RatioLine G160 G250 G400 High-performance turn-mill centers
RatioLine G160, G250, G400 Performance, precision and flexibility in every dimension More precision, more efficiency, more flexibility Experience machine performance and economy in a new dimension: The INDEX RatioLine high-performance turn-mill centers of the G160, G250 and G400 series prepare you optimally for everything that may come along. From the machining of simple workpieces to that of complex parts. From small lot sizes having a wide parts range to the highly automated series production. Safety from the technology leader As the technology leader, INDEX with its turn-mill centers is constantly setting new standards. Every INDEX machine is the result of 90 years of construction, production and application experience. With each improvement of our know-how, technological expertise and serious, individual customer service, we can offer customized solutions for maximum productivity. This is what our customers rely on. Worldwide. 2
RatioLine G160, G250, G400 Ready to meet all demands Innovative machine concept The INDEX RatioLine G series is based on an innovative machine concept: A practiceoriented modular system design allows you to assemble without compromise almost any machine configuration that you may require for economic and future-oriented production. Whether you need a highly productive or a highly flexible turn-mill center for small or large lot sizes: You can assemble exactly the machine that is optimally tailored to your present and future requirements. In any case, we will advise you individually on the right configuration of your machine. This customized machine will make your production more economical. 4
High productivity for your machining tasks Highly productive: G160 2 work spindles, max. bar diameter 65 mm 3 turrets 36 tool stations (all driven) Upper turret with Y/B axis The ideal configuration for series production or for the production of small lot sizes requiring minimum setup work. Highly flexible: G400 2 work spindles, max. bar diameter 102 mm 2 turrets 24 tool stations (all live) Turret with Y/B axis and two multifunctional units for live and fixed tools; 64 magazine stations 1 programmable steady rest Highly suitable for the highly flexible production of a wide range of workpieces. 5
pro Dostinon heab Kisuaheli neumix doc barcmope Rewwitz gofella queju vinre Esni uz balomre rindupu doan Neukifa lenim dakai herangu de sal Henre ounim herero wubu harvas en schreka dol Deck innoviton Olla gefeph rhuss scha kakain hers dok in bulassa de jussel mas am dokum sunim Vernas. Machining center, including a milling center: G250 2 work spindles, max. bar diameter 102 mm 1 motor milling spindle also for fixed tools; up to 80 magazine stations Y/B axis 12-tool turret (all driven) This machine replaces a 5-axis machining center and a milling center. Two machines in one: G400 2 work spindles, max. bar diameter 102 mm 2 turrets X 12 tool stations each (all driven) Z axis movement by main and counter spindle Due to its genuine pendulum machining, no loading/unloading times are required for chuck parts. 6
Your modular building block system Precisely your dimension Bar diameter 42 to 102 mm Chuck sizes 160 to 500 mm Turning lengths 800 to 2000 mm All options Bar machining, machining using chucks or shaft machining 1 or 2 work spindles 1 to 3 turrets Up to 2 Y or Y/B axes Max. 2 multifunctional milling units Up to 2 motor milling spindles Perfect shaft machining Tailstock via CNC axis 1-2 steady rests, fixed or freely programmable 7
RatioLine G160, G250, G400 Impressive machine construction, precisely tuned Excellent machine bed Tubular cast bed Rigid, bending-resistant Vibration-absorbing Strong guides Large-dimensioned linear slideways Wide tracks for enormous metal-cutting performance Precise position gauging systems Direct position gauging systems in all X axes for high-precision machining Motor spindle Patented air cooling for the main and counter spindles of identical design. They are cooled precisely where the heat is generated: directly at the rotor Powerful: high torque and high dynamics 8
