Ultra-precision in a compact box

Kern Micro Machining Centre
Kern Micro Machining Centre

Since arriving in the UK at the MACH exhibition, the Kern Micro Pro 5-axis machining centre from Rainford Precision has attracted interest in the machine tool world.

The new 5-axis machining centre has an ingenious integrated workpiece and toolchanger facility. This means it requires less than 4m² of floor space to provide manufacturers of small parts with everything they could ever need in a machine.

Built for 24/7 operation, the Kern Micro Pro is ideal for high-precision series production. Characterised by its durable stability and outstanding performance, the precision level of the new Micro Pro is in the micron range with levels well below 5μm on the workpiece during 5-axis machining.

Rainford Precision’s managing director Arthur Turner comments: “The Micro Pro is the epitome of precision. It will comfortably achieve precision levels of less than 5µm and for manufacturers educated in true precision and optimised conditions such as high-quality tool holding, workholding and other external factors, the precision and stability improves even further.”

This level of accuracy is built upon a UHPC (Ultra High Performance Concrete) base that has no disruptive interfaces and is thermo-symmetrically constructed from a single casting. This ‘one-box’ design provides a compact machine tool that is ideal for manufacturers with a limited floor area. All units are integrated in the machine with a footprint of less than 4m²; this results in an optimised height of just 2.5m and a width of just 1.59m.

Mr Turner continues: “Kern has made every effort to creatively integrate all features. This includes the tool cabinet for up to 210 HSK40 tools up to 70mm diameter which also accommodates up to 30 workpieces with a height of 200mm and a diameter up to 350mm. The tooling and component storage cabinet is completely modular and can be easily and safely accessed whilst the machine is running to minimise production downtime.”

Giving the modular configuration and space saving claims further credibility is the integrated chip conveyor and the options of integrated dust or emulsion mist extraction systems that can also be configured in the machine without requiring additional space. These features have recently been demonstrated at the IMTS and AMB exhibitions with the Micro Pro demonstrations machining graphite, which is commonly processed by toolmakers and the electronics sector for the production of EDM electrodes.

“The Kern Micro Pro also has a powerful high speed 42,000rpm spindle that increases machining speeds by well over 60-70% when compared to standard machine tools that have a 15,000 to 20,000rpm spindle motor. It can comfortably operate at well over 35,000rpm without excessive stress on the spindle and this makes the machine at least 30% more productive than alternate machining centres,” Mr Turner affirms.

Inside the work envelope is a highly dynamic rotary/swivel axis with torque motors for simultaneous 5-axis machining. The workspace has been maximised to enable machining of the largest possible workpieces thanks to intelligent design and optimum arrangement of the five axes. The X-, Y- and Z-axes offer 350, 220 and 250mm respectively with a 360° rotary axis and 200° swivel axis.

Furthermore, the Kern software specialists have focused intensively on the issue of warm-up times. For some machine tools, the warm-up cycle is a time-wasting necessity when working at particular precision levels. The new Micro Pro will require virtually no warm-up period, hitting impressive SPC levels from the moment the machine is fired-up.

This is underpinned by innovative software developments with Industry 4.0 suitability that includes online remote diagnostic access for fast analysis and process optimisation. The software also incorporates permanent collision monitoring of the workspace elements that includes dividing attachments, laser, chuck, spindle head and toolholder.

Rainford Precision www.rainfordprecision.com

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