s181 Bar stock milling/turning centre with two workstations Ken Otzel /President High Performance Machinery (508)958-5565 ~ [email protected] 2 s181 MORE THAN COST- EFFECTIVE PARTS The s181 product line combines the best "Swiss made" expertise with a high degree of innovation. With its double machining station concept, a 30,000 rpm spindle (40,000 rpm as an option) and an extensive tool capacity, the s181 produces extremely complex parts from bar up to 32 mm in diameter. A mineral cast frame, the latest generation numerical control and linear motors ensure uncompromising thermal stability and performance. Whether you are producing watch parts, surgical implants or instruments, the s181 represents a major asset in helping you overcome current and future market challenges. Watch-Making Medical Micro-Mechanics Electronics SWISS M ADE s181 An innovative concept to boost productivity by up to 40% thanks to simultaneous operations on 2 workstations. 2 machining stations Machine holds up to 90 tools Tool change time < 1.1 s 30,000 rpm tool speed Linear drives 5 simultaneous axes Combined milling/turning CNC FANUC 31iB-5 control Footprint < 4 m2 4 s181 STEP-BY-STEP PERFORMANCE Example: Surgical instrument Steel type: AISI 316L Bar diameter: 14 mm Number of tools: 14 0 1 2 3 4 5 6 7 Single spindle machining centre s181 144’’ 38% 399’’ higher productivity 244’’ 144’’ 244’’ 255’’ 11’’ 11’’ Production cycle : 6’39’’ Production cycle : 4’15’’ Sectioning Bar operations Pickup operation Time savings Production times were measured during production of a high quality endoscopy forceps. AREAS OF APPLICATION DENTAL WATCH-MAKING Implant Bracelet links MEDICAL JEWELLERY PEEK cage MAKING Rings 38% higher productivity AEROSPACE ORTHOPAEDICS Injector Bone plate INSTRUMENT WATCH-MAKING Endoscopy forceps Watch case 6 s181 ELECTROSPINDLE - Attachment: HSK-T/E40 or Capto C4 - Max. power: 6 kW - Max. torque: 7.6 Nm - Max. rpm: 30,000 rpm (40,000 rpm as an option) TOOL CHANGERS - Electromechanical system - Tool change time : 1.1 s - Capacity: 30/60/90 tools - Max. diameter: 80 mm TS27R TOOL MEASUREMENT PROBE OR NC4 LASER - Length measurement - Tool breakage detection MAIN SPINDLE - Bar capacity: 32 mm - Max. power: 11 kW - Max. torque: 40 Nm - Max. rpm: 6000 rpm TOOL GROUP (STATION 2) - Number of tools: 5 - Max. power: 3 kW - Max. torque: 4.4 Nm - Max. rpm: 8000 rpm (28,000 rpm as an option) - HSK-C32 or ER16 attachment - Automated tool length and tool breakage detection 8 s181 TECHNOLOGICAL BENEFITS 30,000 RPM ELECTRO- SPINDLES Greased for life HSK-T/E40 or Capto C4 attachment Tool indexation by means of spindle encoder High rigidity Index turning tools at 360° Mechanical locking system ensuring perfect positioning of turning tools with no load on the ball bearings Integrated elongation measurement sensor (optional) 40,000 rpm (optional, air/oil lubrication) PICKUP VICE Pneumatic vice with adjustable force Option to add a second pickup function 3 axes (U, W, E) Two approaches to grip the workpiece FRONT LIVE TOOLS 5 tools HSK-C32 or ER16 Modular 8000 rpm (28,000 rpm optional) Tool breakage test (optional) TOOL BREAKAGE TESTS The tool breakage test is carried out concur- rently Different options are available when tool breakage is detected: - Production is stopped - Wait for confirmation to carry out the following operation - Selection of a sister tool Time saving > 25 s per production cycle with 12 tools using the tool check on the machine AUTOMATIC TOOL CHANGER Electromechanical system Tool switching in 1.1 s Capacity for 30/60/90 tools Max. diameter of 80 mm Max. length of 120 mm NUMERICAL CONTROL CNC FANUC 31iB-5 panel Integrated industrial PC 15’’ colour screen "Human-machine" interface adaptable on standard PC 10 s181 s181, A CONSOLIDATION OF TECHNOLOGIES 2 machining stations Machine holds up to 90 tools Tool switching in < 1.1 s 30,000 rpm tool speed Linear drives 5 simultaneous axes Combined milling/turning CNC FANUC 31iB-5 panel Footprint < 4 m2 LINEAR MOTORS Y - Z CONCURRENT WORK ERGONOMICS MINERAL CAST FRAME LINEAR DRIVES Y-Z Highly dynamic No wear Compact Smooth movements FRONT LIVE TOOLS Concurrent work Time savings of up to 40% thanks to the double simultaneous machining station 4 back working axes in order to unload the work- piece concurrently Reduced downtime Tool breakage test carried out concurrently Visual tool check MINERAL CAST FRAME Thermal stability Better damping of vibrations Modular High standard of surface finishes Longevity of tool service life Mineral cast Standard cast 12 s181 CLAMPING METHODS MAIN SPINDLE A solution adapted to each workpiece thanks to clamping pressure adjustment, ensuring the most delicate or solid workpieces to be secured. Different options are available and other tailor-made systems can be developed based on your requirements. F16 collet 100 mm 3 jaw chuck collet F35 collet Ottet collet clamping hub F37 collet 1 mobile jaw fixture F38 collet fixture Special customer fixture VICES The versatility