MIKRONHSM 400 LPHSM 400U LPHSM 500 LPHSM 600 LPHSM 600U LPHSM 800 LP

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MIKRON HSM 400 LP / 500 LP MIKRON HSM 400U LP

High-speed milling - universal approach to mold-making and production

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Contents

GF AgieCharmilles presents newreference machines in 3-axis and 5-axis versions for high-speedmilling.

Based on the concept of the presentHSM series, GF AgieCharmillesengineers have developed three newmachine models which represent

optimal answers to all aspects of 3-axis and 5-axis high-speed millingneeds. The HSM LP series (LP = Line-ar Performance) were designed forultimate precision and supreme sur-face quality. The necessary designmeasures focus on the machine bed,cooling, axis drives, motion controland tool measurement.

These vertical high-speed machiningcenters, developed for tool and moldmanufacturing as well as medium-and small-series production of high-quality parts, combine the Swissmachine manufacturer's entiretechnical expertise and extensivedevelopment experience.GF AgieCharmilles.

MIKRON HSM 600 LP / 800 LP MIKRON HSM 600U LP

Applications 3-axis 45-axis 6

Highlights 8

Table versions 10

Basic machine 11

Feed axes 12

Precision 13

Automation 18

Interface for automation systems 20

High-tech motor spindle 22

Tool magazine 23

Chip and Dust management 24

Option: ProdMod 26

Options 28

smart machine 29

About GF AgieCharmilles 30

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MIKRON HSM 400 LP MIKRON HSM 500 LP MIKRON HSM 600 LP MIKRON HSM 800 LP

Applications3-axis

HSC milling of a prototype mold insert

DieMIKRON HSM 800 LPAlloyed tool steelTool and mold making• Surface quality• Shape accuracy• Positional accuracy

Watch components MIKRON HSM 400 LPDifferent materialsWatch making industry/ micro-mechanics• Shape accuracy• Smallest geometries• Parts-specific handling

systems

Electrode MIKRON HSM 400 LPTungsten-copperTool and mold manufacturing• High surface quality• Shape accuracy• Very small geometry features

Ball screw drive Linear direct drive

Graphite electrode MIKRON HSM 600 LPGraphiteMold making• High contour accuracy• Efficient graphite machining

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MIKRON HSM 400U LP MIKRON HSM 600U LP

Machining of mold work in 5-axis simultaneous operation

Applications5-axis

Closed impeller MIKRON HSM 400U LPAluminiumAutomobile industry• 5-axis simultaneous machining• Perfect kinematics insure machining

of complicated geometries

Impeller MIKRON HSM 600U LPTitaniumAutomobile industry• 5-axis simultaneous machining• High vibration damping• Strong cutting ability

Tire moldMIKRON HSM 600U LPAluminiumAutomobile industry• 5-axis simultaneous machining• High feed rates• Thin-walled geometries

MedTechMIKRON HSM 400U LPTitanium / CoCrMedical technology• Adequate spindle performance• Process stability • 5-axis simultaneous machining 24/7• Greatly improved tool life

Casting moldMIKRON HSM 400U LPAlloyed tool steelTool and mold making• High surface quality• 5-axis simultaneous machining of thread

with undercut section

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Highlights Precision and quality for tool- and mold-making as well as accurate part manufacturing

Robust tool spindle with vector control and ceramic hybrid bearings

Flexible workpiece

automation

Crane loading High-performance

machine controlDirect drives on all axes: X, Y, Z, B, C

Machine hood for thermal

and acoustic insulation

Stability and dampingPrimary prerequisites for maximum precision andbest workpiece surface quality include dampingand stability of the components:• Monolithic design• Highly stable portal construction• Machine base of mineral cast with high damping

characteristics• Optimised force distribution within castings

MIKRON HSM 400U LP

MIKRONHSM 400 LPHSM 500 LP

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Robust tool spindle with vector control and ceramic hybrid bearings

Flexible workpiece

automation

Crane loading High-performance

machine controlDirect drives on all axes: X, Y, Z, B, C

The MIKRON HSM LP series impresses with the unrivalled accessibility, regardless of their particular configuration

Ergonomics and process reliability…are key features of this machine series:• Equally accessible in all upgrade levels -

thanks to workpiece automation via the portal• Excellent view into the workspace• Access to the workpiece from three sides • Crane loading• Side window to optimally monitor machining

MIKRON HSM 600U LP

MIKRONHSM 600 LPHSM 800 LP

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• Extremely dynamic and fast:Rotation and swivelling with directdrives in the B and C axis up to 250 min-1

• Extremely accurate and precise:Liquid-cooled motors and absolutemeasuring systems

• Extremely stable and flexible:hydraulic clamping in the rotationand swivel axis plus integratedzero-point clamping system with aB-axis swivel range up to 220°

Table versions

3 axis versions

5 axis versions

As flexible as needed

Greatly reduces unproductive timesFully integrated zero-point clampingsystems from manufacturers System3R and Erowa.

