TOS MILL – VERTICAL FRF

GANTRY TYPE MACHINING CENTRE WITH MOVABLE COLUMN

• Movable gantry with fixed cross rail • Easy access of workspace • Column to column distance from 2 550 to 4 550 mm • Clearance between table and cross rail from 1 800 to 2 050 mm • Ram working travel from 1 100 to 1 500 mm • Motor output from 30 to 45 kW • Heavy-duty cast iron construction • Max. table load on 1m up to 12 000 kg • Small foot print • Wide variety of milling heads • Customized solution on request 2

RAM page 8

Z

Y

Basic machine features pages 4-7

Control system page 12 Automatic exchangeable heads pages 9-10

Exchange of heads page 10 Table page 5

X

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3

BASIC MACHINE FEATURES

• Basic machine parts are made of rigid ribbed castings

Basic parameters TOS VALUE FRF FRF (Q) 200

FRF (Q) 250

2 800

3 300

FRF (Q) 300

FRF (Q) 350

FRF (Q) 400

4 300

4 800

Working travel

Basic differences between machine executions

X (longitudinal)

FRF 200 - 350

Y (cross)

3 000–23 000 [mm]

Z (vertical)

3 800

1 100 / 1 250 / 1 500

1 250 / 1 500

1–15 000

1-20 000

1–15 000

1-20 000

1–12 000

1-15 000

1–30 000

1-30 000

1–15 000

1-30 000

1–12 000

1-15 000

Feed range (standard execution) X Y

[mm/min]

955 mm

Z Feed range (RAPID execution) X Y

[mm/min]

Z Column to column distance Column to column distance

[mm]

2 550

3 050

3 550

4 050

4 550

Clearance between table and cross rail

m

Clearance between table and cross rail

1 030 m Gantry with ram

Cross rail with slide (ball screw)

[mm]

1 800 / 1 950 / 2 050

1 900

Motor output

Cross rail profile

Motor output

• Combined boxway & linear roller packs in axes X, Y, Z • Feed drive in Y-axis: the servomotors drive the ball screws with a pre-loaded nut through the belt transmission

[kW]

30 / 37 / 45

Clamping table parameters TOS VALUE FRF

with toothed belt directly

FRF (Q) 200

FRF (Q) 250

FRF (Q) 300

FRF (Q) 350

FRF (Q) 400

2 000

2 500

3 000

3 500

4 000

9 x 220

11 x 220

13 x 220

15 x 220

17 x 220

Table width Table width

[mm]

Clamping T-slots

FRF 400

Number x pitch Width of middle T-slots

[mm]

22 H7

Width of other T-slots

22 H11

Maximum table load [kg]

4 000

6 000 – 12 000 (heavy duty execution)

920 mm

Maximum table load on 1 m2 table surface

Gantry with ram

Cross rail with slide (master-slave drive)

Cross rail profile

• Linear guideway in axes Y, Z • Linear roller packs in axis X • Feed drive in Y-axis: linear axis feed drive in cross direction is ensured by independent electrical servomotors

700 mm

1 250 mm

in master-slave connection on the feedbox with two pinions driving the rack

4

5

X A B

[mm]

C FRF F L G

FRF (Q) 2 000

[mm]

H

FRF

FRF (Q)

2 500

FRF

3 000

FRF (Q)

FRF

3 500

4 000

F

7 915

8 534

8 415

9 034

8 915

9 534

9 753

10 109

2 640

3 259

2 890

3 509

3 140

3 759

3 390

4 009

3 903

4 259

5 025

For vertical travel 1 250 For vertical travel 1 500

[mm]

5 275

5 525

6 000

8 000

10 000

12 000

14 000

16 000

18 000

20 000

22 000

24 000

8 770

10 770

12 770

14 770

17 070

19 670

21 670

23 770

26 370

28 370

30 370

1 671

1 671

1 671

1 671

1 621

1 621

1 621

1 571

1 571

1 571

1 571

11 070

13 070

15 070

17 070

19 320

21 620

23 620

25 670

28 270

30 270

32 270

2 000

2 500

3 000

3 500

4 000

8 925

9 425

9 925

10 425

11 000

FRF (Q)

