WPK Wiener Produktionstechnik Kongress 2014 2. Wiener Produktionstechnik Kongress 2014 High precision machining with simultaneous axis by Large Universal Machining Centers 7./8. May 2014, Wien - Austria Peter Schneyer Werkzeugmaschinenfabrik WALDRICH COBURG GmbH, Coburg 1
WPK Wiener Produktionstechnik Kongress 2014 Agenda 1. Waldrich Coburg 2. History of Machine Tools 3. Applications for the Machine Tool Industry 4. Applications for the Diesel and Gas Engine Industry 5. Applications Super Large Gear Drives 6. Application for Super Large Ship Propellers 7. High precision Parabolic Antennas for Satellite Applications 8. Technological Trends 2
1. Waldrich Coburg and Veste Coburg 3
1. Waldrich Coburg Products 4
WPK Wiener Produktionstechnik Kongress 2014 History of machine tool Situation in the year 1850 1. Turning Machine since 1830 2. Drilling Machine since 1850 3. Milling Machine since 1850 4. Round Grinding Machine since 1850 Source, Museum Industrielle Arbeitswelt, Steyr, Österreich 5
WPK Wiener Produktionstechnik Kongress 2014 History of machine tools Summery: - From the year 1830 the maching technology of turning was relatively completed. The production of flate surfaces was mainly done by hand. - In England all main types of machine tools for turning, drilling, milling and round grinding were known from the year 1850. Source, Museum Industrielle Arbeitswelt, Steyr, Österreich 6
WPK Wiener Produktionstechnik Kongress 2014 Waldrich Coburg designed Multi-Technology-Concepts since 1980 The call for reduction of costs and machining time requires a most flexible machine concept. Complete workpiece machining on only one machine helps to minimize the expenditure for non-productive work (workpiece setup, -transport,...) as well as it leads to higher Quality. With a Waldrich Coburg Machine customer gets an ALL on ONE solution. 7
WPK Wiener Produktionstechnik Kongress 2014 Agenda 1. Waldrich Coburg 2. History of Machine Tools 3. Applications for the Machine Tool Industry 4. Applications for the Diesel and Gas Engine Industry 5. Applications super large gear drives 6. Application for super large Ship Propellers 7. High precision Parabolic Antennas for Satellite applications 8. Technological Trends 8
MasterTec 4000 AT-M3 High-Precision Application for the Machine Tool Industry Machine Concept, Layout, double Table MasterTec Attachment magazin 6 spindle units M3-RAM, Z-axis hydrostatic guide way M3-Ram-Stock Y-axis, on crossrail hydrostatic guide way MasterTec-cossrail, W-axis, on column hydrostatic guide way MasterTec tool changer and tool magazin with robot MasterTec-double table, X-axis linear guide way Machine Tool Double Table with moving Cross Rail 9
MasterTec 4000 AT-M3 High-Precision Application for the Machine Tool Industry Machine Concept, Layout, double Table Availability > 97% accuracy in µm- Act. value Tolerance Flatness of guide ways 3,9 [µm] 10,0 [µm] Straightness of left guide way 2,6 [µm] 5,0 [µm] Straightness of both guide ways 3,7 [µm] 5,0 [µm] Twist between both guide ways 2,9 [µm/m] 10,0 [µm/m] Attachments Technical Data 9000 rpm max. rpm 3300 Nm max. torque 63 kw max. Power Face contact spindle-tool MMS 10
MultiTec 3500 AT-M4 High-Precision Application for the Machine Tool Industry Machine concept and Layout 11 Drilling Milling Turning Turn-Mill Grinding Machine Tool Double table with one integrated rotary table
MultiTec 3500 AT-M4 High-Precision Application for the Machine Tool Industry Machine concept Grinding Cylindrical Grinding with vertical grinding unit Tolerance Axial run out 5,0 [µm]/1100 mm Cylindrical form 5,0 [µm]/1100 mm Machine Tool rotary table Accuracy of the workpiece 12
MultiTec 3500 AT-M4 High-Precision - for the Machine Tool Industry Machine concept Flat Grinding Flat Grinding with horizontal grinding unit Tolerance Flatness 5,0 [µm]/2000 mm Parallelism 5,0 [µm]/2000 mm Machine Tool rotary table Accuracy of the workpiece 13
WPK Wiener Produktionstechnik Kongress 2014 Agenda 1. Waldrich Coburg 2. History of Machine Tools 3. Applications for the Machine Tool Industry 4. Applications for the Diesel Engine Industry 5. Applications super large gear drives 6. Application for super large Ship Propellers 7. High precision Parabolic Antennas for Satellite applications 8. Technological Trends 14
World Market Leader in Machining of 4-Stroke Diesel Engine Components Main key elements of the engine block Mounting Holes for Cylinder Head 4-Stroke-Engine Machining Cylinder Liner by two simultaneous axis 15
