www.alzmetall.com Machining Center

GS 600

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ALZMETALL -COMPANY INTRODUCTION

is a company with an international reputation and global activities. For more than six decades we have been the leader in technology for drilling, milling and casting.

ALZMETALL products have proven themselves in general machining applications, in the automotive industry, in mould and die business, at the aircraft industry, as well as in many mid-size mechanical engineering enterprises. Our experience is based on over 198.000 machines supplied.

We focus on precision, performance and Quality for all our products. With our own foundry we do not only produce gray cast iron and spheroidal grey cast iron for our own machines, but also are supplier to the machine tool manufacturers and customers worldwide.

Our open company culture encourages innovation and performance by a continuous innovation towards High Tech and customer benefit for added value. Developing the GS-series, we offer highly dynamic and extremely rigid machining centers according to our pretensions: „we drive productivity“.

How to find us

Premises

Airport München“Franz Josef Strauß”

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Highlights• ALZMETALL-Gantry-Concept (AGK)

• Grey Cast Iron and Spheroidal Graphite Cast Iron

• Monobloc Travel-System-Carriage with incorporated Box-in-Box-System

• 4-fold Linear Guidance for Travel-System-Carriage and Z-Axis with integrated Motor-Spindle

• 3-fold Torque-Drives for Swivel-Axis (A-Axis) and Rota-ry-Axis (C-Axis) at GS 600/5-T und GS 600/5-FDT

• Hybrid-Machining-Applications such as: Drilling/Milling/Turning and Grinding at one Clamping-Set-Up

• Up to 750 kg workpiece weight including Clamping-Set-Up-Device at GS 600E/3 (Static Table)

• Up to 500 kg workpiece weight including Clamping-Set-Up-Device at 5-Axis Machines

Focus on operators needs• Access to Machine-Table ergonomically configured at

working height

• Workpiece loading by front, side and from top access. Crane loading possible

• Mist extraction directly at Machine-Table

• Steeply sloping chip tunnel straight below Machine-Table

• Working-Space flushing with coolant (option)

User benefitsStreamlined Force-Circuit between workpiece and Cutting-Tool in addition to geometrical and symmetrical configuration of the Carriage-Travel-System.

➠ Performing

• Thermal consistency at Tool Center Point (TCP) at X-Y- level without additional Axis compensation

• Significant reduction of Cutting-Tool costs

➠ Optimum

• Contour consistency at highest path velocity

• Lifetime of Motor-Spindle

➠ Guaranteed

• High-grade Parallel-Path-Precision through two Servo-Drives at each X- and Y-Axis

• Considerably reduced Total Cost of Ownership (TCO) over lifetime period of Machining Center

Machining Center with options: chip conveyor, cooling unit and coolant filter. These options are either to be installed along the right - or left side of the Machining Center.

AT A GLANCE

5-Axis Machining Center GS 600/5-T

• Automatic Access-Door feature open/close (option)

• Access to all maintenance units at working height

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ALZMETALL - THE CONCEPT

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FEM generated Structural Model - Point of force-input at TCP and simultaneously at Machine-Table

Multi-Elements-SimulationDuring the development process the Finite-Elements-Method was already applied by building the structure of the machine, patterned from the 3D-Volume–Model born from CAD to simulate vibration characteristics. Thus enabling engineers to determine the optimal dynamic rigidity of the machine under terms and conditions of the daily use at the shop floor.

DevelopmentThe „Finite-Elements-Method“ was applied to obtain the desired static and dynamic characteristics of each individual part of the machine and to investigate the collective rigidity of the Machining Center.

Modal-AnalysisResults gained by the Multi-Elements-Simulation of entire machine structure and design had to be confirmed at the prototype of the GS-Machining Center by using the Mod-al-Analysis. The experimental Modal-Analysis procedure is being used to realize and demonstrate the quality of the dynamic machine characteristics under production conditions.

