n°2

news Newspaper by MECAL SpA - Year I, nr 02 - October 2006

Logical guide to choosing the ideal machinery for your specific needs

Which machining centre? The number of axes controlled autonomously is the first point to think about,

but certainly not enough on its own. Here are the jewels of the Mecal technology. When we talk about “machining centres” we are entering a highly variegated field. As a rule one thinks that the difference between several proposals is in the number of axes available or in the fact they are autonomously controlled. Undoubtedly this is a necessary condition but certainly not enough to find the most suitable machining centre for one’s specific needs. For a machine tool to be defined a machining centre it has to meet at least 3 requirements: • have 3 automatically controlled axes; • be able to perform both linear and circular interpolation operations; • be programmable for any work based on a specific drawing.

Machines that do not have this minimum configuration have to be defined as “multifunction milling machines” because they come closer to the copy router milling world than to machining centres (in Mecal this category of product belongs to the FR 8xx series).

Machining centres were first created because of the need to work small quantities of bulky materials: the need, that is, to have machines that are flexible in their positioning and fitted with heads that can move even several yards. Besides the number of axes, one other fundamental aspect is to decide whether you want a machining centre with a moving workpiece or a static workpiece. In the first case, the workpiece is held by pneumatic vices mounted on a swinging beam which can be slanted as necessary. This solution can always be used when the workpieces: • are light in weight; • have a maximum crosswise section of less than 200 x 200 mm; • are under 3,500 mm in length. Exceptions are sometimes applicable after appropriate evaluation. For this type of use Mecal has come up with two specific series: MC 309 and MC 305. MC 309 Nike was designed with the workshop in mind. Its friendly interface allows the traditional craftsman to access the programming of orders however diversified they may be. MC 305 Fat represents the high point of the range in this sector. Configurable in three versions (TF, TP and TM) it is ideal for the professional intent on making doors and windows with a marginal interest in the curtain wall market. But when workpieces become big and heavy, machining centres are used with a static position. On this type of machine it’s the electric spindle that is either slanted or made to rotate around the workpiece. The MC 304 series of machining centres belong to this category. MC 304 Ariel is dedicated to the automotive sector and to the railway sector in particular where some extruded elements have sections as big as 650 x 200 mm with weights in the range of 30 kg/m. MC 304 Atlas is, on the other hand, dedicated to machining closure elements for homes, industrial doors and sectional doors (garage doors). Some of the panels machined can reach 900 mm in width. MecalSoft software controls the Mecal machining centres, an exclusive and customisable programming system based on different programming levels, letting the user control even the most complex work with the maximum of ease.

Avant garde solutions for large extruded elements

From architecture to mechanics The use of extruded aluminium is increasing constantly, even going beyond its architectonic use. And this means that specifically designed instrumental tools must be available. The use of extruded sections as structural elements is currently enjoying a particularly happy time. So it was natural to think about developing machines specifically to machine them. And only the ability to design and produce machines that can economically work large extruded elements with high tolerances distinguish a quali-

ty production. Mecal proposes an adequate line of products, known as series MC 302 and MC 308. MC 302 Geos-5 is the top of the range for use on sections for the architecture sector. Five CNC controlled axes permit to work on any surface in relation to the position of the tool in space. 3D architectonic structures such as pyramids or “winter gardens” will only be restricted by the imagination of the design. Today MC 308 Tethys is the machining centre with the highest opera-

ting capacity used in the extruded sections field. A couple of interesting numbers: sections up to 800 x 400 mm, extruded elements weighing up to 60 kg/m. As a matter of fact, extruded aluminium sections are being increasingly used for industrial movement and in linear movement mechanics. Steel sections (ST52) are, on the other hand, used in the general mechanics field, always for structural purposes. As a rule, on this type of element – which can reach a considerable size – only simple machining is required on significant lengths. MC 308 Tethys is designed and made so contractors can economically supply its clientele a finished extruded product with reduced tolerances, which is what is wanted today.

