Machine Technology: Building ‘monster’ machines

It’s safe to say that most people would call a 20′-long (6.1m), 65-ton milling machine “big.” Such a machine was recently installed at the Connecticut Center for Advanced Technology (CCAT), East Hartford, Conn. But those working for machine tool builder Zimmermann may not describe it that way.

The CCAT machine “is not the largest we have. In fact, it’s one of our smallest,” said Yves Klein, sales and project manager for Zimmermann Inc., Wixom, Mich., the U.S. arm of Neuhausen, Germany-headquartered Zimmermann GmbH.

As you may have guessed, Zimmermann specializes in very large machine tool installations. The company offers milling machines with working ranges from 2.5m to 30m (8.2′ to 98.4′) along the X-axis and from 3m to 6m (9.8′ to 19.7′) along the Y-axis.

Recently installed at a Connecticut site, a customized version of Zimmermann’s FZ37 milling machine offers travel distances of 3m (9.84′) along the X and Y axes. Image courtesy of Zimmermann.

Why go big when choosing a machine tool? For one, extra-large machines allow 5-axis machining of large parts. They also enhance stability and stiffness during machining.

In addition, Zimmermann machines are large enough to allow two separate operations in different areas. “Customers may have a 20m machine with a partition wall that basically gives them two work areas,” Klein said. They can machine a part in one work area and perform secondary operations in another, partitioned-off area. Similarly, they can machine a steel part in one area and an aluminum part in the other. Once the separate tasks are completed, users can remove the partition and create one large work area for subsequent operations, such as assembly.

But why not opt for two smaller machines to perform different tasks rather than one behemoth? According to Klein, it’s actually cheaper to purchase a 10m-long (32.8′)machine than it would be to buy two 5m (16.4′) machines.