MIKRONHSM 200 LPHSM 200U LP

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GF AgieCharmillesThe high-speed reference in the 3-axis and 5-axis range.With the HSM 200(U) LP, the engineersfrom GF AgieCharmilles have deve -loped an entirely new kind of machineconcept.

It puts concentrated power in thesmallest possible space.The HSM 200(U) LP series has beendesigned for the highest precision andsurface quality.

These vertical high-speed machiningcenters are therefore offered for bothtool and mold-making and the pro-duction of high-quality parts.They incorporate the full technicalcompetence of the Swiss machinemanufacturer. GF AgieCharmilles

MIKRON HSM 200 LP / 200U LP

Applikationen 4

Highlights 6

Table variants 8

Precision 10

Automation / interfaces 14

High-tech HSC spindle 16

Tool magazine 17

Chip and dust management 18

Options 20

smart machine 21

GF AgieCharmilles 22

Concentrated power in the smallest possible space – Compact and powerful for our customers in production

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MIKRON HSM 200 LPMIKRON HSM 200U LP

Applications

Perfect 5-axis machining without restriction.

Complex parts Various materialsWatch-making industry / micro mechanics• Form and position accuracy• Extremely small geometries• Part-specific handling systems

Electrodes Tungsten-copper / graphiteTool and mold-making• Surface quality• Dimensional accuracy• Very small geometric features

Drive with ball screw Drive with linear direct motor

Prostheses and implants Titanium / CoCrMedical technology• Powerful torque• 5-axis simultaneous machining• Perfect surfaces and working

accuracy

FluidicsAluminumAutomobile industry• 5-axis simultaneous machining • Shortest machining time• Excellent surface quality

Reflectors Powder-metallurgical tool steelTool and mold-making• 5-axis machining• Specular surface quality

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HighlightsHSM 200 LPHSM 200U LP

Precision and quality for tool- and mold-making, as well as exact parts production

2330

mm

• APS (Advanced Process System)• PFP (Power Fail Protection)• ITC (Intelligent Thermal Control)• OSS (Operator Support System)• RNS (Remote Notification System)

Tool magazine with 30 or 60 tools

Suction

Table design as3 axes (MIKRON HSM 200 LP)

5 axes (MIKRON HSM 200U LP)

Chip tray

High-performance machine control

Robust tool spindle with50,000 rpm

Machine hood for thermal andacoustic insulation

Machine base made of polymerconcrete with 3-point assembly

Minimal distance from laser to workpiece

Automatic tableclamping chuckwith optionalmedia feed-through

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For uncompromising demandsDynamics and precision brought together in one unit

Short power flow, short tolerance chainWith high-speed milling machines,considerable dynamic body forcesarise during cutting. The most impor-tant prerequisites for very high preci-sion and surface quality are dampingand the stability of the machinestructure. The revolutionary axis con-cept of the HSM 200(U) LP thereforeconsists of the following:• Polymer concrete machine base

with strong damping properties andheavy static weight

• Optimized force application andtransmission within a slide con-struction

• Linear axes with recirculating rollerguides 35 mm wide (X, Y, and Zaxes)

• High dynamic rigidity of the lineardirect drives

• Water-cooled direct drives in allaxes: X, Y, Z, B, C

• Highly compact and extremely rigidaxis assembly made of steel withthermal conductivity and expansionbehavior

• All guides above the machiningarea

• Suction openings for graphite

• Chip drawer

ErgonomicsThe spacious work area door enablesthe quick changing of externallyequipped workpieces.

Chip managementMachining chips fall into the centralchip shaft below the machining table.With low chip volumes, chips arecaught in a chip drawer. With highchip volumes, the chips are dischargedvia an external system together withthe cooling lubricant.

Dust managementMachining dust is sucked away cen-trally below the machining point. Twosuction shafts integrated into the machine bed enable a generouslyproportioned suction cross section.

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Table variants As flexible as required

Fully automatic production of smallbatchesAvoid unproductive periods during theproduction of small batches through• Automated changing of pallets or

pallet-bound, part-specific zero-point clamping systems

• Automated changing of customer-specific individual parts through theemployment of part-specific, zero-point clamping systems

A solution for all automation projectsWide selection of simple or complexpallet designs • System 3R GPS 70• System 3R GPS 70 with 3 additional

media• System 3R GPS 70 COCN (central

lifting rod for automated colletchanges)

• System 3R GPS 120• System 3R GPS 120 with up to 4 ad-

ditional media on the pallet surface(can be activated via the M functionand the pressure adjusted variablyvia the cycle, e.g. for System 3RTwistLock)

GPS 120 with 4× media

GPS 120

GPS 70

GPS 70 with 3× media

GPS 70 with COCN

Automatically changeable collets

Automatically changeable expanding mandrel

System 3R TwistLock

Watch plates

Automatic zero-point clamping system for pallets

Options for automatic zero-pointclamping systems for customizedparts

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60-1

40

38-1

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4517

115

GPS120

GPS120

GPS120

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LightsourceLED

Scanningreticle

Referencemark

Photo-voltaiccells

Condenserlens

Glassscale

Gratingperiod

Dynamic precision

Position sensor systemsAll MIKRON HSM 200(U) LP machinesare equipped with direct position sen-sor systems in the linear and rotaryaxes as standard.

