the key technologies in mold and tool making.

Electric Discharge Machines

EDM can be used to machine conductive materials of any hardness (for example steel or titanium) to an accuracy of up to one-thousandth of a millimeter with no mechanical action. By virtue of these properties,EDM is one of the key technologies in mold and tool making. There aretwo distinct processes -- wire-cutting EDM and die-sinking EDM

Tooling, Automation, Software

Tooling for fixing workpieces and tools; automation systems and systemsoftware for configuring machine tools and recording and exchangingdata with the various system components.

HSM Spindle Technology

Development, production and sale of the motor spindles that form thecore components of modern HSM centers. The spindles rotate at speedsbetween 10,000 and 60,000 rpm.

Services and Consumables

Service, maintenance, spare parts and consumables for EDM, millingand HSM systems as well as for other machine tools; consumablesinclude filters, wire, graphite, copper electrodes and special resin.

Contact

www.gfac.com

Achieve more...

Our

con

stru

ctio

ns a

re c

ontin

uous

ly a

dapt

ed to

mee

t the

cur

rent

req

uire

men

ts.

Alt

erat

ions

can

be

mad

e at

any

tim

e. T

he in

form

atio

n in

this

pri

nt is

non

-bin

ding

.

000.

000.

000