MIKRONXSM 400, 400U

GB

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The new reference machines in the 3, 4 and 5-axis field for ultra-highspeed milling: MIKRON XSM 400 andMIKRON XSM 400U. Quality and pro-ductivity with the highest dynamicsand accuracy - the new XSM seriessets new milestones in HSC produc-tion.

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Content Applications 4

Highlights 6-7

Automation 8

Table variations 12

High-tech spindles 14

Tool magazine 15

Options 16

smart machine 17

About GF AgieCharmilles 18

MIKRON XSM 400, XSM 400U

Injection moldMold making steel Electronics industry• Machining of deep cavities with large L/D ratio• Tool diameter min. 0.2 mm• Micro-machining of small details

Blow moldAluminum Packaging industry• High surface quality• Series production• High cutting volume

Injection moldMold making steelElectronics industry• Cost-effective combination of HSC and EDM• High cutting volume• High contouring accuracy

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Economical production of complex and valuable components…

Bone plateAustenitic steelMedical technology• Machining of high-alloyed steel• 5-axis simultaneous machining• Complete machining in one clamping position

HSC hard material milling of a moldcore (crosswise cutout using wire EDM).Components of a zinc die-casting die.

Applications

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Highlights New dimensions in production through the highest dynamics and accuracy

Machine controlHigh performance latest generationcomputer numerical control unit. TheiTNC 530 from Heidenhain is a ver-satile, flexible workshop-orientedmachine control, which takes allrequirements into account.

• Efficient shop-level programmingor external, machine-independentprogram generation

• Parallel programming, free contourprogramming, freely definable sub-program

• Fast execution due to short blockexecution time

• Swiveling of the machining plane • 3D tool offset

Efficient chipmanagement

Effortless crane loading

Effortless crane loading

Outstanding view of the machining process

High performance machine control

Flexible workpieceautomation

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Ergonomics and process reliabilitySafety and accessibility know nocompromises.• Unaltered accessibility in any con-

figuration• Outstanding view of the working

area• Access from 3 sides through

opening a single free-moving door -also for crane loading

• Side windows for optimum super-vision of the machining processes

DynamicsHomogeneous dynamic performanceson all axes due to direct drive tech-nology. Highly dynamic axes are aprerequisite for high-speed milling inmold making and for other high-endapplications.• Highest dynamics (acceleration

> 2g)• Highest rigidity• Excellent precision and contour

accuracy• No lead error, no backlash• No wear• No maintenance

AccuracyWhat use is speed if accuracy suffers? Precision as standard:• High static and dynamic rigidity• Absolute glass scales on all axes

with a resolution of 0.02 μ gua-rantee an incomparable contouraccuracy

• Water cooling of all heat sources• Temperature compensation of the

Z-axis

Process optimizationDeveloped and patented by GF AgieCharmilles: the original OSS SmartMachine module. With OSS the machining process canbe optimized according to the work-piece requirements.

Stability and absorptionPrimary prerequisites for the highestprecision and best workpiece surfacequality are rigidity and stability of thecomponents:• Highly stable portal construction• Monolithic construction• Machine base made of mineral

composite with high absorptionproperties (8-10x better than graycast iron)

• Improvement in the workpiecesurfaces and up to 30% increase intool life

3

μm

1

0

-1

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-30 0.2 0.4 0.6 s 1.0 0 0.2 0.4 0.6 s 1.0

Time Time

Gray cast iron Mineral composite

Temporal decrease of the oscillation amplitude

Am

plitu

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Automation Even more productive due to automation

Ergonomic pallet loading

18x System 3R Macro Magnum

For the best possible efficiency, GFAgieCharmilles Milling has developedits own pallet magazine, which can beadapted to all standardized palletiza-tion systems ex factory.

The pallet magazine can be loadedduring operation, and can be verysimply operated using the CNC con-trol. In this way automatic productionis ensured.

Advantages of automation:• Repetitive machining is executed

without interruption in multi-shiftoperation.

• The machine's efficiency is increa-sed with consequently higher profit

XSM 400U

Outstanding accessibility in any con-figurationThe outstanding feature of MIKRONmachining centers is their exceptionalergonomics. What is impressive aboutthe XSM series is its unrivalledaccessibility, which is not dependenton the machine's configuration.

(Payload max. 80 kg)(Payload max. 80 kg)

XSM 400

Pallet change through portal structure

System 3RMacro Magnum

+ 18xErowaITS 148

+ 20xSystem 3RMacro

+ 48x

System 3RDynafix 280 x 280 mm

+ 7xGPS 240 x 240 mm

+ 10xErowaUCP 320 x 320 mm

+ 7x

e to

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Achieve more...

MIKRON XSM 400, XSM 400U

MIKRONXSM 400, 400U

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Table variations Process-oriented workpiece clamping - the integrated automation interface

Stable and flexible: static table withintegrated zero point clampingsystemOutstanding ratio of weight and rigi-dity - through:• Ferritic ductile graphite iron GGG50• Heavily ribbed construction• Direct load transmission in the

guideways• Optimization by means of FEM

simulation

Main featuresPivoting angle of 220° (+110°/-110°)max. tilt speed: 165 min-1

Rotation angle up to n x 360°Max. rotary speed: 250 min-1

Max. payload: 25 kg

5-axis simultaneous machining - real team workPerfect coordination of all the ele-ments involved in 5-axis simultaneousmachining to achieve the goals ofextremely high speed machining:• Direct drive with "Torque" motor• Direct measuring of the angle

positions by optical rotary encoder• Hydraulic clamping devices• Liquid cooling• Integrated zero point clamping

system

Static table with integrated System 3RDynafix clamping chuck

Rotary tilting table with integrated System 3R MacroMagnum clamping chuck

Table with integrated Mecatool GPS 240type clamping chuck

Table with integrated Erowa UCP typeclamping chuck

Tilting rotary table with Erowa ITS Ø 148pallet clamping chuck

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Complete machining in one clampingposition due to 5-axis milling ensuresproductivity and workpiece accuracy

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High-tech spindles

Constant HSC-operations with smallest tools require a powerful high-speed spindle

smart machine insideSince the high-speed spindle is loca-ted directly on the machining process,it is best suited to monitoring thework process. The spindles contain acomplete sensor system, which withthe versatile choice of Smart Machinemodules, bring intelligence to themilling process.