• Resolution in the nanometer range• Protected by sealing air

Precision Core components:Static and dynamic precision

Static precision

Swiss thoroughnessPrior to delivery, each MIKRON HSMLP machine undergoes a comprehen-sive quality inspection in our air-con-ditioned assembly hall according toGF Agie Charmilles acceptance guide-lines.

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Precision Core components:Thermal precision and component precision

Cooling concept and reserve capacityThe MIKRON HSM 200(U) LP rangeleads precision machining into a newera. Sophisticated cooling manage-ment for heat discharge of the electri-cal drive groups.All linear axes and the circular-swivelunit feature a separate cooling circuit.

Thermal precision

Micro machining made easyThe workpiece and tool measuringsystems are especially suited formicro machining. • Low tactile forces allow for damage-

free and highly precise measure-ment of geometric features

• Precision laser optics for highlyprecise measurement of very smalltool diameters

Component precision

Five separate cooing circuits for the motorsof the drives in the X, Y, Z, B/C axes, and thespindle motor.

Primary and secondary part mounted on alarge cooling plate.

Low tactile forces and high temperature stability – 0.8 N of tactile force in the Z direction onthermo lock interface (hexagon / m&h)

Precise measurement of very small tool diameters from 25 μm to 20 mm

Achieve more...

MIKRON HSM 200 LPMIKRON HSM 200U LP

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....Dank Automatisierung noch produktiverAutomationInterfaces

Customer-specific solutions – More parts in less time at lower costs

Thanks to a standardized robot inter-face, the MIKRON HSM 200(U) LP canbe operated with a robotic articulatedarm system.

Frontal accessibility remains guaran-teed.

Loading and unloading is performed through automated side doors.

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50,000 rpmHSK-E32

HSM 200 LP •HSM 200U LP •

High-tech HSC spindle

Core components of Step-Tec

Tool spindles for demanding machiningWith a MIKRON HSM 200(U) LP machine you get the latest tool spindletechnology.

• 50,000 rpm HSK E-32• High torque up to 20,000 rpm• Low spindle heating increases

working accuracy• Highly stable double-ceramic hybrid

bearings in an “O” configuration forvery high radial capacity and rigidityduring machining

• Contact-free 3-chamber labyrinthseal for optimum sealing of thespindle nose

• Vector control for full torque in thelower speed range

• Oil/air lubrication system with extraction of the consumed oil

• Very short acceleration time – 2 seconds from 0 to 50,000 rpm

• Thread cutting without compensa-ting chuck in steel up to M6 (CK45)

Supplied in the package is the APS(Advanced Processing System) smartmachine module for the reliable recording and display of vibrationsduring the milling process.

Since 1995, Step-Tec has been developing, producing, selling, and repairing precise, high-performancespindles for leading manufacturers ofmachining centers for milling anddrilling applications.

Schematic diagram of three-chamber labyrinth

Fluids,

dirt, d

ust

Oil, oil mist

Oil chamber Environment

Internal sealing environment

Speed

Bearings

Contact-free sealingsystem

External sealingenvironment

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PO

WER

(kW

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SPEED (1/min)P: S1 P: S6 40% ED ts=2‘

8.5 kW (S6)

6.5 kW (S1)

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m)

SPEED (1/min)M: S1 M: S6 40% ED ts=2‘

3.4 Nm (S6)

2.6 Nm (S1)

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Tool magazine Tailored to your needs

Tool storage in many configurations• Disk magazine with 30 or 60 tool

positions• Reliable and extremely quick

double-gripper change system• Chip-to-chip in 4.4 seconds• Secure orientation of the measuring

sensor through a firmly assignedmagazine space

Productivity and process safety• User-friendly tool feeding• Simple feed monitoring through a

large glass panel• Secure access even during full

automation• Feeding during machining possible

Double-gripper change system

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Chip and dust management

Clean work area

Functional diagram

Configuration

Chip managementAutonomouschip volume

Customer requirements

Cutting lubricant (Combination)

• Minimal quantity lubrication (MQL)

• Air blow off external / dry

• Emulsion

• Dust extraction

• Emulsion

• Minimal quantity lubrication (MQL)

• Air blow off external / dry

Small

Small

Large

Large

Small

ChipsChips withemulsion

Supply air Emulsion Air withdust

80 L

400 L

• Chip drawer with closed bottom part

• Coolant tank 80 l • Chip drawer with water-permeable

bottom part and integrated fine filter

• Dust extraction with a suction performance of 1,900 m3 / h

• Chip drawer with closed top layer

• Band filter unit 400 l with chip container

• Chip drawer with opened bottom part

• Chip drawer with closed bottom part

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Chips, graphite, emulsionAlways a solution!