Round tilting table with chuck • System 3R Macro Magnum• Erowa ITS

Round tilting table with chuck • System 3R Dynafix• System 3R GPS• Erowa UPC

MIKRON HSM 400 LP with chuck• System 3R Dynafix• System 3R GPS• Erowa UPC

MIKRON HSM 600/800 LP with chuck

Machine tool sizeTravel X, Y, Z: 600/800x600x500 mm

Machine tool sizeTravel X, Y, Z: 500 x 450 x 360 mm

MIKRON HSM 500 LP 200 kg MIKRON HSM 600 LP 500 kgMIKRON HSM 800 LP 1000 kg

MIKRON HSM 600U LP 120 kgMIKRON HSM 400U LP 25 kg

MIKRON HSM 400 LP 120 kg MIKRON HSM 600 LP 500 kgMIKRON HSM 800 LP 800 kg

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Basic machine For uncompromising demands

Pyramidal constructionThe pyramidal structure ensures bothoptimal dynamic to static mass distri-bution and a perfect distribution ofcutting forces.

Closed structureThe O-shaped portal is outstandinglysuitable for automation solutions byGF AgieCharmilles or other manu-facturers.

Polymer concreteThe polymer concrete features highthermal inertia and excellent dampingproperties.

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

Time Time

Grey cast iron Polymer concreteAm

plitu

de

Moving slidesThe weight and rigidity of the crossslide are optimised to stand up to thehigh dynamic requirements.

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Feed axis Reconciling dynamics and precision

Dynamics and precisionMechanical drive systems have a basicdisadvantage: a loss of precisionmust be accepted to achieve a highlydynamic configuration. This effect isnot relevant for customers in auxiliarymotions such as tool changing oraxial positioning. An HSC machinechanges the situation: During cuttingcontrol, high dynamics must be com-bined with great precision. This iswhere the linear direct drive showsall its advantages.

• Short setting time • No oversteering through drive play

and elasticity • High dynamic rigidity of the attitude

control • Independent of slide position

Advantages• Oustandingly precise, accurate

workpiece machining due to theextremely rigid drive and controlconcept.

• Excellent long-term precision dueto the reduction of friction-inducedwear by the direct drive and centraloil lubrication

• Reduction of main operating timesdue to extremely high dynamicparameterisation (OSS)

• Reduction of auxiliary times by highrapid-traverse speeds

• Reduction of maintenance andservicing, since the lack of ballscrew drives or transmissionsreduces the number of wearingparts.

Linear directdrive

Central oillubrication

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Dynamic precision

Path measurement systemsDirect path measurement systems in the linear and rotational axis arestandard equipment on all MIKRONHSM LP machines.

• Tried and tested Heidenhain pre-cision

• Resolution in the nanometer range• Protected by sealing air

Precision HSC core components: Static and dynamic precision

Static precision

Swiss thoroughnessBefore delivery, every MIKRON HSMLP machine undergoes an extensivequality check in our air-conditionedassembly hall in accordance with GFAgieCharmilles acceptance guideli-nes. Quality-consciousness means addedvalue.

LightsourceLED

Scanningreticle

Referencemark

Photo-voltaiccells

Condenserlens

Glassscale

Gratingperiod

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Precision HSC core components: Thermal precision

Cooling conceptThe MIKRON HSM LP series ushers in a new era of precision cut-ting. Since high axis feeds over longperiods always heat the drive assem-blies, the MIKRON HSM LP seriesbeats the problem with an ingeniouscooling management system. Each ofthe linear axis as well as the circularswivel unit have their own cooling cy-cles. The heat is therefore systemati-cally led out of the machine instead ofbeing distributed inside it. This safe-

Tool spindleEven greater precision with Step-TecOpticool technology• Cooling of the front roller bearings• Low thermal flow in the tool inter-

face• Increases accuracy when working

with the measuring probe on themachine

Measuring probeEven greater precision with new Ther-mo-Lock measuring probe technology. • Easy set-up • Inhibits thermal flow between mea-

suring probe and tool spindle• Increases accuracy when working

with the measuring probe on themachine

• Two strong partners: Thermo-Lockand Opticool

Thermal precision

HSM 400(U) LP

Time

guards geometric stability, which inturn ensures extremely high motioncontrol repeatability.

All electrical heat sources in theMIKRON HSM LP machines arewater-cooled.