8 034 4 775

M

FRF (Q)

7 415

For vertical travel 1 100 E

FRF

4 000

D

[mm]

5 850

Without rasing blocks

With rasing blocks 150 mm

With rasing blocks 250 mm

5 400

5 550

5 650

5 550

5 700

5 800

6 000/6 160*

6 150 / 6 310*

6 250 / 6 410*

1 800 / 1 900*

1 950 / 2 050*

2 050 / 2 150*

* FRF, FRF (Q) 400

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AUTOMATIC EXCHANGEABLE HEADS

RAM

• Main supporting part of the ram is formed by a casting of a square section • By series FRF(Q) 200 to FRF(Q) 350 in the rear, there are guideway areas made of hardened gibes that allow a vertical movement of the ram within the cross slide guideway • Ram by FRF(Q) 400 is in rear part equipped with profile gibs of linear roller bearing which allow a vertical movement of the ram within the cross slide guideway

Milling heads of own development and production

• Different types of head according to machining technology • Heads VP, VO, VK, VKE - continuous rotation around the headstock axis within the range of + 180° with two possibilities: a) mecanical indexing by 1°, b) „C“ axis • Head VO - vertical or horizontal setup; 2,5° positioning setup onto Hirth coupling in the 45° inclined plane Straight head VA1

30 kW 37 kW

Ram detail of FRF 200 - 350

Ram detail of FRF 400

45 kW

Angular head VA2

VP1

VP2

Head length

[mm]

400

700

300

650

Max. torque

[Nm]

2 000 / 1 400

1 000

2 000 / 1 400

1 000

Spindle speed range

[rpm]

20–4 000 / 6 000

20–4 000 / 6 000

20–4 000 / 6 000

20–4 000 / 6 000

Max. torque

[Nm]

2 000 / 1 400

1 000

2 000 / 1 400

1 000

Spindle speed range

[rpm]

20–4 000 / 6 000

20–4 000 / 6 000

20–4 000 / 6 000

20–4 000 / 6 000

Max. torque

[Nm]

2 000 / 1 400

1 000

2 000 / 1 400

1 000

Spindle speed range

[rpm]

20–4 000 / 6 000

20–4 000 / 6 000

20–4 000 / 6 000

20–4 000 / 6 000

Hydromechanical clamping unit Data flow input Electricity input Hirth tooth system

Motor output (S1)

[kW]

30 / 37 / 45

Ram cross section

[mm]

500 x 500

Universal indexing head

Two axis continuous head

Two axis head with electro spindle

VO

VK

VKE

THERMAL STABILIZATION & ELECTRONIC COMPENSATION Machine thermal stabilization

• Thermal stabilization for gearbox, drive shaft mounting in the ram, spindle drive and spindle heads cooling

Electronic compensation

• 8

A sophysticated system of tuning and machine parameters setup for increasing of machine mechanical accuracy

30 kW 37 kW 45 kW

Max. torque

[Nm]

1 250

1 000

87

Spindle speed range

[rpm]

20–4 000 / 6 000

20–4 000 / 6 000

110–18 000

Max. torque

[Nm]

1 250

1 000

87

Spindle speed range

[rpm]

20–4 000 / 6 000

20–4 000 / 6 000

110–18 000

Max. torque

[Nm]

1 250

1 000

87

Spindle speed range

[rpm]

20–4 000 / 6 000

20–4 000 / 6 000

110–18 000

9

AUTOMATIC TOOL EXCHANGE Chain type tool magazine

Special heads

• Customized design of automatic exchangeable heads - examples

Special head VA9

Special head VP10

Turning head IZN1

1 000 mm

R 40 Tool shank

Exchange of heads

Head exchange carriages 10

Additional angular head

ISO 50

ISO 50

HSK 100

HSK 100

BT 50

BT 50

BT 50

40

60

70

Tool maximum diameter – fully occupied magazine

[mm]

