For over 30 years, IBAG has been a pioneer

in the high-speed cutting process. IBAG

offers a full line of motor spindles, suited

for most appilcations. A selection of small

sized spindles used for fine milling, drilling,

and engraving are available. In addition, a

wide assortment of large, powerful spindles

are offered for heavy milling and for CNC

machining centers. High speed cutting of

mold and dies as well as automotive,

transferline, aerospace, aircraft and small

job shop applications are all possible with

IBAG spindles. The benefits of high speed

machining are well known today, and IBAG

delivers a proven solution including the

highest technlogy in spindle design. IBAG

provides components or the complete

system, including drives, lubrication and

spindle cooling. High productivity options

are also available to provide the best

accuracy, reliability, and quality possible.

With high speeds, high power, high torque,

and the complete support of a world wide

service organization you can trust IBAG to

be your productivity partner. With over 30

years of experience and worldwide support

in HSC-Technology, we are the experts ...

... IBAG of course

Over 30 yearsexperience in

High Speed Cutting

Comprehensive Knowledgein High Speed Cutting

Major Advantages of High Speed CuttingImproved Quality and Reduced Production Time

3

ae

ap

d

500

Ranges of cutting speedsfor specific materials

0

0

1500

1000

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

110000

120000

130000

140000

ae mm

ap mm

d mm

fz mmz

n rpm

vf mm/min

vc m/min

Pc kW

Q cm³/min

K cm³/kWmin

� �

� �

� �

� �

� �

� �

� �

� �

� �

� �

Cutting width

Cutting depth

Tool diameter

Feed rate per tooth

Number of teeth

Spindle speed

Feed rate

Cutting speed

Effective power

Volume of material cut per minute

Specific material removal rate

vc

/m

/min

2000

2500

3000

3500

4000

4500

5000

n / rpm

d = 4

d = 10

d = 20

d = 40d = 63d = 100

d = 6

d = 3

HF300 AI10/HF285

HF250 A12/HF260

HF210

HF230 AI20

HF200 MA40

HF170 A24

HF170 AI22

HF170 HA32

HF140 A24

HFK135 S30

HF120.2 A32

HF120 MA70

HF100 A30

HF100 A45

HFK90 S40

HF80 A40

HF60 A60

HF45 S80

HF33 S100

HF42 S120

HF45 S35P

HF33 A60

HF25

HF42 S120P

QK

Pc =

Q =1000

ae ap vfx xvf = fz n zx x

n =vc 1000x

d x

vc =1000

d x x n

Standard values for KSteel 48 - 60 HRCSteel 33 - 48 HRCSteel HB150 - 300BrassCopperAluminum alloy

51020304060

For more Information on HSC and Cutting Parameters ask for our Software P-Calc

ste

el

HB

150

-300

ste

el33

-48

HR

C

ste

el48

-60

HR

C

castiron

&copper

&bra

ss

alu

min

um

&m

agnesiu

m

wood

&pla

stics

In order to use HighSpeed make sure youare using best quality,accurate and wellbalanced tool holdersand face mills,minimum G2.5 and tothe maximum speed ofthe used spindle rpm.

0

0 0 5

0 5 10 0 5 10 15 20 25

0

0

10

40

20

60

80

20

30

40

50

60

5

5 10

n x 1000 /min (rpm)

HF 230.4 AI20 -connected� HF 230.3 AI20 Y - - connected�380 V / 119 A 380 V / 74 A

n x 1000 /min (rpm)S6 40%S1 100%

P(k

W)

M(N

m)

10

10 0 5

15

15 10 15

20

20 20 25

High Power - High TorqueIBAG Motor-Technology

4

0

0 0

0 10 20 30 40

0

0

4

4

2

6

8

12

16

20

10

10 10

n x 1000 /min (rpm)

HF 120.2 AI36 - 220 V -- -55A 32A

Motors available in 220 or 380 VoltBenefit: Optimized spindle drive capacity max. power with 380 Volt drive

Motors available with Delta or Star/Delta WindingsBenefit: Cost saving solution with smaller drive, high power and torque at low and high speeds