Choice of spindleThe XSM 400 and XSM 400U offer awide range of motor spindles for anyapplication in the high speed field.The finely graduated pallet extends upto a 54,000 min-1 spindle for machi-ning with the smallest tools andspindle drive powers up to 13 kW.

The facts• Spindles with vector control• Ceramic hybrid ball bearings• Oil/air lubrication system with

extraction of the used oil• Integrated water cooling• Integrated "smart machine" sensor

technology

Its advantages• High torque at low speeds• Shorter acceleration phases• Longer life limit• Process supervision by means of

smart machine modules• Rigid tapping possible

HSK taper• Outstanding static and dynamic

rigidity• Outstanding reproducibility

(axial stop)• Suitable for high speeds

(Centrifugal tension)• Short initial overhang• Reduced mass

Motor spindlesHSK-E40, 30,000 min-1

HSK-E40, 42,000 min-1

HSK-E32, 54,000 min-1

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Tool magazine Customized solutions for your production

Tool automation in any configuration• Single or double-row disk-type

magazine• Reliable “Pick-up” change system• Loading control by a beam of light• Capacity of up to 68 tools• Tool length of up to 200 mm• Tool diameter of up to Ø 65 mm• Workpiece weight of up to 2 kg

User-friendly tool loadingProductivity and process reliability are guaranteed due to the sidetool loading• Simultaneous machining and

loading • Simple loading control through a

large pane of glass• Ergonomic access

Obtainable installation sizes:HSK-E32: 20; 40 toolsHSK-E40: 18; 36; 68 tools

Double-row HSK-E40 magazine with acapacity of 68 tools

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Options Customized equipment

Further options:

• Chip chute• Spiral conveyor• Chip flushing• HP lift-up conveyor• Working area wash out• Mist extraction system• Dust extraction• Interfaces to external robot

Lift-up conveyor Touch probe Cooling lubricant device

Rotating clear screen Scratch-resistant viewingglass

Indicator lamp smart machine (see www.gfac.com)

3 and 4 operating mode

Mobile hand wheel

Belt filter unit

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smart machine The new dimension in modern production

Bringing intelligence into the millingprocess is the intended aim of "smartmachine". This includes a range of modules thatare collectively referred to under thegeneric term "smart machine" andthat fulfil various functions. In orderto make the milling process "intelli-gent", various requirements have tobe implemented. First of all, establishing comprehen-sive communication between man andmachine, which makes precise infor-mation that the operator requires toassess the milling process availableto him. Secondly, supporting the ope-rator in the optimisation of the pro-cess, which considerably improves theperformance. Thirdly, the machineoptimises the milling process, whichimproves the process safety and thequality of the workpiece - above all inunmanned operation.

The facts• Greater accuracy in shorter

machining times• Increase in the workpiece surface

quality as well as the surface andshape accuracy

• Recognition of critical machiningstrategies

• Improvement in the process safety• Reduction of the machine set due to

longer service life• Higher availability• Better operating comfort• Considerable increase in reliability

in unmanned operation

smart machine construction kit sys-temEach of the modules fulfils a specifictask. Just like in a construction kit,the user can select the modules thatseem to him to be the best option forimproving his process.

Your benefit Producing the workpieces in a pro-cess-secure and precise manner,increasing the reliability in unmannedoperation, increasing the service lifeof the machine and significantlyreducing production costs.

The smart machine is constantlybeing developed further.

The currently available modules canbe found at www.gfac.com

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About GF AgieCharmilles

Milling

EDM

Automation

Spindle

Service

High-Speed and High-Performance Milling Centers

In terms of cutting speed, HSM centers are 10 times faster thanconventional milling machines. Greater accuracy and a better surfacefinish are also achieved. This means that even tempered materials canbe machined to a condition where they are largely ready to use. Oneessential advantage of HSM is that with systematic integration, theprocess chain can be significantly shortened. HSM has developedalongside EDM into one of the key technologies in mold and tool making.

Electric Discharge Machines

EDM can be used to machine conductive materials of any hardness (for example steel or titanium) to an accuracy of up to one-thousandth of a millimeter with no mechanical action. By virtue of these properties,EDM is one of the key technologies in mold and tool making. There aretwo distinct processes -- wire-cutting EDM and die-sinking EDM

Tooling, Automation, Software

Tooling for fixing workpieces and tools; automation systems and systemsoftware for configuring machine tools and recording and exchangingdata with the various system components.

HSM Spindle Technology

Development, production and sale of the motor spindles that form thecore components of modern HSM centers. The spindles rotate at speedsbetween 10 000 and 60 000 rpm.

Services and Consumables

Service, maintenance, spare parts and consumables for EDM, millingand HSM systems as well as for other machine tools; consumablesinclude filters, wire, graphite, copper electrodes and special resin.

Contact

www.gfac.com

Achieve more...

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Achievemore...

We commit our-selves to a promise.That promise is“Achieve more.” It’s a commitmentto create the rightconditions for ourcustomers to obtaincompetitive results.When our customerswin, we win.