The final test of the Modal-Analysis accomplished at ALZ-METALL verified the high degree of performance of the dy-namic requirements in reality. Thus the ALZMETALL GS-Series offers comparable Best-in-Class conditions for high dynamic machining applications.

RESEARCH AND DEVELOPMENT

Development by using Finite-Elements-Method (FEM)

X

YZ

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BASIC DESIGN

Rigidity, Dynamic and Thermal Symmetry „that‘s it what counts“

Extreme rigid, Integral-Basic-Body prepared for:

• Frame Side Walls as carrier for both Y-Axis (Y- and V-Axis)

• NC – Swivel- and Rotary-Table (A- and C- Axis) or Static-Table

• Disc-Tool-Magazine for 40 Tool Positions, alternative twin Disc-Tool-Magazine for [76] Tool-Positions. Rack-Type Tool-Magazine for [224] Tool Positions [Option].

All statically stressed Basic-Machine-Parts made from EN-GJL 300 (GG 30) and all dynamically stressed Basic-Machine-Parts and components made from EN-GJS 600 (GGG 60).

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• Y- and V-Axis Frame Side Walls as static basic structure. On top mounted Travel-System-Carriage with integrated Z-Axis Monobloc

• Dynamically stressed Basic-Machine-Parts and compo-nents made from EN-GJS 600 (GGG60)

• Both Linear-Axis X and Y 4-fold guided, Z-Axis 8-fold guided

TRAVEL - SYSTEM - CARRIAGE

Z-Axis sliding tube

Travel-System-Carriage

Monobloc

Ballscrew 2-fold, Y-Axis

Linear Guidance SystemsLinear-Encoder

Ballscrew

Servo-Drive Z-Axis

Servodrive X-Axis

2-fold Servodrives Y-Axis

4-fold Linear Guidance Systems

• Linear-Axis Y driven by two Ballscrews and two Ser-vo-Drives. X- and Z-Axis each driven by one Ballscrew and one Servo-Drive.

➠ Excellent Axis dynamics

➠ Cutting edge Parallel-Path-Precision

➠ Thermal stability due to geometrical symmetry with Thermo-Symmetric Motor-Spindle

Design Characteristics

Box-in-Box-System:

Y

Z

X

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TRAVEL - SYSTEM - CARRIAGE

• Small lever arms through Z-Axis Monobloc design

➠ Increase of stiffness and thus gain of Stability of overall framework

➠ Maximized cutting capacity

• Thermo-Symmetric

• Narrow and direct Force-Circuit

➠ Thermal stability

➠ High grade stability and stiffness with coexistent weight-optimized Axes-Elements

Krafteinleitung – Symmetrie

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NC - SWIVEL - AND - ROTARY - TABLE (SDK)

Torque-Motor sectional viewTorque-Motor

Torque-Motor

Swivel- (A-Axis) and Rotary- (C-Axis) Unit GS 600E/5

Rotary-Table DIA. 320 mm (Standard)

Rotary-Table 400 x 400 mm [Option]

Servo-Drive with gear

Counter-Bearing with clamping

Highly self-locking Gear-Motor

GS 600/5-T and GS 600/5-FDT

• Direct Rotary Drives (Torque-Motors) for high dynamic and oscillating machining – maintenance free –

• Two internal Torque-Motors at each Frame side wall as NC-Swivel-Axis (A-Axis) – patented-

• NC-Rotary-Table (C-Axis) equipped with Torque-Motor

➠ Highest swivel and rotational speed

➠ Higher accuracies – no mechanical backlash

➠ Elimination of friction at Drive-Components

➠ Wear – and maintenance free delivers reduced Total Cost of Ownership (TCO) over lifetime period of Machining Center

• A-Axes Servo-Drive with DC coupled preloaded gear. Counter-Bearing with hydraulic clamping

