MAG Giddings & Lewis FT 3500 Horizontal Boring Mill Offers Big Capabilities

"MAG Giddings & Lewis makes boring exciting with its massive horizontal boring mill combining highest productivity and precision with 'have it your way' customization," said Linda Kieckafer, Marketing Manager. "The FT 3500 floor-type horizontal boring mill offers modular design flexibility as part of the MAG Giddings & Lewis family of advanced HBMs. The machine features standardized modules allowing HBMs to be configured with travels from 4 to 16 m (13.1 x 52.5 ft) and Y axis headstock travel to 5 m (16.4 ft). Modularity allows economical customization, along with industry's fastest machine build and delivery," said Ms. Kieckafer.

Parts produced on Giddings & Lewis machine tools are in all types of industries including the oilfield, construction, mining and job shop fields.

Modularity
Customers can configure an HBM specifically to their needs for maximizing productivity. Two available platforms (FT and ram-style FTR) can be fitted with choice of travels, headstocks, spindle diameters and spindle power, controls, coolant systems, workholding and tool magazines. An optional attachment changer enables storage and quick change of contouring heads, programmable boring bars, right angle heads and more to speed production.

"The traveling-column design allows unlimited X-axis travel for processing of large and long workpieces or multiple batch parts, while 20 m/min (787 IPM) rapid traverse rates, among the highest by a large HBM, reduce cycle times. Special-geared AC digital drives maintain high torque and stiffness even at high traverse speeds and feed rates. Standard Y-axis vertical headstock travel starts at 2 m (6.6 ft) with optional travel to 5 m (16.4 ft)," said the spokesperson.

Two floor-type models - the FT and FTR Series - give choices in spindle reach from 800 to 1250 mm (31.5 to 49.2 in). Both feature live spindles providing a programmable axis for drilling and tapping as well as adding reach for boring operations. The Z-axis extension capabilities of the live spindle allow the use of standard shorter tools that are more cost effective and can improve the machine's cutting abilities. "Contouring heads or feedout tools can be used with the live spindle, reducing setups and improving cycle times of parts with complex geometries by adding turning capabilities. Standard high-pressure coolant through-the-spindle enhances the cutting process and chip evacuation," said the spokesperson.

In addition to the live spindle, the FTR Series has a collinear ram. Manufactured from cast steel, the ram adds rigidity for machining operations that require extended W-axis reach on parts too large for an ancillary sliding table. The ram provides an adjustable mounting platform for a variety of attachments. The FTR 5000 ram is 500 x 630 mm (19.7 x 24.8 in).

Floor-type boring mill models offer a choice of spindle power train. Two and four speed versions are available with spindle diameters of 130 to 180 mm (5 to 7 inches). Depending on the spindle diameter selected, horsepower ranges from 45 to 75 kW (60 to 100 hp) and Z-axis travel is 800 to 1250 mm (31.5 to 49.2 in).

MAG Giddings & Lewis Engineering
All MAG Giddings & Lewis boring mills include G&L's exclusive spindle growth compensation. The Z-axis thermal compensation software dynamically offsets spindle growth, maintaining tight accuracies.

To mitigate ram displacement resulting from variations in ram extension and attachment weights, a hydraulically-actuated tension rod system is used. With the dynamic Ram Displacement Comp System, the forces applied to the tension rod are adjustable to counteract the static loads of attachments, correcting for the natural effects of ram extension.

"MAG Giddings & Lewis floor-type boring mills stand up to the most demanding machining requirements. Exceptional rigidity and durability are achieved by cross-ribbed column construction, wide way spreads on column and runway, and steel runway fabrication. These design features add structural integrity to resist deflection and minimize vibrations. The resulting rigidity of the cutting platform allows heavy metal removal and it is the foundation of the boring mills' accuracy. Contributing to the high degree of accuracy are standard linear scales, thermal compensation and preloaded axis drives. Positioning accuracy is 0.015 mm (0.0006 in) and repeatability is 0.008 mm (0.0003 in)," said the spokesperson.

"The hardened and ground preloaded roller guideways used on the G&L horizontal boring mills provide the capacity, friction characteristics, durability and maintainability necessary for high-performance manufacturing," said the spokesperson.

The large, zero-backlash ballscrews are hydraulically preloaded adding to the axis stiffness and thrust performance. The X-axis features an electrically-preloaded rack and pinion drive system. The drive is a gear-driven design, which produces higher torque and reduces maintenance compared to a belt drive system.

Maintenance-friendly, ergonomic design
The services area of the HBM was designed using Visual Uptime Management principles which are intended to improve and simplify maintenance and maximize machine and control availability. All services are centralized on a floor level panel. Clear, color-coded labeling indicates types of fluids or gases, direction of flow and normal operating ranges.

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