• X, Y, Z, B, C drives• Tool spindle with Opticool techno-

logy• Electrical cabinet

Uncompensated thermal growth in amachine axis

Standard

Five separate cooling circuits

Liquid cooled primary and secondary drive

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Precision ITM - the breakthrough in tool measuring

ITM (Intelligent Tool Measurement)ITM tool measurement registers theentire tool tip up to ø 12 mm onmodern imaging sensors. Specialsoftware digitally cleans and mea-sures the digitally captured toolgeometry. An idea takes concreteshape: For the first time, ITM makesit possible to measure tools on aMIKRON machine with micrometer-range repeatability.

D = 0.196 mm

Detection of foreign particles

Measurement of smallest tool diameters

Test-piece with continuously increasing Z-level.Step to step: 2 �mOrthogonal cutting to zero point Z-level withintermittent measuring cycle of employedspherical cutting tool.

+1 �m

�

�

+4+2

0-2

+6

+4

+6

+2

0

-2

2 �m

+1 �m

D =

0.4

mm

s

=38

’200

min

-1

D =

0.6

mm

s

=19

’100

min

-1

D =

4 m

m

s =

12’7

00 m

in-1

Achieve more...

MIKRON HSM400 LP, 400U LP, 500 LP600 LP, 600U LP, 800 LP

5 axis versions

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....Dank Automatisierung noch produktiverAutomation Disc type or linear type magazines -more parts in shorter time at lower cost

Pallet magazine is a major plusGF AgieCharmilles has developed itsown compact pallet magazines withcustomer requirements in mind. The disc and linear magazines can beloaded during operation and the CNCcontrol is very easy to operate.

MIKRON HSM 800 LP 800 kg

Erowa UCP 320 x 320 mm

7x

System 3R Dynafix 350 x 350 mm

7x

System 3R Dynafix 280 x 280 mm

7x

System 3R GPS 240 x 240 mm

10x

MIKRON HSM 600U LP 90 kgMIKRON HSM 400U LP 25 kg

Erowa ITS Ø 148 mm

20x

System 3R Macro MagnumØ 156 mm

18x

GF AgieCharmilles 600 x 600 mm

4x

GF AgieCharmilles 800 x 600 mm

4x

Machine tool sizeTravel X, Y, Z: 600/800x600x500 mm

Machine tool sizeTravel X, Y, Z: 500 x 450 x 360 mm

Erowa UCP 320 x 320 mm

7x

System 3R Dynafix 350 x 350 mm

7x

System 3R Dynafix 280 x 280 mm

7x

System 3R GPS 240 x 240 mm

10x

3 axis versions MIKRON HSM 600 LP 500 kgMIKRON HSM 400 LP 90 kg

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MIKRON HSM 600MIKRON HSM 800

MIKRON HSM 400MIKRON HSM 400U

MIKRON HSM 600U

Ergonomic loading of the disc and linear typemagazine during workpreparation

Disc type magazine

Linear type magazine

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....Dank Automatisierung noch produktiverInterface for auto-mation systems

Customer specific solutions - more parts in shorter time at lower cost.

Loading and unloading takes place frombehind through the portal.

A standardised robot interface allowsthe MIKRON HSM LP series to beoperated with robot systems fromreputable providers.

Regardless of the handling systemused, the accessibility of the machineremains outstanding even whennetworking with other machines.

Automation interface (closed)

Automation interface(open)

Limitless possibilities.

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High-tech motor spindle

HSC core components from Step-Tec

Tool spindles for challengingmachining tasksWhatever machine configuration youchoose, a MIKRON HSM LP machinegives you state-of-the-art tool spindletechnology.

The facts• Vector control for full torque in the

lowest range• Ultra-stable ceramic hybrid spindle

bearings• Spindle mantle cooling by means of

a controlled coolant cycle for con-stant temperatures throughoutworking times

• Oil-air lubrication system withsuction disposal of used oil

• Integrated "smart machine" sen-sorics

• Cooling between tool interface andfrontal spindle bearings in theOpticool spindles

You benefit from• Precise high-performance• Shorter acceleration phases• High torque• Thread cutting without compen-

sation chuck

The delivered package includes thesmart-machine module APS (Advan-ced Processing System) for reliabledetection and display of vibrationsduring the milling process.

Step-Tec has developed, produced,sold and repaired precision high-per-formance spindles for leading manu-facturers of machining centers formilling and drilling applications since1995.