Innovations that pay off Y/B axis with genuine 360 360 swiveling range (optional) Machining at any desired angle Full use of turrets at the main and counter spindles 5-axis machining for demanding contours Quill design with hydrostatic, zero-backlash and no-wear bearing for high precision and optimum rigidity Maximum utilization of the tool stock: The same tool can be used at the main and counter spindles, thus reducing the no. of tools required. Highly flexible utilization of the working area in the Y direction by means of the A axis with max. stability and extremely short lever action of the Y axis. The work spindle with center support (optional) The thrust can be programmed to vary continuously Using the counter spindle as tailstock and an integrated live center support makes it possible to support the workpieces. When the counter spindle picks up the workpiece, the center support is simply pushed back into the counter spindle. 9
RatioLine G160, G250, G400 Reducing the setup time - that's the right approach Tool corrections via the Y and B axes Tolerances of the tool position can be compensated with savings in time and with µ precision via the control in the Y and B axes. Patented W serration for high repetitive accuracy in tool changing The patented W serration makes it possible to achieve a repetitive accuracy of a few µ in tool holder changing. Machine setup: up to a max. 150 tool pockets When requiring a wide range of parts and small lot sizes, with these machine designs, you will always be fully prepared. 10
Integrated handling system: fully automatic In production with minimum operator intervention, the optionally integrated WHU/WHW handling system does the automatic loading and unloading of chuck parts and shaft parts. For chuck parts G160 G 250 Max. workpiece diameter 130 mm 200 mm Max. workpiece length 150 mm 200 mm Max. workpiece weight 2 x 6 kg 2 x 10 kg For shaft parts Max. workpiece diameter 60 mm 80 mm Max. workpiece length 500 mm 700 mm Max. workpiece weight 2 x 6 kg 2 x 15 kg INDEX MBL bar loading magazine Max. bar diameter 65 mm Max. bar length 4000 mm Loading position Feeding position Bar end before Endposition 11
RatioLine G160, G250, G400 Four machine examples Example 1: G160 Components to choose Work spindle 1+2 G160 G250 G400 1+2 max. bar capacity mm 65 102 102 65 max. chuck size mm 160 315 500 160 Work area max. turning length mm 800 800/ 1.250 / 800 1.400 2.000 Turret 1-3 1-3 1-3 2 Number of stations per turret 12 (10) 12 12 (10) Tool drive rpm 6.000 6.000 6.000 (3.000) Multi functional unit 1 1-2 1-2 1 Tool system HSK A-40 A-50 A-63 / B-80 max. speed rpm 6.000 6.000 6.000 max. power kw 17 9,4 17 Tool magazines 1-2 1-4 1-2 1 Tooling capacity 32 32 32 Motor milling spindle 1 1 1-2 Tool system HSK A-40 A-63 A-63 max. speed rpm 20.000 18.000 18.000 max. power kw 16 27.5 27.5 max. torque Nm 48 115 115 Tool magazine x stations max. HSK 2x32 4x20 4x20 Capto 2 x 20 2 x 20 Tailstock Thrust N 6.000 15.000 14.000 Mounting SK 30 30 30 (40) Steady rest 1 1 1-2 12
Configure your madeto-order machine Example 2: G 250 Example 3: G 250 Example 4: G 400 1+2 1+2 1+2 90 102 102 315 315 500 3 1 1 1 2 2 4 Examples 1 to 4 show common and interesting solutions. We will be glad to advise you individually on the configuration of your machine. 13
RatioLine G160, G250, G400 Programming with TURBO TURBO H200 - the programming system for the workshop The TURBO H200 programming system gets you faster to the first part. All users - even less experienced ones - are given optimum support High reliability through integrated machining simulation The system is available on the machine control and for external PCs You determine the contour of the blank part and of the finished part on the basis of interlinked geometric and machining elements the clamping devices and he clamping orientations as well as the mounted tools according to tool type and tool assignment TURBO H200 generates the division into machining tasks and their sequence the selection of suitable tools the cutting values that fit the tool the creation of the setup sheet and the work plan 3-D simulation with virtual CNC The 3-D simulation can be run independently of the machine The simulation is available at the machine control as an option The 3-D machine model shows the actual 1:1 machine configuration You already see in advance what process is running Realistic 3-dimensional volume model of machine and workpiece 1:1 copy of the machine control guarantees an accurate sequence and accurate details 100 per cent identical machine performance during machining More reliability, more economy Machine damage is reliably detected even before it is produced and permanently eliminated Previously simulated jobs are started optimally at the machine and are optimized with respect to their runtime. 14
