HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE
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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 1

GMN Paul Muller Industrie GmbH & Co. KG AulSere Bayreuther Str. 230 • D-90411 Nurnberg Phone:+49 (o) 911-5691-0 • Fax:+49 (o) 911-5691-221 www.gmn.de Spindle technology: Phone:+49 (o) 911-5691-240 • Fax:+49 (o) 911-5691-699 Mail: vertrieb.spi@gmn.de High frequency spindles for automatic tool change

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 2

Spindle types - Overview 4 Design and features of HC/HCS style Shaft output power 5 Integra I encoders for closed loop control Advantages of hybrid ceramic bearings 6 Adjustable bearing preload 7 Vibration sensor Tool interface 8 Taper cleaning Clamping system 9 Position sensors Air purge 10 Coolant through shaft 11 Coolant through spindle housing Internal minimized coolant supply- Single-channel system 12 Internal minimized coolant supply - Two-channel system 13 A met hod for controlling axial shaft growth 14 Measurement of the axial shaft growth by sensor Pick-up spindle / Multi couplings...

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 3

speed Output speed Max. speed [rpm] Housing diameter [mm] Spindle type HC = for open-loop drive HCS = for closed-loop drive Tool interface W1 = Bore diameter of front bearings OL = Oil/air lubrication g = Permanent grease lubricatiion SK = ISO taper HSK = Hollow tapered shank Preference type Please ask if spindle drawing is required. We send it as dxf file.

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 4

Shaft Output Power Integral Encoders For Closed Loop Control Chip removal rates are defined by the material's specific cutting speeds. Generally small tool diameters require high speeds and larger tools are operated at lower speeds. Large tools require high torque while small tools require less torque, but higer speeds. Integral motors utilized in the HC/HCS style spindle meet these requirements. The "field weakening" characteristics provide the high torque at lower speed. The spindles can be operated in the following modes: ■ SI Continuous power ■ S6 Continuous duty with intermittent...

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 6

Vibration Sensor Adjustable Bearing Preload Bearing arrangement and preload determine the rigidity, and influence the life time of the spindle system. For small speed ranges, and low speed operation the different versions of a solid preload arrangement are suitable. Large speed range variances, and high speed spindles, require a systems that will not allow the bearing preload to be influenced by either temperature or speed. These applications require spring preloading of the bearings. The above mentioned arrangements cannot be adjusted or changed, without disassembling the spindle. With...

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 7

Tool Interface Taper Cleaning GMN can provide high frequency spindles to accept common tooling interface configurations. The prefered H5K style offers the following advantages versus the ISO taper: ■ High static and dynamic rigidity ■ High tool change accuracy and repeatability ■ Low axial movement during speed variations ■ Increased pull-in force as the speed increases • High torque transmission ■ Increase in personal safety due to the internal drive dogs (Form A/C) "Hollow tapered shanks with flat contact surfaces" are standard per DIN 69893. The different "FORMS" of a particular size are...

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 8

Clamping System Position Sensors Both the ISO taper style and the "HSK" hollow shank tool holders are clamped via a set of gripper fingers. The clamping forces are generated through a spring washer pack, included in the power drawbar. The centrifugal forces exerted by the balls in the pressure intensifier, multiplies the pull in force on an ISO taper style system. It is also speed dependent. Increases in the pull in force for the HSK style tool clamping system is by the centrifugal forces on the internal gripping mechanism. Tool unclamping on either system is accomplished by pressure. An...

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 9

Pressurized air is used to prevent the ingress of contamination into the bearing system. A continuous flow of clean dry air fills the closely machined gaps between the stationary and rotating members of the spindle. The air stream also stops the spent oil lubrication from existing at the front of the spindle and away from the work piece.

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 10

Coolant Through Shaft Coolant Through Spindle Housing The internal coolant supply provides cooling directly to the cutting edge also at difficult form of workpieces. In accordance to the interface size and dependent on the maximum operating speed different systems can be used: ■ Only air ■ Air or coolant in one line ■ Air and coolant in seperate lines For cooling of tool and workpiece the medium is supplied through spindle housings and nozzelstothe cutting surfaces. Compressed air, cooling lubricant/air mixture or cooling lubricant can be used. The representation below is with cooling...

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 11

Internal Minimized Coolant Supply Single-Channel System Characteristics of single-channel minimized coolant supply: ■ Superfine oil mist (aerosol) ■ Speed limitation due to aerosol decomposition ■ For standard rotary unions ■ For tools with coolant bore diameter > 1 mm ■ In comparison with two-channel system longer reaction times at quantity changings ■ For machines with less tool changes Lubrication schematic

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 12

Internal Minimized Coolant Supply Two-Channel System Characteristics of two-channel minimized coolant supply: * No oil mist ■ Oil and air mixable in almost any quantities or only air supply ■ In comparison with single-channel system higher speeds possible ■ For tools with high lubricant consumption ■ For machines with more tool changes Lubrication schematic

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HIGH FREQUENCY SPINDLES FOR AUTOMATIC TOOL CHANGE - 13

Precision machining requires the position of the cutting edge of the tool to be maintained. Temperature variations and centrifugal forces at the balls and bearing races, can cause axial movement of the tool mounting face of the shaft. The "centrifugal forces" factor can be calculated and the speed dependent shaft movement can be compensated by through the machine tool control. Measuring the shaft temperature at the bearing during operation is difficult. Experience has shown that by measuring the temperature at outer diameter of the bearings, approximate temperature variations can be...

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