FCW 140, FCW 150, FCW 160

Horizontal milling and boring machine FCW

FCW 140, 150 and 160 – horizontal milling and boring machines, which are used in dusty working environments and when machining materials such as cast iron, special plastics or GFK.

Horizontal milling and boring machine FCW – Description of main groups of machine:

Bed

Grey cast iron structure – GG 30 (DIN)
Two guide ways
Hardened guiding ribs for X travel. Part of compact linear guiding
HEIDENHAIN linear scale for X-axis located on the bed
Hardened teeth rack for X – axis feed bolted to the bed section
Limit switches for X – axis
Telescopic protective steel-sheet covers over the whole width of the bed

Saddle

Grey cast iron structure – GG 30 (DIN)
On bottom side of saddle there are 5 roller (linear) tanks on each guide way for X travel. Part of compact linear guiding
Lubrication of tanks by means of grease
Backlash-free twin-pinion gearbox driven by SIEMENS AC drive for movement in X – axis
Hydraulically controlled clamping units in each corner of column saddle

Column

Grey cast iron structure – GG 30 (DIN)
Hardened guiding ribs for Y travel. Part of compact linear guiding
Counterweight for ram’s dropping compensation inside the column; including chain pulleys for hanging of headstock
HEIDENHAIN linear scale for Y-axis located on the column
Ball screw with rotating nut for movement in Y – axis
Limit switches for Y – axis
Telescopic protective steel-sheet covers over and below the headstock

Headstock

Grey cast iron structure – GG 25 (DIN)
On backside of headstock there are 2 roller (linear) tanks on each guide way for Y travel. Part of compact linear guiding
Lubrication of tanks by means of grease
Consists of basic parts like ram, boring & milling spindle, frames, gearing etc.
Gearbox for Y – axis movement driven by SIEMENS AC drive mounted on headstock
Three-step spindle drive with gears in continuous mesh and hydraulically shifted claw clutches
Thermal stabilization of oil fillings of the headstock and main drive gearbox
Disc brake of main drive is hydraulically released

Ram

Special cast iron GGG 60 (DIN)
Ram’s movement via ball screw and AC feed drive SIEMENS
Milling and boring spindle seated inside the ram
Compact roller guiding for ram’s out travel
Automatic clamping system of attachments onto ram’s face
Automatic ram’s dropping compensation system

Ram’s dropping compensation system

FCW machines use special SKODA automatic ram compensation system
Ram out-travel is compensated by hydraulic cylinder, which is attached on the front chain of the headstock by means is connected with counterweight.
Additional ram compensation system is working on a basis of supporting of ram from bottom by means of hydraulic cylinder.
Pressures in hydraulic cylinders for both compensation sub-systems are controlled by CNC system of the machine.
Automatic ram compensation is functional along whole out-travel of ram as well as when special milling and boring attachment loaded on the ram.

Boring spindle

Special nitrided forging alloy steel, hardness HV 850
Seated in milling spindle and ram. Seating of spindle in special ball bearings with oblique contact (maker SKF / FAG). Lubrication by means of oil mist
Spindle’s movement via ball screw and AC feed drive SIEMENS
Complete spindles’ seating dynamically balanced
Oriented stop of spindle, spindle’s rotary encoder
Mechanised tool clamping chuck collet as per DIN 69872 (hydraulically operated tool release, tool clamping by disk springs)

Operator’s platform and machine control

Semi-closed operator’s platform firmly bolted to the column saddle. In front part and from above is protected against flying chips and splashing coolant based on international safety standards.
Front part of the platform is moveable in ram’s direction (Z1) for 1 000 mm
Main operator’s panel located on rotary pillar on the operator’s platform.
Auxiliary portable panel with a cable with appr. 6 meters long for set-up and test purpose incl. position read-out

Hydraulic system and equipment

Circuit for lubrication of spindle’s seating
Circuit for thermal stabilisation of headstock and feed boxes with compressed cooler of used oil
Circuit for thermal stabilisation of ram by means of controlled heating
High-pressure circuit for auxiliary functions of machine like tool releasing, ram compensation, clamping units (X, Y), gear shifting, main disk brake, etc.
High pressure air distribution for tool hollow’s cleaning, spindle seating sealing, sealing of scales of measuring system, etc.

Standard accessories

Set of tools for maintenance (according to list in Operation manual)
Set of spare parts for 2 years trouble free run of machine (according to list in Operation manual)
5 pieces of retention studs for clamping tools with tool taper ISO 50 (DIN 69871 – AD)
Checking fixture EMA
Anchoring material ŠKODA for machine (delivered without auxiliary materials for fixing like cement, grouting material etc.)

FU

HORIZONTAL MACHINING CENTER MODEL FU

The horizontal machining center FU is specified especially for milling of complicated shapes in manufacture of moulds, press tools, dies or of workpieces having very complicated shapes and large dimensions.