Minimal encumbrance, maximum yield The ideal machining centre to meet the requirements of medium to small firms. All the innovation designed for limited spaces. MC 309 NIKE Designed and made to meet the needs of medium to small firms as well, MC 309 Nike is distinguished by its relatively compact size and its great operating flexibility. Machinery with an extraordinarily high technological innovation content and featuring all the functions offered by bigger machining centres but which is easy to install even in tiny spaces with an operatorfriendly interface. MC 309 Nike is a mobile upright machining centre, with 3 CNC controlled axes (X, Y, Z) + 1 pneumatically controlled axis (A). The vice beam (axis A) can swing 180° by means of a pneumatic command. Three mechanical stops – adjustable and separate from each other – determine the orthogonal points. It is made specifically for machining extruded sections or items in aluminium, PVC, light alloys in general and steel.

Axis X Working length Max. forward speed Axis Y Working width Max. forward speed Axis Z Working height Max. forward speed Axis A Useful working stroke Positioning speed Electric Spindle Speed Power Dimensions Length Width Height Weight Standard machine weight

2

mm. m./1'

2600 50

mm. m./1'

370 30

mm. m./1'

325 30

° °/s

± 90° 45

rpm kw

18000 3,8

mm. ± 4395 mm. ± 2070 mm. ± 2025 Kg.

± 1200

It is flexible and practical to work with: advantages of a unique machine

• The main axes slide along precision section guides and are operated by brushless dc servomotors. • Milling can be done with linear and circular interpolation on the axes X-Y-Z. • By using a milling disc both ends of the section can be milled (trimming cycle). • Pneumatically controlled reference stops for positioning the section. • The electric spindle is designed for a quick change of the arbour. • Tools are cooled by a unit with minimal system.

Doors and windows open onto the future Copy router and milling functions can be performed singly or integrated by a software programme: double option, maximum flexibility MC 305 FAT TM

A machine with a high added value, created to measure for professionals working mainly on doors and windows. Designed to work at maximum speed and flexibility on pieces that are smaller and lighter, MC 305 Fat TM is the machining centre born from the need to combine different functions – copy router and miller – that can be perfor-

med singly or together thanks to a software programme. The result is a flexible and versatile machining centre, particularly indicated for special machining work. The 5.5 kW electric spindle can drill, cut and tap (M10). The workpieces are secured by 5 pneumatic vices on a swinging beam that can be positioned at any angle up to 180°;

rotation is managed directly by the cyclic redundancy control system. In addition, MC 305 Fat TM, thanks to the differentiated cyclic redundancy control, can also work on long pieces that go beyond the useful working area. In this case, once the operator has programmed the entire machining cycle, he carries out a first work cycle using a

workpiece reference stop and then moves the workpiece by hand against the opposite workpiece reference stop as indicated by the control system.

• Mobile upright machining centre with vertical spindle. • 4 CNC controlled axes (X, Y, Z, A). • It is designed to machine extruded sections or items in aluminium, PVC, light alloys in general and steel. • Milling can be done with linear and circular interpolation on the axes X-Y-Z. • By using a milling disc both ends of the section can be milled (trimming cycle). • Automatic tool change with a 7-place crib that can hold bits, cylindrical cutters, circular cutters (200 mm Ø), angular heads. • DPM. Vice Positioning Device. • MMI alternative. Independent Powered Vices.

Axis X Working length Max. forward speed Axis Y Working width Max. forward speed Axis Z Working height Max. forward speed Axis A Useful working stroke Positioning speed Electric Spindle Speed Power Dimensions Length Width Height Weight Standard machine weight

mm. m./1'

3425 80

mm. m./1'

400 60

mm. m./1'

400 40

° °/s

± 90° 75

rpm kw

18000 5,5

mm. ± 4930 mm. ± 2400 mm. ± 2190 Kg.