Saving time and lowering costs: The INDEX C200-4D control concept based on Siemens 840D powerline provides you with powerful and highly advanced control technology for every practical application. Productive power according to program. Competent operator guidance Plain text dialog in display and use All spindles and axes at a glance Identical interface in all machines of the series In case of errors: place and cause of error are reported "Online" error and service documentation Expert programming Far more than 70 user cycles offer practice-oriented support down to the smallest detail guarantee a secure program run with maximum flexibility ensure optimum running and efficient use of the machine INDEX C200-4D based on Siemens 840D Quick setup... Including axis lock Approach of tool carriers step by step Check of superimposed machining processes at standstill Including T word acknowledgement mode User control prior to each turret indexing All of that is done without any modification in the programs Starts immediately... Via block search key press resumes process at the point of interruption channel-synchronous advance to any desired program point REPOS-guided safely to the (new) starting point Start requirements: the correct machine state can be established simply and without collision Operational safety... Absolute encoder systems know position in any situation Safety Integrated... maintains axis positions and clamping positions even with the protective hood open checks whether safety device function is working correctly with respect to the cycle personal protection quick to react and flexibility! Tool breakage monitoring system upon request Tool control system and replacement tools possible ETHERNET network connection to DNC possible Machine data acquisition (MDA / ODA possible) Teleservice possible 15
RatioLine G160, G250, G400 Technical data G160 Work area Turning lenght mm 800 Swing diameter mm 200 Main spindle, counter spindle D42 D65 Bar capacity (max. bar diameter) mm 42 65 Spindle diameter front bearing mm 85 110 Spindle head ISO 702/1 Size 5 140 (mm) Chuck diameter mm 160 160 Speed rpm 6300 5000 Power at 100% / 40% kw 20 / 27 20 / 27 Torque at 100% / 40% Nm 105 / 145 105 / 145 Alignment and indexing unit degrees 2.5 2.5 C axis resolution degrees 0.001 0.001 Z axis rapid traverse m/min 45 45 Tool carrier 1 and 3 X Z Y B Slide travel mm 180 800 140 360 (degrees) Rapid traverse m/min 22.5 45 10 180 (degr./sec) Turret 1 and 3 Number of stations 12 10 Cylindrical shaft mounting DIN 69880 mm 25 x 48 30 x 50 Tool drive speed rpm 6000 3000 Tool drive power at 25% kw 8 7 Tool drive torque at 25% Nm 16 30 Multi functional unit 1 or 3 Tool system DIN 69893 HSK-A40, HSK-B50 (optional) Speed rpm 6000 Power at 25% kw 17 Torque at 25% Nm 37 Tool magazine max. 2 x 32 HSK-A40 Motor milling spindle 1 Tool system DIN 69893 HSK-A40 Speed rpm 20000 Power at 100% / 25% kw 16 / 16 Torque at 100% / 25% Nm 28 / 48 Tool magazine max. 2 x 32 HSK-A40 Tool carrier 2 X Z Slide travel mm 110 800 Rapid traverse m/min 22,5 30 Turret 2 Number of stations 12 10 Cylindrical shaft mounting DIN 69880 mm 25 x 48 30 x 50 Tool drive speed rpm 6000 3000 Tool drive power at 25% kw 5.5 5.5 Tool drive torque at 25% Nm 10 21 Tailstock Thrust N 6000 Taper DIN 2079 SK 30 Steady rest Clamping range mm 8-80 Dimensions, weight and connected power with maximum configuration Dimensions L x W x H approx. mm 4435 x 1950 x 1930 Weight approx. kg 7500 Connected power 42 kw, 53 kva, 80 A, 400 V, 50 / 60 Hz Control INDEX C200-4D (based on Siemens 840D powerline) 16