Motors available Non-synchronous (DC-Brushless) and SynchronousBenefit: Motor Type selected for very high torque at low speeds or high power at high RPM

HF 120.2 AI36 - 380 V - 32A

n x 1000 /min (rpm)S6 40%S1 100%S1 100%

P(k

W)

M(N

m)

20

20 20

30

30 30

40

40 40

0 5

0 0 55 1010 1515 2020 2525

0 5 10 15 20 25

0

0 0

10

10 20

5 10

15 30

20 40

20

30

40

10 15

n x 1000 /min (rpm)

HF 170.5 AI22 - Non-synchronous Motor HF 170.5 AI22 - Synchronous Motor

n x 1000 /min (rpm)S6 40%S1 100%

P(k

W)

M(N

m)

20 25

IBAG uses latest and best motortechnlogy. AC for highperformance at mid and highspeeds, DC for maximum torque,especially at very low RPM andalmost no heat transferred fromthe rotor to the spindle shaft.

Sealed and enclosed motorwindings allow best heat transferand protection againstmechanical damages

DC rotor with separate stator:major benefits are minimal losses,and vector control fororientation.

Spindle System Options for MonitoringPosition, Temperature and Vibration

5

sensor for axial shift of spindle shaft

axial shift s due to mechanical movement and thermal extension�

thermal sensor

vibrations sensors

analog sensor digital sensors

Integrated Sensors IncreaseCapability, Performance and Reliablity

Option M: Shaft Position MeasurementMeasures axial shaft movement due to mechanicalmotion and thermal growth. Sensors mounted in thespindle nose accurately measure the spindle shaftposition, and provide an analog signal available to themachine tool CNC for Z axis compensation.Note: CNC software not included

Option M + Thermal Sensors on the BearingOption M features plus thermal sensors (PT100 orPT1000) mounted internally provide front bearingtemperature data for analysis and monitoring purposes.Note: This sensor is also available without Option M,rear bearing thermal sensors are optional

Vibration Monitoring (Chatter and CrashMonitor)Integrated sensors measure vibration during spindleoperation. High vibration levels can exist due toimbalanced tools, improper cutting conditions orcrashes. The system can be set up to output three levelsof vibration: OK (green), Warning (amber),Unacceptable (red). When interfaced with a CNC,proper control of the machine tool is possible, whichincludes increased spindle performance and extendsspindle lifetime.Note: Sensors are internally mounted on large spindlesexternally mounted on small spindle models

Tool Position (ATC) SensorsAll spindles utilizing automatic tool change includedigital sensors that monitor the spindle draw bar anddetect tool clamped, no tool and tool unclampedconditions. Digital sensors are adjustable andcompatible with most CNC and PLC systems.Note: single analog sensor with remote adjustmentfeature available on larger spindle models.

�s �s

Rigidity, Accuracy and a long LifetimeGreat Speed Range up to high RPM

IBAG Spindles Are Built UsingVarious Bearing Configurations,

Oil or Grease Lubrication.They Offer a Variable

Bearing Pre-LoadSystem Option

6

“O”- configuration

“O-TD”- configuration

Air seal

Oil Return

AI: Oil-Air-Injection-Lubrication for best performance

Oil-Air-Injection

“TD”(Tandem)- configuration

Controlable, hydaulic variable preload system accordingto spindle speeds. Benefits: additional damping forbetter bearing and cutter lifetime

The tandem (TD) bearing configuration isstandard for small and mid sized spindles andallows very high RPM.The “O” configuration is possible for all spindlemodels. When using the “O” configuration, themaximum speed will be slightly reduced, but thespindle will have equal axial rigidity in bothdirections (pulling and pushing) and less dynamicshaft displacement (typically used for dedicateddrilling applications).The “O-TD” configuration is typically for largesized spindles and high torque spindles for heavycutting and long tools.

The IBAG Oil Air Lubrication System deliversthe optimum amount of oil and air to the highspeed hybrid ceramic bearings. A mechanicalmixing block combines the oil and air in exactamounts.