The machine parameters enable the FU to machine a wide range of materials, including alloy steels and light metal alloys.

The machine has the modular design which enables a considerable variability of its composition. The machine consists of the fixed bed and the longitudinal slide, which moves together with the column on this bed in the longitudinal direction. The knee with cross guideways for headstock travel moves along the vertical column guideways. The machine has the headstock available which can be equipped with the mechanism for automatic clamping of exchangeable spindle heads or headstock with non-echangeable head.

The workpiece working area is performed according to the customer’s requirement by means of fixed clamping plates and rotary tables (and with movable slides) for a variety of applications.

In its basic configuration, the machine is determined to work in the working area with the parameters given by the set of the combination of ambient condition classes IE 33, according to ČSN EN 60721-3-3:1997, A2:1998; however, the air temperature must range from +15 °C to +35 °C and the air pressure must be more than 90 kPa.

To reach the optimum working accuracy, the following conditions must be kept during machine work:

Ambient temperature within +17 °C up to +25 °C
Change of ambient temperature during 24 hours less than 4 °C
Ambient temperature change gradient less than 0,5 °C/hour

The machine is manufactured in standard or strengthened execution. The strengthened execution is used for enlarged strokes in vertical axis (Y ≥ 3500 mm) and cross axis (Z=2000 mm). The reason is to keep accuracy and machine rigidity with extended travels.

The bed is made as a casting of grey cast iron and it is fixed with the machine base by means of anchoraging scewse. The upper part is equipped with profile strips of linear bearing guideways, on which the longitudinal slide and the column are moving. The rack for the motion of the longitudinal slide is mounted next to the front strip of guideways. The distance between the strips of the linear guideways is 930 mm for standard execution and 1200 mm for strengthened execution.

FUT

Horizontal machining centres FUT

Horizontal milling machine is designed for machining of complicated workpieces with respect to jobs hape by both classical milling technology and high speed machining implementation.

Milling machine base structure is designed as individual longitudinal and cross bedin T-shape design feature. Longitudinal slide unit (so called sledges) moveable in X axis (longitudinal direction) alongside the fix bed surface. Upper longitudinal sledges surface is designed with rotary positioning table. Milling machine column is movable in Z axis (cross movement direction). Head stock moves alongside column guide surfaces in Y axis /vertical movement/. Possible shift-out executionin W axis.

Milling machine technological versatility with main respect to possibility of milling attachment selection enables the machine maximal utilization and adaptation for wide range of technological requirements. There is optimal way to choose type of concrete milling head ready for machining of specific operation with possible utilization of maximal level of cutting conditions and utilization of milling machine working area. High milling machine cutting performance / cutting power and high level torque values on m/c milling attachments available with mechanical spindle drive should be implemented during rough milling effectively.

The machine is in basic configuration designed for working with parameters given by file of combination of classes ambient conditions IE 33, according to ČSN EN 60721-3-3:1997, A2:1998, but air temperature must be within +15°C up to 35°C and air pressure higher than 90 kPA.

For reaching of an optimum working accuracy should be reached following conditions:

Ambient temperature within +17°C up to +25°C
Change of ambient temperature within 24 hours less than 4°C
Temperature change gradient less than 0,5°C/hour

Main benefit

modern optimized solution of machine bed and column
rapid feed up to 30 m/min
thermal stabilization of headstock and exchangeable spindle heads
linear roller guideways in linear axes
automatic exchange of spindle heads and tools
axial tool cooling
spindle 4 000 (6 000) rpm with high torque
machine on flat foundation

FRP

Gantry centre FRP

The FRP gantry centre is designed for standard or high-speed machining of large and very complex workpieces. It consists of a bed on which the table is shifted and a fixed gantry with a movable cross-rail. Customers can choose between a linear and hydrostatic guide way.
FRP also allows turning, which is possible thanks to an optional VTL table. The machine is equipped with versatile spindle heads, which allow a variety of machining operations. The customers choose it for machining aircraft engines, locomotive diesel engines or steam turbine casings. Thanks to its high performance and torque, FRP can also be used for roughing operations.

Main benefits:

modern optimized composite solution of major parts of machine
fixed portal, movable table
fixed or movable cross–rail
thermal stabilization of headstock and exchangeable spindle heads
hydrostatic or roller guideways of linear axis
automatic exchange of spindle heads and tools
axial tool cooling
spindle 4 000 (6 000) rpm with high torque
rapid feed up to 30 m/min
machining of large and heavy workpieces

Machine description:

Table and bed

The table is made of a ribbed casting. The upper table surface is furnished with crosswise clamping T-slots. The table is mounted on roller bearing elements.
The bed consists of firmly mutually unitized castings that are fitted with profiled gibs on its top part. Guideways are protected by telescopic metal guards.

