GENERAL INFORMATION

HORIZONTAL BORING MILLS from REM are the Table type (TT) and T type (with column moving perpendicular to the table travel) boring and milling Machines with horizontal spindle are intended for machining prismatic parts made of cast iron, steel, aluminium and other materials, of dimensions and weights within the machine processing capacity.

The operations available with these HORIZONTAL BORING MILLS are: boring, milling, drilling, threading or tapping, counter boring, both in roughing and finishing modes. Through one setting of the work piece, four or five surfaces of it may be machined. The various special accessories available with such machines increase their machining capacity and productivity.

Standard Features

•  3D design for custom made heavy machine tools;
•  Automatic lubrication system;
•  Quality cast iron parts to avoid vibration;
•  Coolant trough spindle;
•  Hardened and ground ways, box or steel inserts;
•  Choice of hydraulic elements;
•  Counter ways with anti friction material;
•  Fanuc, Siemens AC servo motors;
•  Ballscrews on all linear axes;
•  Fanuc, Siemens ,Heidenhain PLC and electric;
•  SKF, FAG high precision bearings;
•  Choice of Fanuc, Siemens, Heidenhain controls;
•  Heidenhain linear and rotary scales;
•  Motorized spindle with ZF gearbox and AC motors;
•  Hydrostatic guide ways (X, Y, W);
•  Ram droop compensation;
•  Telescopic cover for X – axis.

Optional Features

•  Automatic tool changer 50/60 positions;
•  Facing head;
•  Vertical milling head;
•  Universal head;
•  Spindle bearing support;
•  Angle fixtures;
•  Chip conveyer;
•  2-axis CNC head;
•  CNC facing head.

Automatic Tool Changer
The mechanical arm is designed to clamp ISO 50 tools and the distance between two tool axes. The axial and spin movement of hand is provided by double action hydraulic cylinders.

Mechanical arm travels along on the rolling way, which is fixed on the column, and performs the change and carrying of tools between the tools-magazine and the machine spindle.

Mechanical arm consist of a levers mechanism for gripping the tools, an arm taking off and inserting the tools in the spindle taper or in the tool station in the magazine. The unit is completed with a 180 swivelling mechanism of the arm body supporting the tool grippers. The 180? swivelling is performed by means of a pinion-rack mechanism, hydraulically driven by a hydraulic linear motor.

The axial motion in and out is achieved by means of a linear hydraulic cylinder, placed inside the mechanical arm body. On the upper and lower sides of the mechanical arm housing, there are attached the rolls to provide the movement along the rolling guide ways. Rolls are fixed by means of brackets supporting a free swivelling fork, so that the triangle profile roll follows the guide way track. The motion of the mechanical arm on the rolling – way, between the magazine and the machine spindle, is achieved by means of a rotating hydraulic motor. A chain and pinion mechanism moves the arm along its guide way.

All movements are hydraulic, by means of linear and rotary motors, and confirmed by inductive proximity switches, mechanically limited. The tool magazine is chain type, fastened on the column by a rigid welded structure support. It is positioned in vertical plane in the backside of the column. The chain is actuated by a variable speed feed motor through a planetary gear reducer (i=1:10) and a duplex worm reducer. The wormed gear is fastened to the chain gear.

Tools magazine is designed for the tools and tool holders stocking (50/60 – tools/tool holders) and to prepare the necessary tool for the next operation, thus shortening the operating time of the machine – tool. Tool magazine consists of a links chain and of 50/60 tool holder supports.

Tool holder supports are provided with a tool clamping system with balls and springs, a ranking number and an indexing system for placing the tool. Near the driving wheel, two proximity switches are provided to count tools in the magazine – A third proximity switch is placed on the tools-magazine support and is meant to show “O” position.

+ MAIN OPERATIONS

The operations available with these HORIZONTAL BORING MILLS are: boring, milling, drilling, threading or tapping, counter boring, both in roughing and finishing modes. Through one setting of the work piece, four or five surfaces of it may be machined. The various special accessories available with such machines increase their machining capacity and productivity.

+ STANDARD FEATURES

Standard Features

•  3D design for custom made heavy machine tools;
•  Automatic lubrication system;
•  Quality cast iron parts to avoid vibration;
•  Coolant trough spindle;
•  Hardened and ground ways, box or steel inserts;
•  Choice of hydraulic elements;
•  Counter ways with anti friction material;
•  Fanuc, Siemens AC servo motors;
•  Ballscrews on all linear axes;
•  Fanuc, Siemens ,Heidenhain PLC and electric;
•  SKF, FAG high precision bearings;
•  Choice of Fanuc, Siemens, Heidenhain controls;
•  Heidenhain linear and rotary scales;
•  Motorized spindle with ZF gearbox and AC motors;
•  Hydrostatic guide ways (X, Y, W);
•  Ram droop compensation;
•  Telescopic cover for X – axis.