Some spindle models are equipped with the AIInjection Lube System. It feeds a minimumamount of oil through 3 small bores located onthe outer bearing race. This brings the oil directlyto the contact line between the race and theceramic balls, optimising the bearing lubricationand reducing the heat generation. See picture tothe right. The air seal protects the spindle againstexternal contamination.

A variable hydraulic pre-load option is availableon selected spindle models. This feature allowsthe bearing pre-load to be controlled by anexternal hydraulic source. For large cutters andlow speed operation, a high pre-load should beutilized to maximize stiffness and rigidity. Forhigh operation speeds and small cutters, a lowpre-load is used. Varying the pre-load to matchthe desired spindle speed will result in maximumspindle performance, high quality surface finishand extended bearing life.Note: Not available on small spindle models.

8

HSK, SK and BT (Ott Jakob),

Capto (Sandvik),

SKI (IBAG - Patented)

Drawbar Systems Used

Highest Quality Toolingand Drawbar Systems

Built-in Drawbar forDIN 69893 - HSK-E

for Automatic Tool ChangeTool Holder Balanced G2.5to maximum Spindle Speed

Collet Holder (precision)Weldon Type HolderShrink Fit Type HolderSpecial Holder for Grinding

Tool holders available:

BT and BBT Type common inAsia and USAIBAG SKI Type or SK used inEurope and mostly for smallsized tool holder such asSK / SKI 16, 20, 25, and 30Large sized are common inHSK, Capto or BBT

A-Type Spindle withbuilt-in drawbar for allthe above mentionedtool holders (Option Wonly with HSK and BT)

D-Type spindle withGrinding arbors

S-Type spindle withCollet clamping

Built-in Drawbar forJIS B 6340-1992 - BT or BBT,and IBAG SKI Type

Various Tool Interfaces Available:

Utilizing the Latest Developments

IBAG Motor Spindles“Silver Edition”

Offer Exceptional Valueand Performance

High Quality at Much Lower Price!

9

Selected Small and Mid SizeSpindle Models Offered in “SilverEdition”

These spindles are built with thesame IBAG Quality & Accuracy butwith very limited options.

The “Silver Edition” spindles aretypically built in large quantities.This reduces the manufacturingcosts, and reduces the spindle costfor you. “Silver Edition” spindlesmust be ordered in reasonablequantities with identicalspecifications. By providing astandard product, in high quantities,IBAG can provide the most costeffective solution for yourmanufacturing needs.

A-Type Spindles are availablewith CAT, SK, SKI or BT (BBT)Tooling Interface.

Standard Tool Release System isHydraulic (some models availablewith pneumatic)

Permanent Grease BearingLubrication Standard.

Quick Connection for all Hoseson the Spindle and Motor Cablewith Connector.

Precision Hybrid CeramicBearings Used for Long SpindleLife.

Notes

HF120

TypeHF45HF80HF100HF120HF150HF210

rpm55’00040’00030’00030’00024’00020’000

kW0.43.27.816.928.630

Nm0.070.82.15.411.580

Collet mm7810121620

HF100

HF45

HF80

11

These spindles are used forproduction manufacturing,electrodes, and for mold and diemachining. Materials cut includehardened steel, aluminum, brass,copper, graphite, and variousplastics. All mid sized spindles areavailable with built-in drawbar forautomatic tool change (ATC) andvarious tooling systems (See page 8for details).

High Speed and High Quality for Universal UseIBAG Mid Sized Motor Spindles for Drilling, Milling, and High Speed Cutting

HF Motor SpindlesHF80, HF100, HF120,

and HF140

HF80

Milling graphite electrodes with HF80

5 axis milling turbine propeller with HF120HF140

TypeHF80HF100HF120HF140

rpm50’00050’00042’00036’000

kW3.27.816.928.6

Nm0.82.15.411.5

ClampingSKI20HSK32HSK40HSK50

HF120

HF100

12

The Ultimate Spindle for Your Machining CenterIncrease Power, Productivity, Efficiency, and Profits

IBAG’s LargeSized Motor Spindles

HF 230

5 axis machining with HF 230 Mold & Die work with HF 170

Horizontal MC with HF 230 Horizontal MC with HF 250

HF 170

These spindles are built for use inmid to large sized horizontal andvertical machining centers, largebridge type mills and multi-spindleCNC machines.