125

125

125

Tool maximum diameter – without adjacent tool

[mm]

245

245

245

[kg]

25

25

25

Maximal tool length

Special head VA11

ISO 50 HSK 100 [pcs]

Maximal tool weight (boosted)

around the „C“ and „B“ axis)

R 70

Storage capacity

Maximal tool weight (standard)

Special head VK force (increased torque

R 60

[kg]

40

40

40

[mm]

400

400

400

PICK UP tool magazines – optional

• Suitable for heavy and large size tools • Customized solution on request

Head exchange located in the working area 11

GUIDEWAYS

ACCESSORIES

Linear guideway

FRF 200-350 FRF 400

Combined boxway & linear roller packs

Linear roller packs

X

Y

Z

X

Y

Z

X

Y

Z

 

 

 

 

 

 

 

 

 

Tool cooling

• Low-pressure circuit for external coolant supply to the tool • High-pressure circuit for internal coolant supply into the tool High-pressure tool cooling: 20–80 bar, 35 l/min

Low-pressure tool cooling: 5 bar, 60 l/min

3D touch probe

• Designated for workpiece setting on the table and for its measuring • Measuring cycles automatically compensate for the length and diameter of the tool, workpiece and dimensional errors

Combined boxway & linear roller packs

Linear guideway

The laser tool measuring probe

• For non-contact tool setting and tool breakage detection CONTROL SYSTEMS

• Sinumerik 840 D solution line control system • Heidenhain iTNC 530 • Manual control of the machine easily performed from portable panel

Post processors

• Creation of CNC application from CAM system (post processors Catia, Nx, proE, etc.) 3D models

• Milling process simulation (3D Vericut model) „TURN KEY SOLUTIONS” Delivery of customized technological workplaces 

• Milling machine • Clamping fixtures • Tools • Guarantee of cycle times • CNC programmes • Warranty and post • warranty service

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WORKING AREA

REFERENCES

Covering of working area with plastic curtains

• More than 100 FRF machines worldwide sold since year 2000

Two levels of working area

Divided working area

Fencing with semi cabine

Addional VTL table

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REFERENCES

FRFQ 350-VR/A9, M/S Bharat Heavy Electricals Limited, India

FRFQ 200-KR/A6, EMT Púchov, Slovakia

FRFQ 300-VR/A10, NKMZ, Ukraine

FRFQ 250-VR/A6, Shifang Future Aerospace Industry, China

FRFQ 400-VR/A12 , RITES, India

FRFQ 300-VR/A8, Škoda Transportation, Czech Republic

FRFQ 250-KR/A8, SACM Durand, France

FRFQ 200-VR/A8, Cargotec Estonia, Estonia

FRFQ 250-VE/A8, Wikov MGI, Czech Republic

FRF 200-V/A4, Vítkovice Milmet, Poland

FRFQ 350-VR/A10, Fäh Maschinen- und Anlagenbau, Switzerland

FRFQ 200-KR/A6, Rolls Royce, Great Britain

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APPLICATIONS

Crankshaft segment machining

„FAN CASE“ machining

Crane part machining

Compression pump machining

Bogie frame machining

Machining of part for forestry

Bogie frame machining

Kaplan turbine blade machining

Machining of oil pan of diesel engine

Shaft machining

Turbine casing machining

Machining of bogie frame for subway car

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KUŘIM

Štefánikova 41/110, 602 00 Brno, Czech Republic Production plant: Blanenská 257, 664 34 Kuřim, Czech Republic Phone: (+420) 541 101 111 Fax: (+420) 541 102 355 e-mail: [email protected], [email protected] www.tos-kurim.cz, www.ckd-blansko.cz