StarragHeckert Introduces New 5-Axis STC 800

"With the introduction of the STC 800, StarragHeckert once again lives up to its reputation as technology leader in the field of 5-axis machining technology," said a spokesperson. "It was our aim to develop a modular machining center, which can be flexibly configured to meet the different requirements of new production concepts.

"The machine offers maximum stability and performance while also featuring a very compact design. These are crucial requirements to produce highly complex pieces in aluminum, steel, titanium and other difficult-to-machine materials.

"With uncompromising technology, the STC 800 takes on a variety of challenging machining solutions, especially in the fields of aircraft and engine construction, steam and gas turbine construction as well as production engineering and mechanical engineering.

"When completely machining today's impellers and blisks made of difficult-to-machine materials, precision and high flexibility are essential. StarregHeckert has many years of experience in the 5-axis machining of flow surfaces.

"The STC 800 is suited for the machining of complex workpieces, because the machining is done simultaneously in five axes and at any required angle. The machine allows the use of vertical milling heads, overlong tools and bridge-mounted tools with large diameters. Rotating axes and tilt heads work very precisely and deliver economical machining from five sides in one or several setups.

"The STC 800 has a rigid frame structure which has been calculated and optimized by using FEA (finite element analysis). The stable, low vibration machining guarantees long tool life.

"A wide selection of high-performance spindles for different speed ranges, torques and powers is available. This allows the use of the very latest tools. Non-productive times can be reduced thanks to fast rapid traverse rates, and the modularly expandable tool and workpiece handling has been thoroughly tested in the automotive industry.

"To minimize downtime, StarragHeckert has developed the graphic-aided diagnostic system SAM. The software allows users to locate the root causes of errors almost instantly and diagnostic messages help to eliminate these errors.

"Axis drives and guides: Highly dynamic drives with digital control and regulating system features high feed forces for heavy-duty cutting, low-maintenance three-phase servo motors, pretensioned, ground and backlash-free ball screws and absolute optical measuring systems on all five axes. Further, drives and guides are outside the range of operation. Large dimensioned, stiff, precision linear guides with recirculating roller packs complement pretensioned guide carriages that guarantee high machining quality and long-term accuracy.

"Table: Pallet clamping surface is 800 x 800 mm with a maximum workpiece weight of 2,000 kg. X-axis travel is 1,650 mm, Y-axis travel, 1,200 mm and Z-axis, 1,300 mm. Swing diameter is 1,400 mm. Travel is endless on the CNC rotary table B-axis. The B-axis is the fourth simultaneous axis and handles pallet interface with clamping cones and features concentric, water-cooled direct drive, high driving torque and fast table rotation. The A-axis milling spindle is the fifth simultaneously controlled CNC axis. The A-axis features a travel of -100-degrees/+ 60-degrees, stable roller bearings on both sides, high positioning accuracy through direct optical distance measuring and low-wear worm drive. High driving torque, hydraulic axis clamping and heavy-duty cutting are also performance features.

"Rapid traverse rates are 60 m/min (X, Y and Z), 12 RPM in the A-axis and 60 RPM in the B-axis.

"Motor spindles: Concentrically mounted, water-cooled high-performance synchronous /asynchronous motors (motor spindle 1: 60 kW, 81.6 HP, 15,000 RPM; motor spindle 2: 70 kW, 93.9 HP 24,000 RPM) feature oil-air lubrication directly through the outer ring (direct lubrication system), variable hydraulic bearing pretensioning, vector control with constant torque up to corner speed, thereafter constant power. An internal coolant supply is standard and sensors for bearing temperature, thermal spindle growth with compensation and in-process vibration monitoring.

"Gear-driven spindles: Drive is via two-step gearbox and achieves a maximum of 8,000 RPM from a 37 kW, 49.6 HP motor and torque of 940 Nm. Large dimensioned precision hybrid bearings, oil-air lubrication and internal coolant supply are standard.

"Tool handling: There are a variety of tool management approaches: a chain magazine with 60 and 80 pockets, a tower magazine with up to 240 tools for ISO 50 and HSK-100 tapers and a chain line magazine with up to 240 tools for HSK-A63. Magazine loading takes place without interruption of the machining process. Fast tool change is made possible by a twin arm tool changer. Options include tool breakage detection via laser within the working area and tool coding.

"Chip removal: Safe and quick chip removal through a wide chip conveyor in traverse bed. The STC 800 offers integrated washing system with workpiece/pallet shower and is highly suitable for wet and dry machining.

"Coolant supply: Vacuum fleece band filters or alternatively a low-maintenance backflush turbo filter and internal cooling, programmable in 10 bar steps to 70 bar. Coolant temperature regulation is optional.

"Workpiece handling: Rotating load/unload pallet station featuring 4 x 90-degrees indexing and optional hydraulic or vacuum coupling device with a maximum of 6 connections. Quick pallet change via lift-rotate system.

"Control and system capability: State-of-the-art process control and monitoring via Sinumeric CNC 840 D with integrated PLC provides contour fidelity during high-speed machining through look-ahead feature and dynamic preselection. Drive parameter adjustment depending on machining complexity and material, etc. and graphical diagnostic system 'SAM,' remote service and control cabinet with air conditioning unit.

"System extension and system capability: Future configurations of the STC 800 include expansion to a machining cell with linear or circular pallet pool; linking of several machines with single or multi-story linear pool, including all system control software."

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