± 2480

Automation for the automotive sector Great machining work for the railway world: quality that takes a trip round the world MC 304 ARIEL 3

An avant garde machining centre, dedicated mostly to the automotive world. In fact, in the prestigious Mecal range the acronym MC 304 stands for static positioning centres, that is, centres for workpieces that have very big sections or are very heavy. This is why MC 304 Ariel-3 targets the railway sector more than any other and it can work extruded elements weighing 30 kg per metre with sections of up to 650 x 200 mm. More generally, a machine for companies handling great quantities of product or that work with extremely long lengths (for example, machining curtain walls), thanks to the remarkable amount of room of the longitudinal strokes, combined with high movement speed and excellent tracking precision. And that’s not all: the ample working fields guarantee maximum flexibility in the type of sections that can be machined besides the ease with which the workpieces can be positioned on the machine.

Axis X Working length Max. forward speed Axis Y Working width Max. forward speed Axis Z Working height Max. forward speed Axis A Useful working stroke Positioning speed Electric Spindle Speed Power Dimensions Length Width Height Weight Standard machine weight

4

mm. m./1'

7430 80

mm. m./1'

1420 60

mm. m./1'

500 40

° °/s

± 90° 85

rpm kw

18000 5,5

mm. ± 9250 mm. ± 3090 mm. ± 2275 Kg.

± 4450

• Mobile upright machining centre with vertical spindle. • 4 CNC controlled axes (X, Y, Z, A). • It is designed to machine extruded sections or items in aluminium, PVC, light alloys in general and steel. • Milling can be done with linear and circular interpolation on the axes X-Y-Z. • By using a milling disc both ends of the section can be milled (trimming cycle). • The axis of the electric spindle can be positioned at any angle within a 180° range (± 90°) parallel to the crosswise axis (Y). • A 5.5 kW electric spindle designed for a quick change of the arbour, capable of drilling, milling and tapping (M10). • Automatic tool change with a 12-place crib that can hold bits, cylindrical cutters, circular cutters (200 mm Ø). • MMI alternative. Independent Powered Vices. • The working area is delimited by two pneumatically controlled reference stops. It is possible to work indifferently with just the one cycle or with a swinging cycle (shadow time). On request another two intermediate reference stops can be installed so as to work on 4 identical or different items.

Maximum quality dimensionfor doors and main doors

Special bedplate to get as close as possible to the working area and free areas for scrap materials: brilliant expedients that help the operator’s movements and optimise machining

MC 304 ATLAS 3

For great weights and dimensions. A machine conceived for making home closure systems, sectional doors for garages and industrial doors.

MC 304 Atlas-3 is a highly specialized machining centre for working on panels as wide as 900 mm. The machine’s structure and bedplate, as too the movement of the various components, have been designed specifically so the operator can get as close as possible to the working area, facilitating his movements and optimising work. In addition, when designing the work top configuration, free areas have been created so all scrap material, including large pieces, can fall on the floor so they won’t get in the way as the workpiece is machined.

• Mobile upright machining centre with vertical spindle. • 4 CNC controlled axes (X, Y, Z, A). • It is designed to machine extruded sections or items in aluminium, PVC, light alloys in general and steel. • Milling can be done with linear and circular interpolation on the axes X-Y-Z. • By using a milling disc both ends of the section can be milled (trimming cycle). • The axis of the electric spindle can be positioned at any angle within a 180° range (± 90°) parallel to the crosswise axis (Y). • A 5.5 kW electric spindle designed for a quick change of the arbour, capable of drilling, milling and tapping (M10). • Automatic tool change with a 7+1-place crib that can hold bits, cylindrical cutters, circular cutters (200 mm Ø). • MMI alternative. Independent Powered Vices. • The working area is delimited by two pneumatically controlled reference stops. It is possible to work indifferently with just the one cycle or with a swinging cycle (shadow time). On request another two intermediate reference stops can be installed.

Axis X Working length Max. forward speed Axis Y Working width Max. forward speed Axis Z Working height Max. forward speed Axis A Useful working stroke Positioning speed Electric Spindle Speed Power Dimensions Length Width Height Weight Standard machine weight

mm. m./1'

7430 80

mm. m./1'

1320 60

mm. m./1'

500 40

° °/s

± 90° 85

rpm kw

18000 5,5

mm. ± 9500 mm. ± 2980 mm. ± 2200 Kg.

