Machining in a new dimension

 With the R200, INDEX has a cutting-edge turning/milling center with unparalleled efficient manufacturing capabilities in its product portfolio. Two powerful motorized milling spindles and two movable work spindles perform extremely productive and flexible machining operations in two independent subsystems – even for machining with 5 axes.

 

The INDEX R200 turning/milling center—a new dimension in machining

The INDEX R200 turning/milling center—a new dimension in machining

One motorized milling spindle and one work spindle each are assigned to one another in two subsystems located one above the other. In combination with additional tool strips, this design allows for highly productive and flexible machining operations, up to and including simultaneous and independent 5-axis machining on both spindles. A fast tool changer loads the milling spindles with tools and ensures a high degree of flexibility for machining operations. As a result, it is possible to carry out full rear end machining as well as parallel machining with identical sequences. Both heavy-duty roughing operations and highly-accurate fine-turning operations can be performed simultaneously on the main spindle and counter spindle. The innovative design of the INDEX R200 allows it to machine appropriate workpieces almost twice as fast as commercially available turning/milling centers that use only one motorized milling spindle.

Sound and strikingly clear design

The R200 modular system: clearly structured design innovative arrangement of proven components

The R200 modular system: clearly structured design innovative arrangement of proven components

The innovative axis arrangement produces directional kinematics, which in turn enables comprehensive and complete machining. The idea: a machine design in which the main spindle moves in Z, the counter spindle in X and Z, milling spindle 1 (top) in X/Y/B, and milling spindle 2 (bottom) in Y/B. The result: a design with two independent subsystems, exceptional stiffness, and impressive dynamic response. Consequently, workpieces can be machined with efficiency and in parallel on the front and rear ends. During development, emphasis was placed on achieving a high degree of thermal stability and vibration damping to enable machining of difficult-to-cut and high-strength materials under optimum basic requirements. The basis for this is a vertical cast machine bed with a heavily ribbed, enclosed modular design.

Powerful motorized milling spindles and movable work spindles

Two work spindles and two motorized milling spindles perform high-productivity machining operations in two independent subsystems

Two work spindles and two motorized milling spindles perform high-productivity machining operations in two independent subsystems

The two quill-guided motorized milling spindles were placed in the center of the machine bed. This diagonal arrangement allowed the usual cross-slide to be omitted. When combined with the play-free and wear-free hydrostatic circular guide, an overall system with exceptional stiffness is produced. Optimum force transmission is one of the premises that were implemented consistently by the developers. Based on its very short lever arms, the resulting system is less susceptible to vibrations, which in turn has a positive effect on the accuracy of the finished parts and on the tool life. Another plus is the high acceleration and rapid traverse rate at which the INDEX R200 can be moved – aided by powerful drives and weight-optimized assemblies. The tremendous machining flexibility and remarkable speed of the machine are explained by the generous B-axis swivel ranges of 270 and 230 degrees and the rapid traverse rate of 45 m/min. The data for the identically rated work spindles in synchronous design are also impressive: maximum power rating of 33 kW, maximum speed of 5,000 rpm, and peak torque of 150 Nm.

Continuous turret functionality in the working area

Two linear tool carriers affixed to the side of each milling spindle allow fast, high-precision access to 6 stationary tools without a tool change. The W-serration minimizes the associated setup effort and ensures a friction- and form-locking tool fit: this represents the optimum precondition for precise turning operations comparable to that of a turret.

Minimum chip-to-chip times 

Precise turning operations with stationary tools on the motorized milling spindles

Precise turning operations with stationary tools on the motorized milling spindles

Two separate shuttle units independently load the two motorized milling spindles with the HSK-A40 tools required in each case from a common chain tool magazine. With 80 or 120 places, the INDEX R200 has an extensive pool of tools. Short chip-to-chip times of approximately 4 seconds contribute significantly to the minimization of secondary times. While machining is performed on the main spindle, the lower milling spindle can load a new tool, protected from falling chips and coolant. This results in high productivity and improves process safety.

A control designed according to users’ wishes 

The current INDEX C200-4D SL control generation is used. This control is based on the field-proven Siemens Sinumerik S840D Solution Line and has been enhanced by INDEX with user-friendly features. Specially developed cycles simplify the most complex machining operations. They support multi-axis milling and turning operations and provide maximum functional reliability.

 

 

Complex workpieces made easy

Full rear end machining: powerful milling operation (top) and fine-turning operation (bottom)

Full rear end machining: powerful milling operation (top) and fine-turning operation (bottom)

The INDEX VirtualLine software packages support efficient use of the new turning/milling center from the very first workpiece. Ideally coordinated with one another, these packages complement each other in terms of their features and guide the NC programmer and operator in a targeted manner to the right solution for the machining task – both on the PC during the preparation stage and directly at the machine in the factory. In conjunction with the 3D simulation of the INDEX Virtual Machine, machining programs can be created, checked, and optimized on the PC. The CNC Programming Studio provides more advanced support for programming and operating the INDEX R200.

Energy efficiency

Practical experience in action – special cycles simplify multi-axis milling and turning operations

Practical experience in action – special cycles simplify multi-axis milling and turning operations

For years all INDEX machines have obeyed the demand for reduced consumption. Of course, the INDEX R200 is also equipped with all the essential and advanced technologies needed to not only meet but surpass the energy requirements. The definitive design elements in this regard are: weight-optimized components for reduction of energy consumption and for increasing the dynamic response; energy recovery by means of regenerative drives; energy shutdown of units that consume large amounts of energy after a user-defined time (standby mode); minimized friction based on optimally paired materials and low-friction bearings (hydrostatic circular guide); intelligent cooling principles for targeted cooling of the machine, economical use of waste heat, or climate-neutral heat discharge from the production hall. The INDEX cooling concept ensures that the spindles, hydraulics, and control cabinet are cooled constantly and that the heat can be fed to another useful application via a “water interface”, e.g., for service water heating or as process heat for other manufacturing steps.

Performance redefined

Turning and milling in 5-axis machining, as well (impeller)

Turning and milling in 5-axis machining, as well (impeller)

Enormous productivity benefits in milling and turning combined with maximum flexibility are the winning arguments for the new INDEX R200 turning/milling center. This is achieved by means of unrivaled kinematics with two motorized milling spindles, two work spindles, four linear tool carriers, and a large pool of tools with fast access. The innovative design and arrangement of proven components provide for maximum stiffness and optimum vibration damping as well as for optimum thermal and dynamic stability. This enables the INDEX R200 to deliver impressive machining results for challenging materials and machining tasks, up to and including 5-axis machining.

 

Source INDEX-Werke GmbH & Co. KG