Tag Archives: high precision machining

5 axes milling and more

While some are always concerned about the Euro crisis and the issues that it is supposed to result in the real economy, others continue to work and to operate their plant as they have always done. This is particularly true for Hermle the German manufacturer of machine tools. Important investments, new products and successful in-house exhibition displaying a record of visitors, attest the success of its strategy.

The C22U Dynamic machining center with the PW 150 pallet loading system. At the foreground the equipment position.

Last year, the company was not only able to realise his second best annual gross sales, but also, in December 2011, the all-time monthly record turnover. This allowed the company to strongly invest in the realization of a new logistics center and in the optimization of the assembly dept. Currently the order backlog is well filled. However, no one is immune to branch-specific short-term fluctuations. But Hermle seems to be able to respond properly and with flexibility.

C 22 U machining center now with Automation
The high performance C 22 U dynamic CNC machining center of Hermle, developed in 2010, can now be fully automated through the PW 150 pallet change system. Specially designed for the dimensions of the parts machined in the C 22, it can handle weights of up to 250 kg, including the pallet. The system consists of an NC controlled drive unit and a turning unit with double gripper. Both units are positioned compactly on the left next to the machine and allow completely free access to the working area of the machine. The pallet changer does not have to be dismounted for transportation, it does not require a floor mounting and is adapted quickly and easily to the machine at the customer’s.

Double gripper
The key feature of the pallet changer is the double gripper which can be used to simultaneously move two pallets in or out with 150 kg transport weight each or, for a one-sided application, one pallet with up to 250 kg transport weight. The maximum workpiece cube has a diameter of Ø 400 mm with a maximum workpiece height of 370 mm.
This corresponds approximately to the workpiece dimensions of the C 22 to be machined. The standard design can handle up to 6 pallets, with the additional storage up to 11 pallets. The side setup station (optionally rotatable) offers ideal conditions for setup in parallel to production time.

Intelligent loading
Pallet change procedure: The spindle moves to the park position into the tool magazine. The top and the expansion bellows of the left side wall are opened together and therefore provide access to the drive unit/turning unit with adapted double gripper. Meanwhile the double gripper docks with a pallet and moves it through the side access of the machining centre into the working area. The free side of the double gripper docks with and lifts the finished part pallet on the NC swivelling rotary table. Rotated through 180°, both pallets are replaced and the blank pallet is placed on the table. The drive unit/turning unit conveys the finished part pallet into the storage or into the setup station

Maschinenfabrik Berthold Hermle AG
Industriestraße 8-12
78559 Gosheim • Germany
Tel.: +49 (0) 7426 95-0
Fax: +49 (0) 7426 95-6110
[email protected]

CERN relies on microtechnology machining

With its 10’000 users – staff, researchers, colleagues from other institutes etc., the European Organisation for Nuclear Research CERN, which is headquartered in the canton of Geneva, Switzerland, is the largest research centre for particle physics in the world. At CERN, wide-ranging fundamental physics research activities are carried out with the help of a series of accelerators, including the LHC (Large Hadron Collider).

One of CERN’s very interesting research projects is the study of a new accelerator concept, the CLIC (Compact Linear Collider), an electron-positron machine 48.3 km long and with a centre-of-mass energy of up to 3 TeV. The new concept comprises a linear two-beam accelerator in which the counter-rotating beams interact at a designated collision point in the centre of the machine.

High precision machining
And this is where Kern Micro- und Feinwerktechnik comes into the picture. One of the key components for this project is a part manufactured by Kern: the PETS (Power Extraction and Transfer Structure), an 800 mm long copper rod made of highly conductive, oxygen-free copper with a high-precision, toothed comb profile. Eight of these copper rods (PETS) running parallel to one another are installed in an octagonal arrangement. An electron beam is then passed through this arrangement at the speed of light and some of the beam energy is extracted in the form of high-frequency microwaves. This power is then used for the acceleration process as such in a second parallel accelerator, with the copper surfaces being exposed to huge electromagnetic fields in the process.

Fully hydrostatic
To reach the very high precision needed, Kern offered its star performer – the Kern Pyramid Nano! Faced with this very demanding challenge, the machine’s key innovations come to the fore, i.e. its completely hydrostatic guides and drives. These run on a constantly controlled 15 µm thick hydraulic oil cushion. The Kern Pyramid Nano is one of the very few milling machines in the world on which the workpiece is not moved by mechanical components. Positioning accuracy is only possible if the friction is equivalent to zero – as is the case with the Kern Pyramid Nano.

KERN Micro- und Feinwerktechnik GmbH & Co.KG
Olympiastr. 2
DE-82438 Eschenlohe
Tel +49 (0)8824 9101 281
Fax +49 (0)8824 9101 124
[email protected]

We will detail this success story in one of our next issues.