The compact machine design of the ABC65 with up to 3 simultaneously working tool carriers not only ensures high productivity, but also provides a high performance density with a main spindle of 65 mm bar capacity and a swivel counter spindle for extensive rear end machining. At only 5,5 m2 footprint (without bar loader), workpieces with complex geometry can be machined economically in addition to traditional CNC automatic lathe parts of up to 250 mm in length. With the new CNC turret indexing axes (H-axis), the ABC65 has also two standard Y-axes (interpolation X-, C- and H-axis). Furthermore, the main spindle allows easy integration of loading and unloading equipment for preshaped blanks into the new machine concept.
Upper tool carrier with tool turret (10 stations, X=140 mm, Z=300 mm)
The precision of the workpieces is ensured by a direct measuring system in the X-axis.
All stations in the upper turret can be equipped with live tool holders on the ABC65. Turret indexing is designed as an NC rotary axis with a direct measuring system without mechanical lock, thereby allowing fast positioning of the turrets at any angle. This allows multiple tool assignments at each station, so that the upper tool carrier can be equipped easily with up to 20 tools. By eliminating the mechanical lock, short chip-to-chip times of 0.4 seconds from station to station can be realized.
New to a lathe of this size is the optionally available “Dual Drive” system for the upper turret. This tool drive system has two integrated drive trains to ramp up the speed for the next tool while still cutting with the current tool. The new tool is then indexed to the machining position at full speed. This not only reduces secondary processing times, the live tool holders also experience a significantly longer service life.
For polygon turning, even in difficult-to-cut materials, the upper tool turret can be fitted with an optional polygon turning unit.
Dual function of the lower X/Z slide
Apart from its function as a lower tool turret with 9 stations and identical functionality as the upper tool turret, the lower cross-slide with travels of also X = 140 mm and Z = 300 mm serves as a swivel counter spindle for rear end machining of workpieces. The swivel movement of the counter spindle is achieved via the CNC turret indexing axis (H-axis). As an INDEX innovation, the ABC65 thus provides a counter spindle with a C-axis that can be moved in three axes (X/H/Z), allowing unrestricted counter spindle machining at 6,000 rpm and 52 mm spindle clearance as well as 9 kW (25% DC) drive power and 20 Nm (25% DC) torque. The counter spindle also allows the machining of parts with a chuck diameter up to 110 mm. Alternatively, hollow clamping up to 200 mm clamping depth or the attachment of mandrels can be realized.
For extensive rear end machining, 8 tool stations are available which can accommodate the same tool holders as in the turret tool. Five of them can be used for live tools at a speed of max. 6,000 or 12,000 rpm and a torque of up to 7 Nm (25% DC) at 6.4 kW (25% ED) drive power. Two stations with stationary tools are suitable for simultaneous centric machining on the counter spindle as well as in parallel with the 2nd tool turret on the main spindle.
When the counter spindle operates on the rear end machining unit after gripping and cutting-off, the work area is available to the upper tool carrier for any internal and external machining operations.
Dynamic main spindle with electric collet feed for short idle times
High cutting performance is ensured by the rigid and precise work spindle with C-axis and a power of 35 kW (40% DC) at up to 6,000 rpm. With a spindle clearance of 65 mm for bar work, the ABC65 also allows the use of chucks up to 160 mm in diameter at a torque of 120 Nm (40% DC). With the optional collet mounted on the main spindle and in conjunction with the INDEX bar guide LMI, bars up to 52 mm in diameter can be fed on a length of 125 mm with numerical control.
Dual Y-functionality for both tool turrets
The standard built-in Y-axis for the two turrets is formed by the interpolated movement of the CNC turret indexing H-axis and simultaneously the C-axis of the work spindle as well as the X-axis of the tool carrier. Through the combined motion in conjunction with a powerful tool drive (with max. 9 kW / 10 Nm / 12,000 rpm), the ABC65 provides a large Y-travel of ± 50 mm = 100 mm for all turrets, e.g., to mill surfaces and grooves on workpieces, to drill axis-parallel off-center holes, and to realize off-center deep-hole drilling. With effective programming, the travel paths for selection and removal of tools can be optimized. The high precision and rigidity of the Y-axis is ensured by high-resolution incremental encoders on the C-axis and by the H-axis integrated in the turret, in conjunction with stable position control. Milling operations which were possible only through the transmit function can now be easily programmed in Y coordinates for both turrets.