Columns

The columns are rigid ribbed castings firmly fixed to the machine base, on the top they are furnished with surfaces for mutual connection with the crossrail.

Crossrail

The crossrail is a cast-iron casting which, firmly connected with the columns, forms an interconnected portal. On the front vertical part the guideway crosswise guides are furnished with linear roller bearing profiled gibs to guide the cross slide.

Cross slide

The cross slide is a casting with a complicated shape in its rear vertical part furnished with spring-loaded roller bearing elements making up a guideway enabling the cross slide to move on crossrail guideways. There are guideways for headstock travel in the front vertical part, the guideways consist of preloaded linear roller elements.

FRF

Gantry Machining Center FRF

The gantry machining center FRF is specified especially for milling of complicated shapes in manufacture of moulds, press tools, dies or of workpieces having very complicated shapes and sizes which require machining with five continuously controlled axes, three linear axes and in two rotary axes.

The machine parameters enable you to machine a wide range of materials, including alloy steels and light metal alloys.

The basic machine feature is represented by the fixed table. The gantry consisting of two columns connected with the fixed cross rail moves along on both table sides. This arrangement enables a considerable utilization of the working area together with the minimum requirements on the built up surface.

The machine is equipped with a vertical headstock having the mechanism for automatic clamping of exchangeable spindle heads or it is equipped with the headstock having a non exchangeable head.

To reach the optimum working accuracy, the following conditions must be kept during machine operation:

Ambient temperature within +17 °C up to +25 °C
Change of ambient temperature during 24 hours less than 4 °C
Ambient temperature change gradient less than 0,5 °C/hour

Table specification:

The base of the working area is the working table which serves at the same time for the column travel. The table consists of a cast iron casting and its upper part is machined for the part clamping surface equipped with T slots serving for workpiece clamping. The table consists of sections which are connected together in the required length. Due to its design and the anchorage system, the table enables clamping complicated and heavy workpieces with large dimensions. The hardened strips of the longitudinal guideways are attached to both side surfaces of the table casting. The longitudinal X axis is covered by means of telescopic protective guards mounted on the table and on the column.

FRU

Gantry Type Machining Center FRU

FRU – The Gantry Type Machining Center model FRU consists of the fixed bed and the gantry moves on this bed in the longitudinal direction. consists of the fixed bed and the gantry moves on this bed in the longitudinal direction. The gantry is equipped with fixed cross rail. The cross slide moves along the horizontal guideways on the cross rail. The vertical headstock moves in the vertical guideways.
The machine has the headstock which is equipped with the mechanism for automatic clamping of exchangeable heads.
The work area is performed by rotary table.

Ambient temperature within +17°C up to +25°C;
Change of ambient temperature during 24 hours less than 4°C;
Ambient temperature change gradient less than 0,5 C°/hour

The longitudinal bed is made of grey cast iron and it is fixed with the machine base by means of anchorage elements. The upper part is equipped with profile strips of linear guideways with bearing packs. The longitudinal slide and the column move along these linear guideways. The rack for the motion of the longitudinal slide is mounted between the strips of the guideways with bearing packs.

The base of the longitudinal slide is made of grey cast iron. On the lower surface it is equipped with bearing packs of the linear guideways. The upper part is adapted for the attachment of the column. The longitudinal telescopic protective guards are screwed on the faces. The feed box is screwed on the back slide face.

The feed box is attached to the back surface of the longitudinal slide. The box is made as a casting of grey cast iron, where two branches of gears can be found. The gear backlash is eliminated hydraulically. There is a servomotor attached to the box. The servomotor drives the input shafts through the belt drive. The pinion is mounted on the output shaft.

The servo drives of the feed boxes are controlled by the GANTRY system.

SKDY

SKDY – the model range of two-stand carousels with a mobile portal offers the advantages of both a vertical lathe and a portal machining center. According to the customer’s wishes, we can meet almost all requirements up to the size of the workpiece, which can be demonstrated on the maximum load of the work table of up to 1,100 tons. The basis of the machine is made of cast iron, guaranteeing very high rigidity, geometric accuracy and a long service life of the machine. The carousels are constructed as a modular concept that ensures high variability in the final design of the machine. The SKDY vertical lathe enables, in addition to internal and external turning, milling, threading, grinding, drilling, reaming and other work operations. The machine can be used, among other things, for machining components in the railway, ship, aviation and armament industries.

SKD

SKD – vertical turn mill center

The machine of modular design enables a considerable variability of its composition. The machine consists of the portal which is fixed on the foundation. The portal is equipped with the cross rail which is fixed in the vertical direction. The rail‑head slide moves along the horizontal guideways on the cross rail. The ram moves in the vertical slide guideways.

