VTC VERTICAL TURNING CENTRES

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1 VTC VERTICAL TURNING CENTRES

2 VTC VERTICAL TURNING CENTRES VERTICAL TURNING CENTRES precision VTC VERTICAL TURNING CENTRES DANOBATGROUP is one of the largest machine tools and production systems manufacturers in Europe. For more than 55 years we have supplied machine tools and production systems to highly reputable customers establishing a worldwide presence. DANOBATGROUP is the machine tool division of one of the most prestigious Spanish industrial holdings, Mondragon Corporation with a workforce of 85,000 people, and more than milion Euros in turnover. The VTC range has been designed to create new high standards of turning and machining capability for users in the most demanding industries. Proven performances in combining turning, milling, drilling and grinding operations with high precision and mass productivity have created an important position for the VTC range in the following industries: aerospace, railways, power generation, marine, large precision bearings, mining, valves and subcontracting. 2 VTC

3 High precision, multifunction machine CONFIGURATION OF THE MACHINE VTC The VTC machines are extremely rigid. The main elements of the machine such as the base, the column/columns and the cross rail are ribbed castings providing a high degree of stability to the machine assembly. They are fully stress relieved prior to final machining to enable the machine s structure to absorb the stresses and dampen the vibrations induced by cutting forces even under the heaviest cutting conditions. The RAM is made from a normalised steel forging, induction hardened and precision ground. The main spindle is driven from the motor through a two-speed epicicloidal gearbox. From this, the drive to the spindle is provided through a gear reduction transmission. A pressurised re-circulating oil lubrication system ensures adequate lubrication for the main spindle gearbox and the table bearing. Additionally and to ensure thermal stability and minimise table thermal growth, an oil chiller unit is also provided. The C axis positioning and repeatability, produces extremely high accurate parts during milling and drilling operations. The positioning of the tool holders and milling heads into the RAM is made by means of a Hirth gear system. This system guarantees the accuracy and repeatability during the tool change. The rotary tools are assembled into the milling heads, straight or angular, at 90º, providing an extremely rigid assembly. This results in high accuracy drilling, threading and milling operations. LATEST STATE OF THE ART TECHNOLOGY VTC accuracy The VTC range is optimised to achieve excellent machining results regarding dimension accuracy and surface finish performing the best results for X, Z and C axes positioning and reducing deformations due to thermal expansion. Multifunction machine Combining turning, milling, drilling, grinding and special measuring devices in a single machine tool has generated considerable interest in DANOBAT s VTC range. DANOBAT has also designed and manufactured several special new heads/spindles for customised applications, such as head with Y axis and head with B axis. Thermal expansion The machines design and their structural cast iron components, enable a high thermal stability face to temperature changes caused by the main motor, ram motor, etc. During every machine test, we check that those thermal expansions do not affect the quality of the machining. Danobat has developed the VTC-H range in order to meet the market demand for the large diameter Vertical Turning Centres. Hydrostatic technology has been applied in the following areas of the machine: Hydrostatic slideways are used in both the X and Z axes. The table is supported radially and axially by hydrostatic elements. 3 VTC

4 VTC VERTICAL TURNING CENTRES VTC 1600/1800/2100/2500/2800/3200/4000 Leading technology: TABLE X AND Z AXES The rotary table is directly mounted on a high precision crossed roller bearing. The Danobat design enables highest accuracy and rigidity for hard vertical turning operations. The main crossed roller bearing is assembled one by one based on Danobat expertise in this field. The slide ways design is based on roller guidance system for both X and Z axes. These Danobat designs enable the maximum rigidity avoiding any stick slip effect and improving interpolation results. VTC-1600 and VTC-1800 range is developed with transmission movement by ballscrews. VTC-2100 and larger models are developed with double rack and pinion system instead of a ballscrew one. This rack and pinion system used by Danobat, eliminates any positioning error due to possible deformations of long ballscrews. The RAM design optimises thermal expansion and provides the maximum rigidity (in comparison to other RAM types, such as the octogonal one). The vibration and dampening mechanism developed by Danobat is fully integrated with the slideways and optimised to give the best turning results. ACCURACY RESULTS Due to the Danobat described design, the VTC range is optimised to give excellent turning results regarding dimension accuracy and surface finish, performing the best results for X, Z and C axes positioning and checked with ball bar and NAS tests. 4 VTC

5 VTC-H 5000-H/6000-H/8000-H Leading technology: TABLE X AND Z AXES The table is directly mounted on a hydrostatic bearing system. Danobat offers different range of hydrostatic bearing systems depending on the axial load as well as the peripheral speed requested case by case. Danobat designs cover cases from a single hydrostatic axial bearing system to double / triple systems. Additionally Danobat developments ensures an easy maintenance of hydrostatic systems. The slideways design is based on full hydrostatic system for both X and Z axes. These Danobat designs enable the maximum rigidity for heavy turning work. The transmission system is developed with double rack and pinion system. This double system eliminates any positioning error due to the backlash and long ballscrew deformations. The RAM design optimises thermal expansion and provides the maximum rigidity (in comparison to other RAM types, such as the octogonal one). Danobat implements a full hydrostatic mechanism for the slideways offering maximum rigidity and vibration dampening. ACCURACY RESULTS The VTC-H range optimise the turning results regarding dimension accuracy and surface finish for heavy parts, up to 150 Tn due to the Danobat described design, These designs enable Danobat to increase this capacity to larger parts, weights and dimensions. TRAVERSE The Danobat designed traverse mechanism optimises the possible deformation of this particular element of the VTC, heart of the machine. Different mechanisms compensate the deformation of the traverse due to the gravity effect. Firstly, the finite element calculation of the traverse, with its own weight compensation system reduces deformations. Secondly, the Danobat designed weight compensation actuators reduce the geometrical errors produced due to the gravity. 5 VTC

