Smart machining solutions from WFL

In 2020, Austrian machine tool specialist WFL channelled decades of expertise into a machine that has been entirely redeveloped in terms of its design and technology. ‘Smart machining’ is at the heart of the technological innovations at WFL, bringing about an increase in performance through a diverse range of machining technologies.

WFL says the range of applications covered by the M20 is almost infinite; it is capable of carrying out the demanding and complex machining tasks found in the aviation, automotive, engineering and plastics industries.

A particular highlight is the innovative design of the machine. The M20 Millturn has a one piece, straight-lined appearance, with a modern, functional design. The front of the machine is manufactured from hardened glass and features an integrated display of performance data as well a sliding window to the tool magazine. The machine's fresh appearance is further supported by new livery and a design that incorporates optimum ergonomics as well as convenient, user-friendly operation.

A small machine for every task

When developing the M20, the objective was to introduce a compact and rigid machine designed for long-term accuracy. With a length of 5,500mm, a depth of 3,190mm and a height of 2,500mm, the M20 is ideal for machining a diverse range of workpieces.

It comes complete with a 250mm or 315mm diameter chuck with impressive travels of 575mm (+475; -100) in X, 260mm (±130) in Y and 1,250mm in Z. The machine is suitable for machining workpieces up to 500mm diameter and is equipped with a powerful 44kW (32) main spindle at 40% (100%) duty cycle and 4,000rpm.

The M20 is equipped with a B-axis and a swivel range of ±120° for unlimited contour machining, as well as with a new 20,000rpm milling spindle. This means that there is a universal range of possible applications for the use of high-speed tools. The motor spindle system is designed as a compact cartridge assembly with housing flange interface.

The frame is made from spheroidal graphite, which is strong and guarantees excellent damping characteristics. Through the solid construction – which incorporates vibration-absorbent cast components for optimum rigidity – even heavy cuts are vibration-free. Large spaces between the guide rails and trolleys on the slide guides also ensure a high degree of system rigidity.

The configuration of the machine allows for a wide range of possibilities: a traditional machining centre with steady rest and tailstock; a counter spindle machine with tool turret or an individual tool holder at the bottom; as well as an optional integrated workpiece handling system.

Tool management and automation

The tool magazine can hold a maximum of 40 or optionally 80 tools with HSK-63 or PSC63 (Capto C6) accommodation. The maximum tool weight is 10kg and the maximum tool diameter is 90mm (adjacent) or 130mm (non-adjacent).

In addition, the lower compound slide with tool turret can hold 12-24 tools. If necessary, the machine can be equipped with a bar feeder. A particular highlight is the automatic tool change into the lower individual toolholder with B-axis. This makes it possible to set up the tools during machining and then automatically access tools in the magazine. Stored tools can therefore be placed in the upper and lower tool holder. The internal coolant supply to the toolholders is 80 bar maximum.

Based on specific customer requirements, a range of automation options are available for automatic workpiece loading and unloading. An integrated workpiece handling and/or loading system, which can be added on the right side of the machine, represents a completely new variant of automation. The main guide rail for the handling system runs into the working area from the right. The gripper slide moves on the guide piston and can load and unload workpieces. Components are stored on a strip accumulator.

High dynamics for demanding tasks

The integrated motor spindle concept turns high dynamics into a reality. The M20 is ideally suited to universal and demanding machining processes. The X travel at -100 mm beneath the centreline also opens up new opportunities for complete machining.

A drill pattern with a circumference up to 200mm diameter can be drilled by moving the XY coordinates, without moving the workpiece. The two B-axis systems in the machine also offer possibilities for machining thin-walled, funnel-shaped turbine parts.

Simultaneous B-axis turning is also a highlight. The interpolating NC-driven B-axis is also suitable for turning with a pivoting axis. Through the continuous adjustment of the setting angle during a cut, a complex contour (e.g. for turbine wheels or piston heads for large diesel engines) that would normally require multiple tools can be produced in a single cut. This reduces the number of turning tools required and produces a seamless machining result.

New operator panel with a modern design

For the control, WFL relies on Siemens technology, namely the 840D sl with IPC 477E industrial flat panel touchscreen interface which offers fast response times for instantaneous screen updates. The multitouch widescreen variant in 16:9 format and full HD (1920 x 1080) is installed on the M20 Millturn.

Another noteworthy characteristic is the fact that the display can be divided and various programs can be displayed on multiple sub-sites. This allows functions such as WFL iControl process monitoring, graphics, programs, statistics and real-time data to be displayed simultaneously.

All of this helps optimised performance. The CrashGuard, CrashGuard Studio and Millturn Pro programs can be displayed in the header bar in a clearly structured way. The window below is used to display information on axis loads, tools, the CrashGuard Viewer, axis movements in real- time and more. This provides operators with a large number of options for monitoring the manufacturing process

In the UK, WFL machines are sold and supported by Kyal Machine Tools

Kyal Machine Tools www.kyalmachinetools.co.uk

WFL www.wfl.at