Technical data G250 Work area Turning lenght mm 800 / 1400 Swing diameter mm 560 Main spindle, counter spindle D65 D90 D102 Bar capacity (max. bar diameter) mm 65 90 102 Spindle diameter front bearing mm 110 140 140 Spindle head ISO 702/1 Size 6 8 8 Chuck diameter mm 200 / 250 250 (315) 250 (315) Speed rpm 5000 3500 3500 Power at 100% / 40% kw 43 / 57 43 / 57 44 / 60 Torque at 100% / 40% Nm 275 / 363 275 / 363 400 / 610 Alignment and indexing unit degrees 2.5 2.5 2.5 C axis resolution degrees 0.001 0.001 0.001 Z axis rapid traverse m/min 30 30 30 Tool carrier 1 and 3 X Z Y B Slide travel mm 300 800 / 1400 200 360 (degrees) Rapid traverse m/min 22.5 45 10 360 (degr./sec) Turret 1 and 3 Number of stations 12 Cylindrical shaft mounting DIN 69880 mm 30 x 55 / 40 x 63 / Capto C4 Tool drive speed rpm 6000 Tool drive power at 25% kw 9.4 / 17 (optional) Tool drive torque at 25% Nm 19 / 36 (optional) Multi functional unit 1 and 3 Tool system DIN 69893 HSK-A50 Speed rpm 6000 / 1500 Power at 25% kw 9.4 Torque at 25% Nm 19 / 76 Tool magazine max. 4 x 32 HSK-A50 Motor milling spindle 1 X Z Y B Slide travel mm 300 1840 286 360 (degrees) Rapid traverse m/min 22. 5 45 47 360 (degr./sec) Tool system DIN 69893 HSK-A63 Speed rpm 12000 / 18000 (optional) Power at 100% / 25% kw 27.5 / 27.5 Torque at 100% / 25% Nm 75 / 115 Tool magazine max. 4 x 20 HSK-A63 max. 2 x 20 Capto C6 Tool carrier 2 (bottom) X Z Slide travel mm 140 775 / 1375 Rapid traverse m/min 22.5 45 Turret 2 Number of stations 12 Cylindrical shaft mounting DIN 69880 mm 30 x 55 / 40 x 63 / Capto C4 Tool drive speed rpm 6000 Tool drive power at 25% kw 9.4 Tool drive torque at 25% Nm 19 Tailstock Thrust N 15000 Taper DIN 2079 SK 30 Distance between centers mm 830 / 1430 Steady rest Clamping range mm 12-152 20-165 50-200 Dimensions, weight and connected power with maximum configuration Dimensions L x W x H approx. mm 4170 x 2275 x 2220 5025 x 2275 x 2220 Weight approx. kg 13500 Connected power 68 kw, 81 kva, 107 A, 400 V, 50/60 Hz Control INDEX C200-4D (based on Siemens 840D powerline) 17
Technical data G400 Work area Turning lenght mm 1250 / 2000 Swing diameter mm 630 Main spindle, counter spindle D90 D102 D102 Bar capacity (max. bar diameter) mm 90 102 102 Spindle diameter bearing mm 140 170 170 Spindle head ISO 702/ 1 Size 8 11 11 Chuck diameter mm 315 400 400 (500*) Speed rpm 3500 3000 3000 (290*) Power at 100% / 40% kw 43 / 57 50 / 70 53 / 67 (30 / 60*) Torque at 100% / 40% Nm 275 / 363 900 / 1300 675 / 900 (1275 / 2000*) Alignment and indexing unit degrees 2.5 2.5 2.5 C axis resolution degrees 0.001 0.001 0.001 Z axis rapid traverse m/min 30 30 30 * with additional drive 35% (only main spindle) Tool carrier 1 and 3 X Z Y B Slide travel mm 320 1250 / 2000 220 360 (degrees) Rapid traverse m/min 20 40 12 180 (degr./sec) Turret 1 and 3 Number of stations 12 Cylindrical shaft mounting DIN 69880 mm 40 x 63 Tool drive speed rpm 6000 Tool drive power at 25% kw 17 Tool drive torque at 25% Nm 36 Multi functional unit 1 and 3 Tool system DIN 69893 HSK-A63, HSK-B80 (optional) Speed rpm 6000 / 1500 Power at 25% kw 17 Torque at 25% Nm 36 / 144 Tool magazine max. 2 x 32 HSK-A63 / 2 x 24 HSK-B80 Motor milling spindle 1 and 3 Tool system DIN 69893 HSK-A63 / Capto C6 Speed rpm 12000 / 18000 (optional) Power at 100% / 25% kw 27.5 / 27.5 Torque at 100% / 25% Nm 75 / 115 Tool magazine max. 4 x 20 HSK-A63 max. 2 x 20 Capto C6 Tool carrier 2 X Z Slide travel mm 210 1250 / 2000 Rapid traverse m/min 20 40 Turret 2 Number of stations 10 Cylindrical shaft mounting DIN 69880 mm 40 x 63 Tool drive speed min -1 6000 Tool drive power at 25% kw 11.3 Tool drive torque at 25% Nm 21 Tailstock Thrust N 14000 Taper DIN 2079 SK 30, SK 40 (optional) Steady rest 1 and 2 Clamping range mm 35-220 22-150 Dimensions, weight and connected power with maximum configuration Dimensions L x W x H approx. mm 5350 x 2760 x 2616 6300 x 2760 x 2616 Weight max. approx. kg 21000 Connected power 120 kw, 140 kva, 200 A, 400 V, 50 / 60 Hz Control INDEX C200-4D (based on Siemens 840D powerline) 18
RatioLine G160 4435 1364 G160 / 800 mm 1950 RatioLine G 250 4170 1680 5025 1425 G250 / 800 mm 2275 G250 / 1400 mm 2275 RatioLine G400 5350 1675 G400 / 1250 mm 2760 6300 1475 G400 / 2000 mm 2760 19
LL9002.4456-09.08 ME Printed in Germany Subject to change without prior notice INDEX-Werke GmbH & Co. KG Hahn & Tessky Plochinger Straße 92 73730 Esslingen, Germany Tel. +49 (711) 3191-0 Fax +49 (711) 3191-587 www.index-werke.de INDEX Corporation 14700 North Point Boulevard Noblesville, IN 46060, USA Tel. +1 (317) 770-6300 Fax +1 (317) 770-3166 www.index-usa.com