Powerful spindles are typically usedfor large parts manufacturing, heavymold and die cutting, andautomotive parts production.Theyare ideal for aircraft applicationswith high material removal rates inaluminum, High Speed Cutting oftitanium, carbon fiber compositesand plastics. Many of these spindlesare used in automotive transfer linesin production at companies likePeugeot, Renault and BMW.

These powerful and high torquespindles are used for roughing, semifinishing and super finishing work.IBAG supplies one spindle type forall your needs.

Each large spindle is available withvarious motor specifications, usingboth AC and DC technology. (Seepage 4 for details.)

TypeHF170HF210HF230HF250HF260HF285HF300

rpm30’00024’00024’00015’00012’00012’00010’000

kW26303540455080

Nm3880118222350350380

ClampingHSK63HSK63HSK63HSK100HSK100HSK100HSK100

13

Developed for Special Customer Applications and SpecificationsCustom Made IBAG Motor Spindles with High Speed and Superior Quality

You name it -we do it for you!

Many Sizes and Types ofSpindles Can Be Made to Meet aSpecific Application orSpecification

From very small, to mid sized, andup to very large spindles can becustom made exactly to your needs.Do you need super high speed orextreme accuracy? Or, more powerwith high torque at a specific speed?

Custom spindles can be suppliedwith special tooling systems andbuilt-in drawbars for automatic toolchange (ATC).

Spindles are available with custommounting flanges. One design, usedon a robotic application, features adouble ended shaft with collets onboth sides to cut quickly without atool change.

Spindle designs are possible with asquare housing, or with one flatsurface to adapt on the machine toolfor easy 5-axis use. This design isused by the Handtmann Company.

HF90 - double end shaft

HF120 - special flange

HF160 - special flange

HF190 - one flat surface

TypeHF90HF160HF190

rpm30’00036’00038’000

kW4.228.616.9

Nm1.411.55.4

Clamping8 mmHSK40HSK40

14

Easy to Mount on Any Machine ToolCosteffective and Profitable for You

The HFK95 is the Economy ModelIt needs NO WATER COOLING.Features include permanent greaselubricated bearings, positive air overpressure and labyrinth air sealprotection. Cooling is provided bypassing compressed air over the heatsink ribs on the outside of thespindle housing.

The HFK 90.1 features a watercooled housing, and offers higherpower and torque than the aircooled model. It is available asstandard with grease lubricatedbearings, and uses a 220 V ACmotor.

The HFK 90 features a water cooledhousing and is available with greaseor oil air lubrication for the hybridceramic bearings. A 380 V ACmotor provides more power andhigher torque. We deliver as singlecomponents, or as a completesystem including mobile Supply-Unit 20.

The HFK 135 is the most powerfulmodel, utilizing water cooling and a380 V AC motor. Grease or oil airlubrication for the hybrid ceramicbearings available. We deliver assingle components, or as a completesystem including Supply-Unit 35.Optional S62 quick change system isavailable for easier tool change andtool length presetting.

IBAG’s “PLUG & GO”spindles HFK Type

with 4 Models

HFK 95:40’000 rpm, 1 kW, 0.20Nm, clamping capacity6 mm

HFK 90 with 380 VAC motor:42’000 rpm with greaselubrication, 60’000 rpmwith oil air lubrication,2.7 kW, 0.45 Nm,clamping capacity 10mm, available as turn-key finished systemwith Supply-Unit 20

HFK 135 with 380 VAC motor:26’000 rpm with greaselubrication, 40’000 rpmwith oil air lubrication,10 kW, 5.6 Nm,clamping capacity 16mm

HFK 135 turnkeyfinished system withSupply-Unit 35

HFK 90.1 for USA &Asia with 220 V ACmotor:42’000 rpm, 1.9 kW, 0.4Nm, clamping capacity10 mm, picture showscomplete system withHFK 90.1, converterand chiller