New innovations in the micro range

Since its introduction in 2019, the Micro HD 5-axis machining centre from Kern has firmly established itself in the marketplace. It is expected that by the end of 2022 at least 40 machines will be delivered. PES hears about the latest innovations developed for the machine.

German machine builder Kern Microtechnik says it is setting new standards again for its Micro HD machining centre. In order to further increase the productivity of the high-end machine for a wide variety of applications, the company's engineers have developed innovative additional options that it says guarantee major advantages.

Making its specifications better is as difficult as it is important, so Kern invests heavily in the development of its machines – particularly where technological advances are concerned.

Technical director Sebastian Guggenmos comments: “We are constantly in contact with our customers, partners and scientific research partners to encourage suggestions and potentially realise them in our new machine developments.”

Among other things, Kern has succeeded in integrating a new generation of shaft-cooled spindles which can fully exploit the machine tool’s strengths, particularly in combination with the microgap technology built into the Kern Micro HD. Known as the CSC spindle (Compact Shaft Cooled) and equipped with HSK 40 toolholding, it reduces shaft growth, extends spindle service life, increases the general machining performance and shortens the tool spindle's run-in times by a further 80%. 

Mr Guggenmos is enthusiastic about the improvements that have been achieved with the latest spindle technology introductions.

He explains: “The spindle is temperature-stable after a very short time, even with the speed increases. With this feature, the highest accuracy values can be achieved immediately on the workpiece and for our customers this significantly increases precious machining uptime. In addition, probing processes for workpiece inspection can be made much more efficient.”

Integrated cooling

The basis for the spindle improvements is a newly designed, integrated cooling process. The bearing-less rotary joint of the shaft cooling system is extremely compact. Thus, the dimensions of the CSC spindle remain almost unchanged compared to the standard spindle.

On request, it can also be installed in existing machines according to Kern, meaning an increased speed of 45,000rpm as an additional advantage. This is about 3,000rpm above the default value, which means an additional increase in productivity during the machining process.

Equally interesting for many operators is the option to set priorities intuitively and quickly with the new software feature ‘Advanced Setting’. While the three parameters of speed, accuracy and surface quality are equally balanced in standard operation, they can now be adjusted as required.

For example, if the operator wants to optimise roughing, prioritising the processing speed can help. This allows roughing to be accelerated by up to 30% compared to standard operation, which raises the productivity of the machining centre to a new level.

If the finish depends on maximum shape efficiency or on surface quality in the nano range, the user can also set the appropriate parameters in the program. The selection can already be made during programming. A mouse click with a change of a parameter is sufficient, and the desired cycle is integrated. 

Automatic coolant adjustment

As another option, Kern now offers coolant nozzles that automatically adjust to the tool tip which eliminates the need for manual readjustment. The nozzles correspond to the stored tool database and the tool length entered into it. This way, the coolant always does its job exactly where it is needed most – at the tool centre point. An additionally integrated blow-out function also ensures reliability of the coolant nozzles in the long term. As a result, the tools are further protected and their service life is increased.

Last but not least, on the new Kern Micro HD machines it will be possible to retrofit ‘coordinate grinding’ – an option that is already popular with some users on the machine builder’s latest models. Until now, this was not possible because of several differently structured individual components.

Machine building and contract manufacturing

Kern Microtechnik, employs 200 people and operates successfully in more than 30 countries worldwide. The focus is on two business areas. The development and manufacturing of high-precision machining centres and the contract manufacturing of milled parts in the micro and nano range.

Milling centres from Kern are used in its contract manufacturing series production. Customers become technology partners and are a part of the Kern family. Advice for ideal operation and process integration is always available – from initial concept to finished part. This enables Kern customers to increase their profits and competitiveness.

Kern’s contract manufacturing product portfolio includes prototypes, single item and serial production as well as assembly work. Parts are produced via a multitude of processes including milling, drilling, EDM and grinding.

Kern machines are sold and supported in the UK by Middlewich, Cheshire-based Rainford Precision.

Rainford Precision
https://rainfordprecision.com

Kern Microtechnik
www.kern-microtechnik.com