+ OPTIONAL FEATURES

Optional Features

•  Automatic tool changer 50/60 positions;
•  Facing head;
•  Vertical milling head;
•  Universal head;
•  Spindle bearing support;
•  Angle fixtures;
•  Chip conveyer;
•  2-axis CNC head;
•  CNC facing head.

Automatic Tool Changer
The mechanical arm is designed to clamp ISO 50 tools and the distance between two tool axes. The axial and spin movement of hand is provided by double action hydraulic cylinders.

Mechanical arm travels along on the rolling way, which is fixed on the column, and performs the change and carrying of tools between the tools-magazine and the machine spindle.

Mechanical arm consist of a levers mechanism for gripping the tools, an arm taking off and inserting the tools in the spindle taper or in the tool station in the magazine. The unit is completed with a 180 swivelling mechanism of the arm body supporting the tool grippers. The 180? swivelling is performed by means of a pinion-rack mechanism, hydraulically driven by a hydraulic linear motor.

The axial motion in and out is achieved by means of a linear hydraulic cylinder, placed inside the mechanical arm body. On the upper and lower sides of the mechanical arm housing, there are attached the rolls to provide the movement along the rolling guide ways. Rolls are fixed by means of brackets supporting a free swivelling fork, so that the triangle profile roll follows the guide way track. The motion of the mechanical arm on the rolling – way, between the magazine and the machine spindle, is achieved by means of a rotating hydraulic motor. A chain and pinion mechanism moves the arm along its guide way.

All movements are hydraulic, by means of linear and rotary motors, and confirmed by inductive proximity switches, mechanically limited. The tool magazine is chain type, fastened on the column by a rigid welded structure support. It is positioned in vertical plane in the backside of the column. The chain is actuated by a variable speed feed motor through a planetary gear reducer (i=1:10) and a duplex worm reducer. The wormed gear is fastened to the chain gear.

Tools magazine is designed for the tools and tool holders stocking (50/60 – tools/tool holders) and to prepare the necessary tool for the next operation, thus shortening the operating time of the machine – tool. Tool magazine consists of a links chain and of 50/60 tool holder supports.

Tool holder supports are provided with a tool clamping system with balls and springs, a ranking number and an indexing system for placing the tool. Near the driving wheel, two proximity switches are provided to count tools in the magazine – A third proximity switch is placed on the tools-magazine support and is meant to show “O” position.

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MACHINE STRUCTURE

Structurally, such a TT type machine is designed with a bed along which the saddle supporting the cross slide and rotary table is moving longitudinally, describing the Z axis. The cross slide and rotary table assembly move transversally along the saddle guideways, describing the X axis. On the bed end, a fixed column is located. Along the column guideways, the headstock moves on the vertical direction (Y axis). Inside the headstock the milling spindle is supported, having inside its bore the boring spindle that moves as W axis.

The T series structure features two beds: one bed along which the cross slide and rotary table assembly is moving (X axis) and one bed, perpendicular to this, along which the column saddle and column assembly is moving (Z axis). Along the column guideways, the headstock moves on the vertical direction (Y axis). Inside the headstock the milling spindle is supported, having inside its bore the boring spindle that moves as W axis.

The main cinematic linkage consists of a gear box with two mechanical steps, connected to the spindle by a timing belt transmission. The gear box is driven by a stepless adjustable speed motor.

The feed mechanisms are driven by stepless adjustable speed servomotors. Each of the 5 moving axes of the machine has independent feed mechanisms and limit switches for travel limitation. The rotary motion coming from the feed boxes is transformed into translation motion by means of a preloaded ball screw-nut mechanism. The machine is endowed with auxiliary cinematic linkages that provide the locking of the movable assemblies as well as the tool clamping/unclamping.

The motion measurement of the movable assemblies is performed through linear scales and rotary encoders compatible with the electrical equipment. The machine controls are centralized on a control panel that may be of pendant or swivelling type. The machine is available for accommodating several special accessories that increase its machining capacity and productivity. The bed guide ways are protected by telescopic covers.

•  X axis – the rotary table cross motion;
•  Z axis – the rotary table longitudinal motion;
•  B axis – the table rotation;
•  Y axis – the headstock travel along the column guideways;
•  W axis – the boring spindle axial motion.

•  X axis – the rotary table cross motion;
•  Z axis – the column saddle motion;
•  B axis – the table rotation;
•  Y axis – the headstock travel along the column guideways;
•  W axis – the boring spindle axial motion.

The bed is made of high quality cast iron and has a heavily ribbed structure. Its top surface features the guide ways for longitudinal motion of the saddle, cross slide and rotary table assembly (Z axis). These guide ways are coated with hardened and ground steel plates (55 HRC and Ra=0.4). On the bed end, a fixed column is located. It is fixed to the bed by means of special bolts and dowel pins for alignment. Along the column guideways, the headstock moves on the vertical direction (Y axis). The bed is fixed to the foundation by means of levelling blocks and special foundation bolts. Oil collecting ducts are fixed to the bed, for collecting the guideway lubrication oil.

This assembly is composed of the saddle that supports the guideways along which cross slide and rotary table assembly are moving.