± 3870

Completeness and flexibility MC 308 TETHYS

It is the machining centre with the greatest operating capacity in the extruded sections field, designed to machine large items in light alloy, like those for linear movement mechanics and for the mechanics world in general. All the components of the MC 308 Tethys are designed to withstand heavy weights while its special structure is conceived to facilitate the loading and unloading of cumbersome and heavy extruded ele-

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ments with particular attention to protecting the covering of the sections. With the MC 308 Tethys it is possible to work on items with completely different machining requirements, utilising the working cycle in shadow time (swinging cycle) and dividing the working area into two completely separate areas.The vices move into position at maximum speed and precision; each vice can be controlled separately so it can be

repositioned automatically to avoid collision if machining falls into an area interfering with the backing system. Lastly, programming is simplified thanks to a completely guided approach. It is possible to programme directly in ISO or with the facilitated geometry system, perfected by Mecal specifically for those who are not too familiar with the ISO codes.

at the service of mechanics The maximum of technology for great items used for industrial movement

• • • • • • • • • •

Mobile portal machining centre with vertical spindle. 5 CNC controlled axes (X,Y, Z, C, A). Milling can be done with linear and circular interpolation on the axes X-Y-Z. By using a milling disc both ends of the section can be milled (trimming cycle). It is designed to machine extruded sections or items in aluminium, light alloys in general and steel. The head of the spindle (C) can turn at any angle within a range of ± 220° and the spindle (A) angled within a range of ± 125°. A 18 kW electric spindle designed for a quick change of the arbour (HSK-F-63), capable of drilling, milling and tapping (M10). It is cooled with liquid. Automatic tool change with a 30-place crib that can hold bits, cylindrical cutters, circular cutters (250 mm Ø). MMI alternative. Independent Powered Vices. The working area is delimited by two pneumatically controlled reference stops. It is possible to work indifferently with just the one cycle or with a swinging cycle (shadow time). On request another two intermediate reference stops can be installed so as to work on 4 identical or different items.

Axis X Stroke Max. forward speed Axis Y Stroke Max. forward speed Axis Z Stroke Max. forward speed Axis C Stroke Positioning speed Axis A Stroke Positioning speed Electric Spindle Speed Power Dimensions Length Width Height Weight Standard machine weight

mm. m./1'

8000 50

mm. m./1'

1300 50

mm. m./1'

950 30

° °/s

± 220° 85

° °/s

± 125° 85

rpm kw

22000 18

mm. ± 10000 mm. ± 3250 mm. ± 3260 Kg. ± 12900

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When the extruded item is a structural element Modern automation for great dimensions: a specific machining centre for sections used in architecture

MC 302 GEOS 5

Axis X Stroke Max. forward speed Axis Y Stroke Max. forward speed Axis Z Stroke Max. forward speed Axis C Stroke Positioning speed Axis A Stroke Positioning speed Electric Spindle Speed Power Dimensions Length Width Height Weight Standard machine weight

Working with maximum quality also on big sizes is no longer a problem. In fact, MC 302 Geos-5 is the ideal solution for structural sections used in architecture. A machine born to meet the need to machine combined and complex surfaces, reasoning on volumes: thanks to the 5 CNC controlled axes, this machine can work on any surface in relation

8

mm. m./1'

7500 70

mm. m./1'

1450 50

mm. m./1'

620 30

° °/s

± 220° 85

° °/s

± 125° 85

rpm kw

24000 7,5

• • • • • • •

mm. ± 9800 mm. ± 3180 mm. ± 2900 Kg.

± 7980

to the position of the tool in space A machining centre that combines great structural solidity with maximum flexibility.In fact,it is quick and simple to fix the workpieces as it uses systems widely tested on smaller machines. The top of the range, for items in line with the most advanced designing demands.