The machine design with the exchangeable heads enables to adapt the machine for as many specified technologic requirements as possible. The exchange of milling heads and of turning tool holders allows to select the optimum type of the milling head for the particular operation with the possibility to use more efficient cutting conditions and at the same time, it enables to enlarge the machine working area.

There is a turning table located in the working area between the columns.

Depending on their equipment, double-column machine SKD permits:

In the turning mode:

turning the front, cylindrical, conical and general rotation inner and outer surfaces
turning the inner and outer threads on the cylindrical and conical surfaces, with a constant and variable lead
frontal and peripheral grinding of frontal and cylindrical, inner and outer surfaces (machines equipped with a grinding attachment)

In the milling mode:

milling the surfaces and co-axial slots with the head feed (axis X or Z) or with the rotation feed of the table (axis C)
milling the eccentric slots and general forms with the interpolation of axes X, Z and C
drilling and boring the openings in the axis and outside the axis of the table with the usage of a precise positioning
thread cutting in the axis and outside the axis of the table
milling, boring and cutting the threads under various angles towards the axis of the table (machines equipped with angular milling head)

Material such as cast iron, cast steel, alloy steel and fabricated steel can be machined.

SKJ

Single column turning vertical lathe SKJ

The single column vertical lathe SKJ is designed with latest technical design and manufactured with quality material and fittings, with best process for manufacturing and assembling. Material such as cast iron, cast steel, alloy steel and fabricated steel can be machined.

Depending on their equipment, single column vertical lathe SKJ permits:

In the turning mode:

turning the front, cylindrical, conical and general rotation inner and outer surfaces
turning the inner and outer threads on the cylindrical and conical surfaces, with a constant and variable lead
frontal and peripheral grinding of frontal and cylindrical, inner and outer surfaces (machines equipped with a grinding attachment)

In the milling mode:

milling the surfaces and co-axial slots with the head feed (axis X or Z) or with the rotation feed of the table (axis C)
milling the eccentric slots and general forms with the interpolation of axes X, Z and C
drilling and boring the openings in the axis and outside the axis of the table with the usage of a precise positioning
thread cutting in the axis and outside the axis of the table
milling, boring and cutting the threads under various angles towards the axis of the table (machines equipped with angular milling head)

Safety fence of the table

The safety fence of the table includes fence up to height 2,2 m which prevents open entrance of attendance into working area of the machine. Back part of the working area is covered fully (see opening picture). The safety fence is equipped with inspection holes. For entrance of operator and tool change the front part of above fence is equipped with sliding door with limit switch.

ROLLER 2800 CNC

The special machine ROLLER 2800 CNC

The special machine ROLLER 2800 CNC is built based on our standard turning machine MT 70/3000 CNC. The function of the machine consists from rolling technology of cylindrical and transition radius surfaces of shaft-shape parts (e.g. wheels axles). These technological possibilities of machine predestine using of machine for special parts production with possibility of rolling surface technology.

A rolling device is located on the longitudinal support. The movement of support is obtained by CNC controlled Z axis by machine’s bed in longitudinal direction. The movement is realized by rolling head quills in X axis direction. Rolling heads serving for clamping of rolling tools. Quills as well as rolling heads movement is made out hydraulically.

Rolling technology enables as rolling of cylindrical surfaces as transition radius or others surfaces. The kinematic of rolling process is given by condition that vector sum of immediate radial and axial force of rolling tool works vertically to rolling surface. This condition enables tilting of rolling heads in range of ±35° from middle position, which is vertical toward machine´s spindle axis (B axis). Tilting of heads is realized as independent double CNC axis. Tilting arrestment of rolling heads in given position is secured by drive with self-locking warm gearboxes.

Because of hydraulic drive of quills of rolling heads, the machine is delivered with a hydraulic unit. For press control of rolling process the hydraulic unit contains special proportional reduction valve. The valve enables continuously fluent change of pressure, it mans change of force of rolling tools during working cycle in defined range of pressure. A checking manometer, located on rolling quill head, enables direct monitoring of force of rolling tool.

Next advantage of the machine is indirect, independent measurement of rolling force, which is registered during cycle and archived. The machine allows comparison of real force with required. The control panel conforms to rolling process.

Another difference of ROLLER 2800 machine is adjustment of tailstock for hydraulic controlled quill. For secure transfer of axle forces, arising from rolling of tilting rolling heads (B axis) from zero position, the tailstock is equipped with special locking device and headstock of machine is placed on the bed with intensified centring point too.

As special accessory for rolling technology the machine disposes of system of lubrication oil supply on rolling tools. The lubrication oil supply consists from separate container with pump and special collecting tank located under machine working space.

Whole system of rolling support is integrated into covering space of machine. Sliding guideways of additional rolling support are lubricated from central lubrication system. The machine can run in manual or automatic cycle. In automatic cycle the operator of the machine is responsible for clamping and unloading of workpieces from working space and working cycle checking.