Fives brings the combination live spindle and integrated contouring head (ICH) to its Cincinnati MEGA and Giddings & Lewis HMC Series horizontal machining centers, for expanded processing flexibility and dramatically reduced workpiece transfers and setups, with improved accuracy. The ICH's 220-mm (8.7-in) U-axis slide stroke provides the ability to produce small- or large-diameter features without head changing or manual intervention, allowing complex features to be machined in one setup with reduced cycle time and labor. The contouring head can produce features such as bottle bores, valve seats, seal faces, phonographic sealing surfaces, O-ring grooves, straight/tapered threads, chamfers, and external profiles. It is ideal for single setup, rough and finish machining of any large parts that combine bored, milled and turned features.

The ICH is located immediately above the machine's main spindle, but slightly offset in the Y and W/Z axes to avoid tool interference. The 45-kW/60-hp (S6-40%) contouring spindle for HMCs handles parts up to 540 mm (21.3 in) ID and 340 mm (13.4 in) OD. It is available with standard Kennametal KM80 or Sandvik Coromant Capto C8 tool interfaces, and accommodates tools as long as 600 mm (23.6 in), weighing up to 18 kg (39.6 lb). Tools are loaded via the machine's toolchanger/" data-glossary-id="142091" data-glossary-teaser="Mechanism typically included in a machining center that, on the appropriate command, removes one cutting tool from the spindle nose and replaces it with another. The changer restor…" title="Mechanism typically included in a toolchanger. See automatic toolchanger." title="CNC machine tool capable of drilling, reaming, tapping, milling and boring. Normally comes with an automatic toolchanger. See automatic toolchanger." aria-label="Glossary: machining center">machining center that, on the appropriate command, removes one cutting tool from the spindle nose and replaces it with another. The changer restor…" aria-label="Glossary: automatic toolchanger">automatic toolchanger for faster processing without operator involvement. The W/Z-axis live boring spindles can use 50-taper tools. With an auto coupler, the Giddings & Lewis HMC Series handles programmable boring bars up to 750 mm (29.5 in) long and 50 kg (110 lb). Live spindle travel is 800 mm (31.5 in) for all machining center models.

"The combination of the U-axis head and main W/Z-axis milling/boring spindle provides boring and turning capabilities in a single multitasking machine," said Fives Cincinnati Product Manager Ken Wichman. "The range, power, accuracy and tool-handling capability of the ICH provide a much wider range of processing capabilities than possible with contouring attachments or other options. The integrated head is much more rigid than attachments bolted on or held by the spindle taper, resulting in superior part quality, surface finish and dimensional accuracy."

A touch probe can be used in the boring spindle or on the HMC Series an optional auxiliary probe is available for in-process or post-process measurement of part features. Standard services, such as coolant supply, are plumbed through the contouring head to eliminate manual intervention and ensure maximum tool life.