• • •

Mobile portal machining centre with vertical spindle. 5 CNC controlled axes (X, Y, Z, C, A). Milling can be done with linear and circular interpolation on the axes X-Y-Z. By using a milling disc both ends of the section can be milled (trimming cycle). It is designed to machine extruded sections or items in aluminium, light alloys in general and steel. The head of the spindle (C) can turn at any angle within a range of ± 220° and the spindle (A) angled within a range of ± 125°. A 7.5 kW electric spindle designed for a quick change of the arbour, capable of drilling, milling and tapping (M10). It is cooled with liquid. Automatic tool change with a 18-place crib that can hold bits, cylindrical cutters, circular cutters (250 mm Ø). MMI alternative. Independent Powered Vices. The working area is delimited by two pneumatically controlled reference stops. It is possible to work indifferently with just the one cycle or with a swinging cycle (shadow time). On request another two intermediate reference stops can be installed so as to work on 4 identical or different items.

MecalSoft Control Unit The machine is controlled by the electronic system CLIPPER interfaced with a PC. Operator interface is a Desktop Personal Computer (Compaq or Hewlett Packard), chosen for the global availability of a post-sales assistance network. Programming Double programming system: according to ISO standard specifications or CAD/CAM graphic parameters. A mixed method is also possible, that is, entering parts of work in an ISO programme with the graphic method or entering/modifying a CAD/CAM graphic generated programme with the ISO language. Mecal has created a simplified user interface: the fundamental operations are visually displayed with icons; with the sub menus the operator is asked to define a minimum number of parameters or to complete a minimum number of variables.The machinings used most can be defined as parameters and stored in a specific file. Graphic Method (CAD/CAM) With the graphic method the operator can create machining programmes without having to know even one instruction in the ISO language. All he has to do is draw the machining to be done, also by superimposing elementary figures (circles, slots, rectangles) quote them as wanted (with fixed values, with parameter values – that are defined in the next step – with fixed formulas or parameter formulas), “position” the drawing of the

Superior intelligence for machining centres 3D CAD Programming with 3D CAD introduces, in machining centres, the power of visually displaying the result immediately. The operator can see any errors he may have made straight away and, with just a few touches with the mouse, he can add, modify and give the values for each single machining operation. There are two display methods: • View • Render In the first case (View) the machinings are placed against the workpiece so they can be recognised straight away. In the second case (Render) the machinings are dug out of the workpiece to actually see the final result, as it will come out of the machine after the programme has been executed. All the values, including depth, are real, reproduced in scale on the

machining on the workpiece (that is, define “where” the machining is to be done) and choose the tools to use. The drawings of the machining can be connected to other drawings to obtain new, more complex drawings which, in turn, can be connected to other drawings, and so on as many times as wanted. Method with the ISO language All the standard functions are possible, the use of macro instructions, the creation of macros, using parts of a programme or using parts of a programme in another.

workpiece; in both display methods the workpiece can be turned at any angle and zoomed to check each single detail.

An avant garde software programme for all functions, from the simplest to the most difficult, with operator- friendly interface Positioning the vices To avoid possible collision, the system also provides the positioning values for each single vice; it’s up to the operator to move them into the right position. A graph is shown on the screen indicating, in red, the areas of work or of a potential collision hazard. Using the mouse, the operator can see the same image at different angles; as may be necessary, he can move the vices manually, selecting them with the mouse and dragging them into the position wanted. The system will, of course, take any alterations made into account and adjust all the relative values. If the machine has an automatic Vice positioning system, the controller will see to repositioning the relative vices before machining begins.

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MecalSoft Simulator

The reliability of the end result There is a special precision programme for optimising work and avoiding mechanical damage By simulation we mean a real-life model that can be used to evaluate and predict the dynamic unfolding of a series of events subsequent to the imposition of certain conditions by the analyst or user. Simulations are a very powerful experimental tool and use the calculation possibilities offered by the computer expert; in fact, simulation is nothing other than the transposition, in logical-mathematical-procedural terms, of a true-to-life conceptual model; such a conceptual model can be defined as the group of processes that take place in the system evaluated and such a group allows us to understand the operating logic of the system itself.