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

HSK-E40 HSK-E50 HSK-E40 HSK-E32HSM 400 LP • • •HSM 400U LP • • •HSM 500 LP • • •HSM 600 LP • • •HSM 600U LP • • •HSM 800 LP • • •

Opticool

Opticool

Opticool

Opticool

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Tool magazine Individual solutions tailored to your production needs

Tool automation in every configuration level• Simple or double-row disc magazine• Reliable "pick-up" changing system• Feed control via light beam• Capacity of up to 68 tools with magazines internal to the machines standard

footprint• Orientation of the touch probe

Optionally available in a variety of capacities:MIKRON HSM 400 LPMIKRON HSM 400U LPMIKRON HSM 500 LPHSK-E40 : 18; 36; 68 toolsHSK-E32 : 20; 40 tools

Double-row HSK-E40 magazine internal to the machines standard footprint with acapacity of 68 tools

User-friendly tool feedingProductivity and process reliability areensured by lateral tool feeding• Simultaneous machining and

feeding • Simple feed monitoring through

large glass panel• Ergonomic access

MIKRON HSM 600 LPMIKRON HSM 600U LPMIKRON HSM 800 LPHSK-E50 : 15, 30, 60 toolsHSK-E40 : 18; 36; 68 tools

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Chip and Dustmanagement

Clean workspace

Equipment versionsChip forms and volumes aredetermined by the work material andthe machining strategy. The optionsoffered range from an emulsion cool-ant tank with chip flushing to versionswith cutting oil and coolant tempera-ture stabilisation ...

or with a lift-up chip conveyor with chip auger.

To increase the tank capacity an ex-ternal filter system of 650 l is alsoavailable.

Vacuum removal of graphite

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Option: ProdMod

Automated parts production: 24/7

Air blast through the spindle centerand/orThrough spindle coolant (TSC)With TSC up to 70 bar you can bringthe cooling lubricant with high pres-sure and process reliability to thecutting edges of the tool. Differingtool diameters do not require newalignment of the coolant hoses.The purity of the lubricant effects thelife time of the spindle. A filter systemis therefore essential.

Thanks to its flexibility and reliabilitythe MIKRON HSM ProdMod productseries is a benchmark for automatedproduction of high quality parts.

• Efficient management of chips• A flushing system reliably keeps the

workspace doors free of chips.• Feed of coolant through the center

of the spindle• Extended tool-storage capacities

E40 (168x or 308x)E50 (120x, 170x, 220x)

• Integrated laser tool measuringsystem

Extended tool magazineThe tool storage device external tothe machines standard foot-print isbuilt as a circular hanger with up to308 tool positions. Time for changing tools: < 2 sec.Time for preparing tools: < 10 sec.

Built to withstand tough productionconditions

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Options Tailor-made equipment

Further options:

• Rotating window• Dust extraction system• Beacon• Laser tool measurement• ITM (Intelligent Tool Measurement)• ...

High performance band filterunit

Mist extraction system

Touch probe TIAutomation interface (open)Automation interface (closed)

Cutting oil package with temperature stabilisation

Lift-up chip conveyorChip flushing Spiral chip conveyor

smart machine (www.gfac.com)

Mist extraction system

Minimum quantity lubrication

Cooling lubricant container

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smart machine The new dimension in modern production

Bringing intelligenceinto the millingprocess is the inten-ded aim of "smartmachine".

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 machine set 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 further developed.

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

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 beimplemented. 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.

Protection

Precision

Productivity

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About GF AgieCharmilles

Milling

EDM

Laser

Customer Services

Automation

High-Speed and High-Performance Milling CentersIn 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 materialscan be machined to a condition where they are largely ready to use.One essential advantage of HSM is that with systematic integration,the process chain can be significantly shortened. HSM has developedalongside EDM into one of the key technologies in mold and tool making.

Electric Discharge MachinesEDM can be used to machine conductive materials of any hardness (forexample steel or titanium) to an accuracy of up to one-thousandth ofa 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.

Laser ablationLaser ablation supplements and extends the technologies offered byGF AgieCharmilles. With our laser technology we enable you to producetexturizing, engraving, microstructuring, marking and labeling of 2Dgeometries right through to complex 3D geometries. Laser ablation,compared to conventional surface treatment using manual etchingprocesses, offers economic, ecological and design advantages.

Operations, Machine and Business SupportCustomer Services provides with three levels of support all kind ofservices for GF AgieCharmilles machines.Operations Support offers the complete range of original wear partsand certified consumables including wires, filters, electrodes, resin andmany other materials.Machine Support contains all services connected with spare parts,technical support and preventive services.Business Support offers business solutions tailored to the customer’sspecific needs.

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

Contact

www.gfac.com

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© Agie Charmilles SA, 2011The technical data and illustrations are not binding.They are not warranted characteristics and are subject to change.

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