The saddle is made of special cast iron and is strongly ribbed for a proper rigidity. On its lower surface the counter guideways are located, through which it moves along the bed longitudinal guideways, describing Z axis. This motion is supported on both sides by outriggers that slide along two side guideways, rail type. On the top surface of the saddle the guideways designed for the cross motion (X axis) of the cross slide and table assembly are located. These guideways are coated with steel inserts, hardened and ground (55 HRC and Ra=0.4).

The cross slide is made of special cast iron and is strongly ribbed for a proper rigidity. On its lower surface the counter guideways are located, through which it moves along the saddle guideways, describing X axis. Its top surface features the table rotation (B axis) guiding surface (the matching surface) coated with antifriction material. On the cross slide the table rotation mechanism (servomotor, feed box, wormed gear) is located, as well as the table clamping and indexing systems.

T series machines has two beds: a cross bed, along whose guideways the saddle, cross slide and rotary table assembly moves, by describing X axis and a longitudinal guideway along whose guideways the column saddle and column assembly moves, by describing Z axis. Both beds, made of special cast iron, have strongly ribbed construction that gives them outstanding rigidity.

The top surface of the beds the guideways for the motion of the two moving assemblies are located, related to the X and X axes respectively. These guideways are coated with steel inserts, hardened and ground (55 HRC and Ra=0.4). Beds are fixed to the foundation through levelling blocks and special foundation bolts.

To the beds collecting troughs for the lubrication oil are mounted and guideways are protected with telescopic covers.

The column saddle is a cast iron component sustaining the column and headstock assemblies as well as other equipment and mechanisms.

The column saddle moves along the bed guideways. It contains the hydraulic installation ensuring the Z axis guideway lubrication and lubrication of the Z axis feed reducer. To the saddle there are fixed the guide ways covers, cable carrier, the encoder of the Z axis measurement system etc. The column saddle feed motion is generated by an A.C. stepless servomotor and a planetary reducer /gearbox. The bed guide ways are protected with telescopic covers distributed on both sides of the column saddle.

The cross slide, of cast iron, has on its upper side circular guideways for the rotary table and its lower side has guideways. The cross slide also accommodates the mechanism for the table locking. The slide “X” axis displacement feed drive is done by an AC brushless electrical motor with continuously adjustable speed, through a ZF speed reducer and a ball­screw ­ nut mechanism. The slide displacement is measured and checked by an accurate encoder.

The rotary table ­ made of special cast iron ­ is provided with “T” slots for the work piece clamping. The table is supported by an accurate roller bearing mounted on the cross slide. The table turning is achieved by an AC brushless electrical motor with continuously adjustable speed, through a teeth belt reducer and two pre­tensed pinions, with a backlash­free operation. The rotary table can be automatically index and could be locked in any position hydraulically. The table rotation is measured and checked by an accurate rotary encoder.

The feed movements on all axes are driven by gears transmission via planetary speed reducers by servo motors with step less variation of the speed. The rotary motion coming from the feed box is transformed into translation motion by means of a preloaded ball screw-nut mechanism.

The double wall, ribbed cast iron column supports the headstock that travels along its two vertical guide ways (Y axis). The column guideways are provided with hardened and ground steel plate inserts.

A counterweight, to balance the headstock, is guided inside the column. On TT series, the column is mounted on a bed end through special bolts and dowel pins for alignment. On T series, the column is mounted to the column saddle.

The headstock is a heavily ribbed cast iron structure designed to withstand the extensive forces generated by the main motor. The headstock houses the spindle assembly and slides along the vertical guide ways of the column. The headstock guide ways are lined with anti-friction material. The spindle is driven by an A.C. stepless spindle motor through a precision ZF gear box, electrically shifted and a timing belt transmission that connects the ZF output shaft directly to the spindle.

The sleeve-type spindle assembly is composed of the milling spindle and boring spindle. Its bearings feature high precision angular grease lubricated ball bearings: four in the front and two in the rear. Cooling is achieved by a closed circuit oil refrigerating system inside the outer spindle sleeve.

The boring spindle is guided inside the milling spindle by nitrated bushings. The ISO 50 taper allows automatic clamping and unclamping by the mechanical-hydraulic system inside the boring spindle. Both its outer surface and the ISO 50 taper are nitrated. The rear side bearing consists of four radial-axial ball bearings, mounted within the special cast iron bearing of the ram. This one is actuated by the ball screw nut which creates the W-axis feed motion. The main shaft is provided with internal coolant system of 20bar work pressure and 60 lpm flow.

The tool clamping/unclamping is located inside the boring spindle and the back bearing body. Tool clamping is mechanically performed by a disk springs package. Tool unclamping is achieved hydraulically.

­ Electrical cabinet ­ Control panel ­Measuring rotary encoders or linear scales for the travels of the movable elements The electric equipment on the machine includes: AC motors, electric wiring on the machine, connection boxes, actuators and control elements, encoders. The connecting cables between machine and cabinets are protected in flexible tubes, cable carriers and channels.

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