• C-Axes Compact-Unit with Servo-Drive and integrated gear

➠ High grade torsion stiffness

➠ Fast rotary motion of gear through capacious gear transmission at short positional movements of the Axes

➠ No single-edged wear

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A-AxisC-A

xis

min

. 150

/m

ax. 5

50 m

m

100

mm

500

mm

350

mm

ø 800

mm

ø 640 mm

Machining Space• Maximum utilization of Machining Space

• C-Axis DIA. 640 mm

• A-Axis DIA. 800 mm

• Swivel range ± 140°

• Table Load max. 500 kg

• Stainless steel Machining Space cover [Option]

WORKPIECE DIMENSIONS - MACHINING SPACE

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➠ All components at one cabinet

➠ At ground level ergonomic access

➠ Easy to maintain

➠ Integrated cooling unit for Motor-Spindle at GS 600E

SUPPLY - MAINTENANCE - SERVICING

Switchboard cabinet Pneumatic-System

Lubrication

Hydraulic-SystemCooling unit for Motor-Spindle

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OPTIONS

Table-Set 1) 2)

Clamping surface mm 555 x 320

T-slots acc. DIN 650 5 x 14 H12

Configuration parallel in X-direction

Distance mm 63

Table Load max. kg 500

Notice Rotary-Table ø 320 mm

Rotary-Table C-Axis 1) 2)

Clamping surface mm 400 x 400

T-slots acc. DIN 650 1 x 14 H7 und 4 x 14 H12

Configuration parallel

RPM max. 100 1) 1200 2)

Table Load max. kg 500

Distance T-slots mm 63

Rotary-Table C-Axis with NPS 1) 2) 3)

Clamping surface mm 400 x 400

T-slots without

Configuration NPS 4 x 90 °

RPM max. 100 1) 1200 2)

Table Load max. kg 500

Clamping surface mm 600 x 630

T-slots acc. DIN 650 1 x 14 H7 und 8 x 14 H12

Configuration parallel in X-direction

Distance T-slots mm 63

Table Load max. kg 750

1) GS 600/5-T2) GS 600/5-FDT

3) NPS = Nullpunkt Spannsystem

Further executions on demand

GS 600E/3 3-Axis-Machine with Static Table

400 mm400 mm

400 mm

200 mm

200 mm

400 mm

630 mm

600 mm

Static Table

ø 320 mm

555 mm

320 mm

NC - Swivel - (A-Axis) and Rotary-Tables (C-Axis)

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CNC-Contro lsHeidenhain iTNC 530 HSCI (standard) Heidenhain TNC 640

KINEMATIK GaugingAccuracy check and compensation - KinematicsOpt., Heidenhain - C 996, Siemens

3D-Touch ProbesInfrared transmission- TS 640, Heidenhain- TS 740, Heidenhain - IRP 25.41, m&h Inprocess- OMP 60, Renishaw- TC 50, Blum

CNC-Contro lsSiemens SINUMERIK 840 D sl

Electrical Handwheels - HR 410, Heidenhain- HR 520, Heidenhain- Mini-Handwheel, Siemens

Multiple-Media-Couplingfor Rotary-Table4-fold on selection air and/or fluids

OPTIONS

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Tool Setting SystemLaser System for Tool Setting and Breakage Detection on selection including mechanical Touch Trigger Probes LTS 35.65, m&h, (without mech. Touch Trigger Probes) LC NT, Blum, (without mech. Touch Trigger Probes) TC 76, Blum, (with mech. Touch Trigger Probes)

Tool-MagazinesTwin-Disc-Tool Magazine for 76 Tool Positions

Tool-MagazinesRack-Type Magazines with 224 Tool positions

Production PackageOn selection A, B, C with Scratch-Type-Conveyor, Hinge-Type-Conveyor, Magnetic-Conveyor

Production PackageCoolant Cleaning Unit with Metal-Edge-Filter or Compact-Paper-Filter