World Market Leader in Machining of 4-Stroke Diesel Engine Components Form and position Tolerances of the Diesel Engine Casing Tolerance Roughness of Camshaft Bearing Ra 1.6 Roughness of Crankshaft Bearing Ra 1.6 Cylindrical form of Camshaft Bearing Cylindrical form of Crankshaft Bearing Coaxiality of Camshaft Bearing Coaxiality complete Camshaft Bearings Coaxiality of Crankshaft Bearing Coaxiality complete Crankshaft Bearings 0,01 mm/100 mm 0,01 mm/100 mm 0,02 mm Bearing-Bearing 0,08 mm/6000mm over all Bearings 0,02 mm Bearing-Bearing 0,08 mm/6000mm over all Bearings Diameter of Crankshaft Bearing 250 H6 +0.025/0 Diesel Engine Casing Accuracy of the workpiece 16
World Market Leader in Machining of 4-Stroke Diesel Engine Components Machining by Universal Head and Boring Bar 4-Stroke-Engine Machining Cylinder Liner by two simultaneous axis 17
World Market Leader in Machining of 2-Stroke Diesel Engine Components Machining the 3 main parts 2-Stroke-Engine High Precision Machining 18
World Market Leader in Machining of 2-Stroke Diesel Engine Components Four Waldrich Coburg PowerTec Gantrys in a Super Factory 2-Stroke-Engine PowerTec s in a New Diesel Engine Plant 19
World Market Leader in Machining of 2-Stroke Diesel Engine Components Four Waldrich Coburg PowerTec Gantrys in a Super Factory 2-Stroke-Engine Machining Crankshaft Main Bearing of Bedplate 20
World Market Leader in Machining of 2-Stroke Diesel Engine Components Four Waldrich Coburg PowerTec Gantrys in a Super Factory 2-Stroke-Engine Machining Coupling Flange of Crankshaft 21
World Market Leader in Machining of 2-Stroke Diesel Engine Components MOST POWERFUL 2-STROKE STROKE- DIESEL- Engine 14 Cylinder Engine Max. Power: 108,920 hp at 100rpm Each Cylinder 7780 hp 22
WPK Wiener Produktionstechnik Kongress 2014 Agenda 1. Waldrich Coburg 2. History of Machine Tools 3. Applications for the Machine Tool Industry 4. Applications for the Diesel Engine Industry 5. Applications super large gear drives 6. Application for super large Ship Propellers 7. High precision Parabolic Antennas for Satellite applications 8. Technological Trends 23
PowerTec 13000 AG-S2 High-Precision Large Gear Driving Industry Machine Concept, Gantry with Rotary Table Super Large Gear Drives High Precision Machining outer Gear Ring 24
PowerTec 13000 AG-S2 High-Precision Large Gear Driving Industry Machine Concept, Gantry with Rotary Table Super Large Gear Drives High Precision Machining outer Gear Ring 25
PowerTec 13000 AG-S2 High-Precision Large Gear Driving Industry Spindle Unit HSPO 900, S2, P=75 kw Super Large Gear Drives High Precision Machining outer Gear Ring 26
WPK Wiener Produktionstechnik Kongress 2014 Agenda 1. Waldrich Coburg 2. History of Machine Tools 3. Applications for the Machine Tool Industry 4. Applications for the Diesel Engine Industry 5. Applications super large gear drives 6. Application for super large Ship Propellers 7. High precision Parabolic Antennas for Satellite applications 8. Technological Trends 27
PowerTurn 10000 M3/NC High-Precision Ship building Industry Machine Concept, Vertical lathe for 5axis Ship driving industry High Precision Machining of Ship Propeller 28
WPK Agenda WPK Wiener Produktionstechnik Kongress 2014 1. Waldrich Coburg 2. History of Machine Tools 3. Applications for the Machine Tool Industry 4. Applications for the Diesel Engine Industry 5. Applications super large gear drives 6. Application for super large Ship Propellers 7. Parabolic Antennas for Satellite applications 8. Technological Trends 29
Machining of Parabolic Antennas 5-Axis- High-Performance-Cutting Assembled Parabolic Antenna Waldrich Coburg Assembly Shop Technology Forum 2011 30
Machining of Parabolic Antennas 5-Axis- High-Performance-Cutting Tolerances Surface form 30,0 [µm]/6000 mm Roughness Ra 1,6 [µm] Waldrich Coburg Machining Shop 3 Segments on a Gantry Machine 31
Machining of Parabolic Antennas 5-Axis- High-Performance-Cutting Waldrich Coburg Assembly Shop LaserTracker is checking the part 32
WPK Wiener Produktionstechnik Kongress 2014 Agenda 1. Waldrich Coburg 2. History of Machine Tools 3. Applications for the Machine Tool Industry 4. Applications for the Diesel Engine Industry 5. Applications super large gear drives 6. Application for super large Ship Propellers 7. Parabolic Antennas for Satellite applications 8. Technological Trends 33
8. Technological Trends ALL on ONE concept Multi-Technology-Machine Tools Larger sizes and weights of workpieces (up to 500 t.) New materials for Turbines, Inconell, IN 617, IN 718 More powerful tooling concepts Complete machining, less Set Up s Powerful and larger Machine Tools Higher Automation (AAC, ATC, APC) Laser integrated measuring system for controlling workpiece and machine tool Super Machines PowerTec 10000 AG, S20 RAM, 4000 mm PowerTec 13000 AG, S2 RAM, 3000 mm, Gearmilling D18000 mm PowerTurn 10000, S2-RAM, 4000 mm, +ST3 34