6 VTC VERTICAL TURNING CENTRES CUSTOMISED SPINDLES Tool holders for modular tools: Capto, KM... Part probing system ATC (Automatic Tool Changer) Tool presetting system Straight and 90º milling heads for live tools EQUIPMENT Standard CNC: Fanuc / Siemens / Fagor T slotted table Automatic tool changer (18 tools) Fixed cross rail Hydraulic equipment Levelling pads Automatic lubrication equipment Coolant through spindle Options Hydraulic chuck Moving cross rail Live spindle C axis Two RAM models for maximum metal removal Straight and 90º milling heads for live tools Grinding head Automatic tool changers up to 120 tools Tool presetting system Part probing system Tool force monitoring and tool breakage detection Paper filter Full enclosure and fumes extractor Automatic pallet loading system 6 VTC

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9 TECHNICAL SPECIFICATIONS VTC CHARACTERISTICS VTC-1600 VTC-1800 VTC-2100 VTC-2500 VTC-2800 Table diameter mm Turning diameter mm Table speed rpm Table drive motor kw 55 (81)(105) 55 (81)(105) 55 (81)(105) 55 (81)(105) 55 (81)(105) Max. work piece weight kg RAM size mm 250 x x x x x 250 RAM stroke Z mm 1000 (1500) 1000 (1500) Maximum height table to RAM mm 1500 (2000) 1500 (2000) 1800 (2600) 1800 (2600) 1800 (2600) RAM traverse X mm Vertical travel of cross rail mm Live spindle power kw 22 (30) 22 (30) 22 (30)(37)(40) 22 (30)(37)(40) 22 (30)(37)(40) Live spindle speed rpm Standard ATC tool 18 (2 x 18) 18 (2 x 18) 18 (2 x 18) 18 (2 x 18) 18 (2 x 18) Approx. weight kg CHARACTERISTICS VTC-3200 VTC-4000 VTC-5000-H VTC-6000-H VTC-8000-H Table diameter mm Turning diameter mm Table speed rpm Table drive motor kw 55 (81)(105) 55 (81)(105) 48 x 2 (71 x 2) (105 x 2) 48 x 2 (71 x 2) (105 x 2) 48 x 2 (71 x 2) (105 x 2) Max. work piece weight kg RAM size mm 250 x x x 250 (300 x 300) 300 x 300 (400 x 400) 300 x 300 (400 x 400) RAM stroke Z mm (2000) 2000 (2500) 2000 (2500) Maximum height table to RAM mm 1800 (2600) 2000 (3000) 3250 (3600) 3600 (4650) 4650 (6200) RAM traverse X mm Vertical travel of cross rail mm (3500) 2000 (3500) Live spindle power kw 22 (30)(37)(40) 22 (30)(37)(40) 30 (37)(40) 37 (40) 37 (40) Live spindle speed rpm (2000) 2000 (1500) 2000 (1500) Standard ATC tool 18 (2 x 18) 18 (2 x 18) 18 (2 x 18) 18 (2 x 18) 18 (2 x 18) Approx. weight kg VTC

10 OUR COMPANY, YOUR PARTNER In DANOBAT we offer a service to perform a machining test on our machines with your workpieces. You can check the capacity of our process team and DANOBAT machines, thus making an investment with a guarantee. Next to the customer from the beginning: Customised solutions: Local sales service team at your disposal. Production process analysis by local product engineers. Feasibility analysis. Technical & economical study. Project management: Machine set-up & commissioning. Personnel training. Production assistance. more information about DANOBAT VTC VERTICAL TURNING CENTRES at Together during the complete machine live: Technical assistance by local service engineers. Teleservice. Hotline. Preventive maintenance. Spare parts available. SPECIALIZED MULTI-TECHNOLOGICAL SOLUTIONS Horizontal lathes Vertical lathes Grinding machines Customised machining solutions. Improving machining process study. Fixturing. Band sawing machines and drilling units Tooling. Software. Acceptance trials machining customer s parts. Composite If your mobile phone has the QR code reader tool you will be able to go directly to our site at 08/2011 DANOBAT 2011 This document is not a contract. DANOBAT reserves the right of making changes to all models without prior notice. The illustrations in this catalogue remain property of DANOBAT. DANOBAT Arriaga kalea, 21 E ELGOIBAR (Gipuzkoa) Spain Tel.: Fax: sales@danobat.com