Camera and ScreenCamera mounted at Machining Space with transmission to external flat screen or Video-Server for process-set-ups and process-controls

OPTIONS

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ServicesMachining Center Installation, Set-Up, Production Assistance and Maintenance

Mist Extraction UnitAttached to Machine-Basic-Body

OPTIONS

[ ] Options• Rotary-Table (C-Axis) various configurations• Mutiple-Media-Coupling for Rotary-Table (C-Axis)• Motor-Spindles RPM-Range 18.000 RPM/24.000 RPM• Disc-Tool Magazine up to 76 Tool Positions• Tool Magazine Rack-Type up to 224 Tool Positions• Chip Conveyor: Scratch-Type-, Hinge-Type-,

Magnetic-Conveyar 1)

• High pressure Coolant Units up to 150 bar 1)

• Electrical Handwheels• 3D-Touch Probes• Automatic Workpiece-Changing-System• Tool Setting and Detection Systems• Workpiece-Pallet-Changing-System• Robot-Systems• Custom-Made Solutions• Services

1) Optional placement along the right- or left side of the Machining Center

Services NC-Program-Training, Operator-Training for Heidenhain and Siemens

Machining Center Acceptance Workpiece according to ALZMETALL-Standard, on selection Customer-Workpiece (option)

Remote Diagnosis, Remote Maintenanceand for NC-Programming-Support

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Type GS 600E/3 GS 600E/5 GS 600/5-T GS 600/5-FDT

Working RangeTraverse Path 460 / 600 / 400 mmStatic TableDistance Spindle - Static-Table min./max. 100/500 mmClamping Surface (w x d) 600/630 mm8 T-Slots acc. DIN 650 at X-Direction 14H12 x 63 mm1 T-Slot at Table Center Line at X-Direction 14H7Machine-Table Load 750 kgNC-Swivel-and Rotary-TableDistance Spindle - Table min/max. 150/550 mm

Drives at Swivel- and Rotary-Axis conventional indirect Torque direct

Swivel Range of A-Axis ± 140 ° ± 140 °

Swivel Speed at A-Axis 30 min-1 90 min-1

C-Axis Rotation 360 ° endlessC-Axis RPM max. 50 min-1 100 min-1 1200 min-1

Diameter Machine-Table C-Axis Ø 320 mm Ø 320, [400 x 400] mm8 T-Slots acc. DIN 650 14H12Star-Shaped Configuration 4 x 90 ° 4 x 90 ° [ 5 x parallel|, Distance 63 mm]Machine-Table Center Bore Ø 50 H7 mmTable Load max. 500 kgC-Axis Rotary-Diameter at A-Axis Center Ø 640 mmA-Axis Swivel Diameter (Swing) at X-Axis Center Ø 800 mmDistance A-Axis-Center to Rotary-Table 100 mmFeed-Drive-System X-, Y-, Z-AxisDigital AC-Servo-Motors, maintenance freeMax. Rapid Travel X-, Y-, Z-Axis at TCP 30 m/min 30 m/min 60 m/minFeeding Force X-, Y-, Z-Axis at CDF 40% 4 - 4 - 5 kNMotor-Spindle-DriveHigh Frequency Motor-Spindle Cutting-Tool Interface HSK-A63 HSK-T63Motor-Spindle-Power at CDF 20% 16 kW [26] [17] kW 13 kWVariable Speed Range max. 10.000 min-1 [18.000][42.000] min-1 10.000 min-1

Motor-Spindle Torque at CDF 20% 102 Nm [82] [11] Nm 80 NmTool-Magazines Tool positions, Type 40 Disc, [76 Twin-Disc] [224 Rack-Type]Max. Tool Diameter, Chain fully loaded 80 mmMax. Tool Diameter, Chain neighbour positions unloaded