• The simulator is nothing other than a programme that verifies and visually displays programmed operations. • Mecal created it for application to the MESOFT programming system installed on machining centres. • It can only work when the main MESOFT programme is already working in the 3D graphic release configuration. • It carries out a simulation of the machinings programmed by the operator who can check that all the procedures entailed are performed without any mistakes or collisions before any work actually begins on the piece.

Simulation shows that the point of collision occurs inside the body of the electric spindle and the vice support, in a certain area.

In this case the area where the tool collides with the vice locking structure is shown.

Tool change operation movements are also simulated, giving the time needed in real time which is connected to the pneumatics part of the machine.While the workpiece is being machined, the time taken is counted and displayed at the bottom left.

Whatever machining is programmed, the simulator carries out a preview of it which makes it a very useful tool for programming the Centre as it lets you verify each programme and thus avoid all mechanical damages.

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T N A W IF YOU W O N K TO

E R O M THE ELECTRIC SPINDLES The electric spindles used on the machining centres are designed for working on light materials such as aluminium, wood, PVC and steel. They are operated by a sinusoidal wave frequency static converter controlled by reference signals. The converter allows you to vary rotation speed from zero to 24,000 rpm. Each electric spindle is made

ANGULAR AGGREGATES With the term “aggregate” we mean a specific set of accessories designed to extend machine tool operating capacity. As we know, in a 3axis machine tool with a vertical spindle, the tool can perform linear or circular interpolation operations only on a bi-dimensional geometric plane generated by the longitudinal axis (X) and by the transversal

to withstand axial and radial loads with oblique precision contact bearings; ceramic bearings are used when high speeds are called for as they are suitable for the high temperatures that can be reached. It also features tool detecting sensors so the electric spindle can be used with the NC to become an

axis (Y). In this case it is said that the subject machine can work only on one side of the workpiece. Angular heads can be used to get round this restriction. The function of an angular head is to transform the rotary movement of the machine spindle into a rotary movement with a fixed angle, or manually variable, peculiar to angular heads.

An example The graph lets us establish a time to stop machining: an actual working time of 1.25 minutes at maximum rotation speed requires a pause of 2.8 minutes at an ambient temperature of 20°C and 4.7 minutes at an ambient temperature of 25°C.

integral part of the machine tool. Maximum power remains constant at the highest of speeds. The choice of arbours is all-important – they must be of top quality, be well balanced and heat treated. The cone locking system (ISO 30 or HSK) is via a clamp to DIN standards that grips the arbour.

Usage restrictions Use of these particular accessories does have certain restrictions, regulated by the manufacturer and which mostly concern stop times between two consecutive work intervals. Failure to observe these indications reduces the mechanical life of each single component, compromising the reliability of the aggregate itself. The user, for his personal requirements, has to evaluate the parameters referring to the service class and to the times mentioned previously.

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Advanced technology, which always makes the difference

Mecal, all the value of an extensive range The machining centres are the crowning achievement of an exclusive series of machines and systems for machining aluminium and PVC sections From the single working unit to the “turnkey” factory. The machining centre is the most in innovation and quality in this sector but one should not forget that Mecal is, and always has been, at the top of the market with a complete range of exclusive machines for all production needs: cutting-off machines, end milling machines, copy routers, drilling machines, crimping machines and even specialized software to optimise the automation. Avant garde solutions in their conception, the result of thirty years’ experience in the sector, of constant commitment in research and development and strict controls in all production phases. An extremely wide and versatile fleet of machines to meet the requirements of all companies, from the craftsman making door and window frames to the big company, with solutions made to measure: from the single machine for a certain machining job to the “turnkey” factory with a complete series of solutions for the whole production cycle. And that’s not all: high specialized advice to optimise working efficiency and avant garde systems to co-ordinate and manage all production phases. And then, flanking the “classic” aluminium section sector, Mecal has even developed a completely new range of machines for machining PVC: welders and cleaners that find themselves at the top of the sector for technological innovation and flexibility of use.

Machining centres Cutting-off machines End milling machines Copy routers Crimping machines Drilling machines Software

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