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A new sidehead option on MAG vertical turning centers (VTCs) utilizes a 250-mm-square (10 inch) ram to deliver 34,000 N (7,600 pounds) thrust from the optimum angle for efficient turning of tall or flanged parts in vertical orientation. The sidehead option is available on machines with table size 1,250 to 3,500mm (49.2 — 137.7 inches), capable of handling parts up to 3,700mm (145.6 inches) maximum diameter and 3,300mm (129.9 inches) height. The sidehead provides a 1,250mm (49.2 inch) X-axis span and 1,900mm (74.8 inch) Z-axis, with a traverse rate of 20,000mm/min (787 ipm). It is equipped for automatic tool change with a 40-tool chain magazine, and available with modular Capto C8 or KM tool interface.
With tall shaft-type parts mounted on the machine table and supported by a live center in the main ram, the approach angle of the sidehead minimizes bending forces on the part and machine components during maximum-thrust cuts to allow faster, more efficient metal removal with highest accuracy. The sidehead also improves access for undercutting flanges or reaching features beneath them. The sidehead option is ideal for producing parts for the energy/power industry, heavy machinery, transportation and off-road equipment. It adds another level of one-stop processing capability to MAG VTCs, which can already be equipped for gear cutting and grinding.
One of the most versatile turning systems for large parts, MAG VTCs in table size 1,000mm to 8,000mm (39.4 — 315 inches) can already perform standard and hard turning, as well as live-spindle machining, contouring and part probing operations on multiple sides and the full diameter of a part. Full contouring with the C-axis enables drilling or mill turning of features anywhere on the workpiece, with contouring/positioning by a 360,000-position table. Standard features include use of modular tooling; green design with minimal hydraulics; minimal foundation requirements; and innovative chip management and removal that minimizes operator intervention.
The machines are FEA-designed for maximum strength-to-weight ratio, stiffness and rigidity, with heavily ribbed cast iron or robust steel weldments used for major components, such as base, column and cross slide, depending on the machine size. The adjustable cross slide, with MAG's unique leveling technique and patented rail clamping system, allows ram extension to be minimized to ensure highest rigidity and accuracy during high-thrust cuts. Adjustable-rail models use dual linear scales to ensure parallelism between table and rail, with leveling accuracy of 10µm (0.0004 inches).
The machines use a thermally-symmetrical, hydrostatic main ram to resist torsion and vibration to produce superior surface finishes, delivering downward feed thrust up to 34,000 N (7,600 pounds). Preloaded roller guideways enhance system stiffness and reduce friction for excellent contouring accuracy.
Tables are extensively supported with a combination of tapered roller and flat thrust bearings to handle constant use at maximum load ratings. The table design resists tipping with unbalanced loads, and superior accuracy is ensured with factory-specified maximum 0.005mm (0.0002 inch) table runout. Table drives are rated 46 kW (62 hp) to 142 kW (190 hp), and capable of producing maximum torque of 7,538 Nm (5,560 ft lb) to 255,000 Nm (188,000 ft lb).
A standard 26-position tool changer accommodates large, heavy boring bars and 20 modular tools. Various options for the VTC line include expanded tool capacity, part and tool probing systems, pallet changer and fourth axis. Fanuc 31i or Siemens 840D controls are standard.
Related Glossary Terms
- approach angle
approach angle
Angle between the insert’s side-cutting edge and the line perpendicular to the milling cutter’s axis of rotation. Approach angle, which is also known as cutting edge angle, is used with metric units of measurement. See lead angle.
- boring
boring
Enlarging a hole that already has been drilled or cored. Generally, it is an operation of truing the previously drilled hole with a single-point, lathe-type tool. Boring is essentially internal turning, in that usually a single-point cutting tool forms the internal shape. Some tools are available with two cutting edges to balance cutting forces.
- centers
centers
Cone-shaped pins that support a workpiece by one or two ends during machining. The centers fit into holes drilled in the workpiece ends. Centers that turn with the workpiece are called “live” centers; those that do not are called “dead” centers.
- feed
feed
Rate of change of position of the tool as a whole, relative to the workpiece while cutting.
- flat ( screw flat)
flat ( screw flat)
Flat surface machined into the shank of a cutting tool for enhanced holding of the tool.
- grinding
grinding
Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.
- hard turning
hard turning
Single-point cutting of a workpiece that has a hardness value higher than 45 HRC.
- milling machine ( mill)
milling machine ( mill)
Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.
- stiffness
stiffness
1. Ability of a material or part to resist elastic deflection. 2. The rate of stress with respect to strain; the greater the stress required to produce a given strain, the stiffer the material is said to be. See dynamic stiffness; static stiffness.
- turning
turning
Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.