130 mm

Max. Tool Length 300 mm [150 at upper Disc]Max. Tool Weight 4 kg [10 kg at Rack Type]Tool-Change-Cycle (approx.) 2 sChip-to-Chip Cycle 4,5 sLinear Encoders X-, Y-, Z-Axis indirekt absolut, directPositional Tolerance TP acc. DIN/ISO 230-2 (VDI/DGQ 3441)

≤ 0,007 mm

Angle Encoder System A-, and C-Axis direktMachine Weight excl. Options 6800 kg

CNC-Controls Heidenhain iTNC 530HSCI, [Heidenhain TNC 640], [Siemens 840 D sl]

Siemens 840 D sl [Heidenhain TNC 640]

[Option]

TECHNICAL DATA

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MOTOR - SPINDLES RPM - Power - Table

16P S6/25%

Md S6/25%

1.500 10.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

14

11

70

90102

Md

(Nm

)

P (k

W)

13P S6/25%

Md S6/25%

1.500 10.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

11,5

9

7

7383

Md

(Nm

)

P (k

W)

26P S6/25%

Md S6/25%

3.000 18.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

23

17

55

7382

Md

(Nm

)

P (k

W)

17P S6/25%

Md S6/25%

15.000 42.000 n (min -1)

P S6/40%

Md S6/40%

P S1

Md S1

13

10

6,4

8,311

Md

(Nm

)

P (k

W)

GS 600E/3, GS 600E/5, GS 600/5-T

RPM max. = 10.000 min -1

GS 600E/3, GS 600E/5, GS 600/5-T

[RPMmax. = 18.000 min -1] Option

GS 600/5-FDT

RPM max. = 10.000 min -1

Hirth-Gear-Indexing for turning Operation

GS 600E/3, GS 600E/5, GS 600/5-T

[RPM max. = 42.000 min -1] Option

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appr

ox. 2

.300 m

m

max.

2.800

mm

incl. Options A) und B) approx. 3.250 mm

Coolant Unit

approx. 1.900 mm

appr

ox. 3

.150 m

m

incl. O

ption

s E) ,

appr

ox. 4

.010 m

m

appr

ox. 6

00 m

m

R 1.150

approx. 1.350 mm

A)B)

E)

F)

C)D)

GS 6

00

MACHINING CENTER DIMENSIONS

Machining Center (Single Unit) - Transport Dimensions) GS 600

• Width approx. 1.900 mm

• Depth approx. 3.750 [4210] mm

• Height approx. 2.370 mm

OptionsA) Chip Conveyor

B) Chip Trolley

C) High pressure Coolant Unit

D) Coolant cleaning system

E) Rack-Type Tool-Magazine

F) Mist Extraction Unit

Please observe: Options A, B, C and D are either to be installed along the right- or left side of the Machining Center!

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AUTOMATION SOLUTIONS

PowerCell Robot-Loading-System and Zero Point Tooling System with 24 workpiece-pallets

Robot-Loading-System for workpiece-pallets with external Rack-Type-System

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ALZMETALL Werkzeugmaschinenfabrik und Gießerei Friedrich GmbH & Co. KG

Postfach/P.O. Box 1169D-83350 Altenmarkt/Alz · GermanyHarald-Friedrich-Straße 2-8D-83352 Altenmarkt/Alz · Germany Tel./Phone +49 (0) 86 21/88-0Fax +49 (0) 86 21/88-213E-Mail: info@alzmetall.comInternet: www.alzmetall.com

Also contact us for further Machining Centers of the CS-Series, Drilling Machines-Series and Custom made Cast-Iron-Products.

• GS 800/3• GS 800/5-T• GS 800/5-FDT

• GS 1000/3• GS 1000/5• GS 1000/5-T

• GS 1000/5-FDT• GX 1000/5-AF• GX 1000/5-LOB

• GS 1400/3• GS 1400/5-T• GS 1400/5-FDT• GX 1400/5-AF

• CS 600• CS 1200• CS 1200 P

PRODUCT RANGE - PLEASE CONTACT US

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