Improved tooling system
The new compact shank system with a diameter of 45 mm is an improved system for stable and precise mounting of tool holders in the turret and in the rear end machining unit. The tool holders are seated deeper in the tool carrier, which results in less leverage effect and, thus, higher stiffness. For live tool holders, the large shank diameter enables insertion of roller bearings with large diameters. This increases the performance and life of the tool holders. In addition, stationary tool holders with VDI25 shank mountings can be used easily by means of an adapter plate.
Fast and gentle workpiece removal
Workpieces are removed fast and gently by a CNC-controlled shuttle. In parallel to the upper turret working on the main spindle, the counter spindle switches from the turret’s axial effective range and moves to the right to the transfer position to the workpiece gripper. There, the finished part is taken over by the workpiece gripper of the shuttle unit during secondary processing time and placed without damage on a timed part removal conveyor outside the machine.
Practical user benefits
The vertical design of the machine with a setup-friendly work area not only provides good conditions for unobstructed chip flow but also significantly better ergonomics which facilitates setup operations. The basis for this is a vertical cast machine bed with a highly ribbed, enclosed modular design that is mounted on a heavy machine base. A total weight of 6.5 t and the associated vibration damping are the basic requirements for high-precision machining of difficult-to-cut and high-strength materials. Although even long workpieces (up to 250 mm) can be manufactured on the ABC65, the lathe with its footprint of only 4,070 x 1,380 mm needs only 5,5 m² of floor space (without bar loader).
Furthermore, all functionally important elements such as the headstock, tool carrier guides, gear drives, and workpiece removal unit are mounted on the machine bed, providing the basis for high quality of the machine geometry. The distance from the upper tool carrier to the spindle center is exactly the same as the distance of the lower tool carrier, resulting in the thermo-symmetrical structure of the machine.
An INDEX-typical headstock, low projection of the tool holders and thermal insulation to the rest of the machine further contribute to the precision. Instead of intensive-care telescopic plates, a one-piece sheet metal is used for the vertical inside cover of the work area in X and Z. The work area is easily accessible to the operator by its generous sliding door.
High manufacturing precision with elaborate cooling concept
The symmetrical design, the vertical arrangement of the work area, the actively cooled main spindle, glass scales in the X-axes, and the hydraulic-free (cold) technology of the turrets with direct measuring systems in the turret indexing axes ensure high temperature stability of the machine. Lost heat that is generated in the spindles, the control cabinet and the hydraulic unit is dissipated from the machine by a central fluid circuit. A water interface integrated into the ABC65 allows two solutions to heat dissipation: either connecting to a local cooling unit or to a central system. By cooling off the production area and by eliminating the traditional fans, noise and heat emissions in the machine environment are reduced to a minimum.
CNC-control with touch-screen operation
For years, all INDEX machines have met the demand for reduced energy consumption. The latest INDEX control generation C200-4D sl, based on the Siemens Sinumerik 840D Solution Line, was complemented by an 18.5-inch wide-screen display with full multi-touch surface and new user-friendly features for the ABC65. With this control panel, INDEX has succeeded in incorporating numerous rotary and touch buttons of the machine control panel directly in the screen. Thus, the new INDEX ABC65 is the first to display switches and buttons as active only that really apply to the current machine status and whose movements are allowed.
The benefits of this approach are obvious in the operation of the control:
Because input and selection fields can be selected by simply touching the screen surface, comparable to smart phones, tedious navigating with the keyboard and the mouse is eliminated. A touch of the finger is enough to activate functions, to open files and folders, or to move entire display pages.
Part of this new approach are, also LED-backlit buttons and switches on the machine control panel by which the touch philosophy is implemented throughout all levels of operation. Buttons and switches available for selection are selectively backlit, illegal ones are dimmed, and necessary operator actions are indicated by flashing buttons.
Source INDEX-Werke GmbH & Co. KG