of the Bumotec s181 enables production of the most diverse and complex parts in a single production cycle. Different options are available and other tailor-made systems can be developed based on your requirements. The 2 sides of the back working unit can be fitted with clamping devices. Side A Collet Collet KZS-P64 KZS-P100* Side B Common Collet base KZS-P64* Internal and external mini Ottet Tailstock clamp *Combination not possible 14 s181 HMI INNOVATIVE DESIGN, INTUITIVE FUNCTIONS AND EASE OF USE WITH THE TOUCH SCREEN More menus are dedicated to the characteristics of the machine, therefore the machining programs do not include precise information linked to the machine. Full interchangeability between the machines is given. Production start-up is quicker and maintenance management has been simplified with traceability of information available for simple handling. BENEFITS - Management of sister tools - NC connectivity with PC interface - Ease of use - Optimised service life - Continuous work 24/7 - Automation of information in order to prevent the manual entry of information as well as collisions HANDLING Bumotec has developped a vast array of smooth interactive subroutines, helping to simplify programming. The graphic options for the interface make it easy for junior operators to take charge of the machine. 16 s181 EQUIPMENT AND PERIPHERALS A range of equipment is offered to further improve the performance of the machine. EQUIPMENT - Front Live Tools - Tool breakage detection in the changer - Magazine extended from 60 to 90 tools - C axis on the main spindle - Part unloading system - Tool measurement with probe - Contactless tool measure (with laser) - Measurement probe - Paper filtration tray PERIPHERALS - Automatic tool loader - High-pressure unit - Chip conveyors - Fume extractor system - Fire protection system Front Live Tools Chip conveyor Coolant tray with filtration Automatic bar feeder paper Tool measurement with Measurement probe laser Part unloading system & High-pressure unit recovery drawer 18 s181 M = Milling TECHNICAL DATA MT = Mill/turn Base machine Axis stroke X = 490 mm / Y = 160 mm / Z = 430 mm Power / Axis force X 2.5 kW / 340 daN Z-Y 4.8 kW / 180 daN Rapids X-Y-Z 40 m/min Acceleration X-Y-Z 8 m/s2 / 0.9 g Resolution X-Y-Z 0.0125 µm Main spindle C (direct drive) Power S1 / S3 15.5 / 11 kW Torque S1 / S2 / S3 18 / 32 / 40 Nm Rpm milling M version 90,000 °/min Rpm turning MT version 6000 rpm Clamping force 11,100 N at 6 bar, analogue control, pressure operated by the CNC Resolution 0.0001° Bar capacity Ø32 mm Clamping systems F38 / Ottet / Mecatool / Jaw-chuck Tilt axis B (direct drive) Torque S1 / S6 109 / 226 Nm Tilting speed 36,000 °/min (7500 °/s2) (0 to 90° in 0.35 s) Locking torque 336 Nm Resolution 0.0001° Tilting angle -25° / +115° Milling spindle Power S1 / S6 5 / 6 kW Torque S1 / S6 6.3 / 7.6 Nm Max. speed 30,000 rpm (40,000 rpm optional) Tool holder clamping force 6.8 kN Tool holder interface M version HSK-E40 MT version HSK-T40 (compatible with holder HSK-A40) Lubrication in the centre of the tool 100 bar (optional) Tool changer Capacity 30 (60 or 90 optional) Number of indexed tools All tools possible Tool change time 1.9 s Chip-to-chip time 5.2 s Max. tool weight 1.2 kg Max. tool diameter Ø40 mm (80 if adjacent tool pockets are empty) Max. tool length 120 mm CNC control Numerical control / Screen FANUC series type 31iB-5 Screen 15'' Panel i with Windows 7 Back working axis Axis stroke U 160 mm V 250 mm W 170 mm Power / Axis force U-W 2.5 kW / 100 daN V 0.75 kW / 340 daN Rapids U-V-W 40 m/min (8 m/s2) Resolution U-V-W 0.0125 µm Retaking vice Rotation of the vice Electrics Self-centring parallel vice Pneumatic Clamping force 4200 N at 6 bar Front turning tools Number of indexed tools 5 milling tools, cooled spindle sheath Power S1 / S6 1 / 3 kW Torque S1 / S6 2 / 4.4 Nm Max. rpm 8000 rpm Tool shank clamping ER16 or HSK-C32 Max. tool diameter 10 mm (ER16) or 8 mm (HSK-C32) Installation information Machine weight (without any options) 5000 kg Dimensions (machine only) 1860 x 2000 x 2325 Air supply Min. 6 bar / dry and oil free air Electric supply 3 x 400 VAC / 63 A Standard tray oil volume 195 l Base machine Axis stroke X = 490 mm / Y = 160 mm / Z = 430 mm Power / Axis force X 2.5 kW / 340 daN Z-Y 4.8 kW / 180 daN DIMENSIONS Rapids X-Y-Z 40 m/min Acceleration X-Y-Z 8 m/s2 / 0.9 g Resolution X-Y-Z 0.0125 µm Main spindle C (direct drive) Power S1 / S3 15.5 / 11 kW Torque S1 / S2 / S3 18 / 32 / 40 Nm Rpm milling M version 90,000 °/min Rpm turning MT version 6000 rpm Clamping force 11,100 N at 6 bar, analogue control, pressure operated by the CNC Resolution 0.0001° Bar capacity Ø32 mm Clamping systems F38 / Ottet / Mecatool / Jaw-chuck Tilt axis B (direct drive) Torque S1 / S6 109 / 226 Nm Tilting speed 36,000 °/min (7500 °/s2) (0 to 90° in 0.35 s) Locking torque 336 Nm Resolution 0.0001° Tilting angle -25° / +115° Milling spindle Power S1 / S6 5 / 6 kW Torque S1 / S6 6.3 / 7.6 Nm Max.