Drawer with opened bottom part foremulsion operation with large chipvolume

Supply air for dust extraction

Suction openings for dust

Chip drawer with water-permeablebottom part and integrated fine filter

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Options Tailor-made equipment

Further options:

• Beacon• Air blow off external (on the spindle slide)

Touch probem&h 40.40 LF/TI

Spray ring with up to nine indi-vidually adjustable nozzles

Touch probeRenishaw OMP400

Rotating window

Mist extraction

Automation interface

Dust extraction Heidenhain iTNC530 HSCI FS

External coolant supplyvia two nozzles

smart machine(www.gfac.com)

Air blow on C-axis positionedover laser system

Coolant tank 80 l

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Protection

Precision

Productivity

smart machine The new dimension in modern production

Bringing intelligenceinto the milling process is the inten-ded aim of "smartmachine".

The facts• Greater accuracy in shorter machi-

ning times• Increase in the workpiece surface

quality as well as the surface andshape accuracy

• Recognition of critical machiningstrategies

• Improvement in the process safety• Reduction of the machine set due to

longer service life• Higher availability• Better operating comfort• Considerable increase in reliability

in unmanned operation

smart machine construction kit systemEach of the modules fulfils a specifictask. Just like in a construction kit,the user can select the modules thatseem to him to be the best option forimproving his process.

Your benefit Producing the workpieces in a pro-cess-secure and precise manner,increasing the reliability in unmannedoperation, increasing the service lifeof the machine and significantly redu-cing production costs.

The smart machine is constantlybeing further developed.

The currently available modules canbe found at www.gfac.com

This includes a range of modules thatare collectively referred to under thegeneric term "smart machine" andthat fulfil various functions. In order tomake the milling process "intelligent",various requirements have to beimplemented. First of all, establishing comprehen -sive communication between man andmachine, which makes precise infor-mation that the operator requires toassess the milling process available tohim. Secondly, supporting the opera-tor in the optimisation of the process,which considerably improves the per-formance. Thirdly, the machine opti-mises the milling process, whichimproves the process safety and thequality of the workpiece - above all inunmanned operation.

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About GF AgieCharmilles

Milling

EDM

Laser

Customer Services

Automation

High-Speed and High-Performance Milling CentersIn terms of cutting speed, HSM centers are 10 times faster thanconventional milling machines. Greater accuracy and a better surfacefinish are also achieved. This means that even tempered materialscan be machined to a condition where they are largely ready to use.One essential advantage of HSM is that with systematic integration,the process chain can be significantly shortened. HSM has developedalongside EDM into one of the key technologies in mold and tool making.

Electric Discharge MachinesEDM can be used to machine conductive materials of any hardness (forexample steel or titanium) to an accuracy of up to one-thousandth ofa millimeter with no mechanical action. By virtue of these properties,EDM is one of the key technologies in mold and tool making. There aretwo distinct processes – wire-cutting EDM and die-sinking EDM.

Laser ablationLaser ablation supplements and extends the technologies offered byGF AgieCharmilles. With our laser technology we enable you to producetexturizing, engraving, microstructuring, marking and labeling of 2Dgeometries right through to complex 3D geometries. Laser ablation,compared to conventional surface treatment using manual etchingprocesses, offers economic, ecological and design advantages.

Operations, Machine and Business SupportCustomer Services provides with three levels of support all kind ofservices for GF AgieCharmilles machines.Operations Support offers the complete range of original wear partsand certified consumables including wires, filters, electrodes, resin andmany other materials.Machine Support contains all services connected with spare parts,technical support and preventive services.Business Support offers business solutions tailored to the customer’sspecific needs.

Tooling, Automation, SoftwareTooling for fixing workpieces and tools; automation systems and systemsoftware for configuring machine tools and recording and exchangingdata with the various system components.

Contact

www.gfac.com

Achieve more...

© Agie Charmilles SA, 2012The technical data and illustrations are not binding.They are not warranted characteristics and are subject to change.

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Technical dataMIKRON HSM 200 LP, 200U LP

MIKRONHSM 200 LP

MIKRONHSM 200U LP

Working rangeLongitudinal X mm 160 160Cross Y mm 160 160Vertical Z mm 200 200B-axis mm - +30 / –120°C-axis mm - n x 360°Number of simultaneous axis 3 5

Feed driveFeed rate X, Y, Z m/min 42 42

B,C min-1 - 150 / 250Acceleration X Y Z m/sec2 up to 14 up to 14

B, C rad/sec2 - up to 165 / 418

Accuracy (Standart)Accuracy A μ 4 4Repeatability R μ 3 3

Work tableClamping surface mm according Pal. according Pal.Max. workpiece weight kg 20 8

AutomationTool magazine Positions 30, 60 30, 60

WeightIncluding Pallet magazine approx. kg 3600 3600

OptionsLaser Tool Measuring • •Coolant tank 80l / 400l • •Mist extraction • •Dust extraction • •

SpindleSpindle 50 000 rpm Spindle power 40% ED kW 8.5 8.5HSK E32 Spindle torque 40% ED Nm 3.4 3.4

Pallet InterfacesGPS 70, GPS 120, with or without media COCN

Achieve more...

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2140

2560

1940

8301360

2330

830 700530

R 430

R 430

R 690

R 530

R 98

0

73-8

0

www.gfac.com

© Agie Charmilles SA, 2012The technical data and illustrations are not binding.They are not warranted characteristics and are subject to change.