union pr 150 / pcr 150
Horizontal Boring and Milling Machine and Machining Center RAM Type with traversing column
UNION PR 150 / PCR 150
UNION PR 150 and UNION PCR 150 – Horizontal Boring and Milling Machines with traversing column and RAM for heavy cutting operations on large components up to a length of 25 m The newly developed UNION PR- and PCR-Series – offer our latest boring mill concept for a efficient multilateral machining of huge components. A traversing column version with a longitudinal traversing RAM which meets your total machining needs and reduces the through put times to a minimum.
General Specification Boring spindle diameter 150 mm Traverse X 4000 mm + n · 1000 mm Traverse Y 2500, 3000, 3500 or 4000 mm Traverse Z 1000 mm Traverse W 700 mm Main drive power max. 51 kW Control iTNC 530, Sinumeric 840 D or Fanuc 16 i MA Floor plate field according the X-traverse of the machine or to customer request
Main features • Hydro-mechanical compensation of the RAM deflection due to the extension and weight of attachments • 4, 6 or 8 axis control provide for contouring, NC tables or NC milling heads • Infinitely variable AC-motors employing digital drive technique, ensures high driving power • Wide range of speeds and feeds • Nitrided axially traversing boring spindle • Precise guiding of all linear traversing slides guarantees optimum machining accuracy • Horizontal and vertical adjustment of operator platform • 5-side machining by fast interchangeable milling heads as well as NC facing heads and other attachments for contouring operations • Customisation of machine specification to suit customer needs • Optimum flexibility through a multitude of available options
Machine with automatic tool changer for 60 tools, automatic accessory changer and pick-up station for angular milling heads and cover plate as well as tools, which will be automatically changed into the milling head
Highest efficiency assured on multilateral machining with UNION RAM-TYPE Boring Mills and Machining Centers 2
Design Highlights Main machine frame units
Automatic Tool Changer
• Wide 3-way bed adjusted by levelling shoes in three rows • Column transverse movement with backlash-free rack and double pinion drive • Column transverse traverse can be extended in steps of one meter up to a max. length of 25 m • Double-walled box-type column with guides for the vertical traversing head stock as well as two ball screw spindles as parallel axes • Massive saddle slide as carrier for the heavy duty column • Sturdy main components, latest design driving and guiding elements provide high power transmission and vibration-free operation • Very high machining accuracy especially on circular milling is guaranteed by means of preloaded Linear-Compact-Roller Guides for the main traverses.
Tool magazine for 40, 60 or 80 tools fitted on the rear side of the column and arched track system for the changer with double arm gripper
Machine in assembly stage with enclosure partly removed and ram, prepared for automatic accessory changer
Different versions of RAM's prepared for automatic milling head change having all electrical and hydraulic connections for the operation of a variety of milling heads
with cover plate and coolant nozzle block which can be swivelled by remote control from operating panel
Machine bed with column saddle and column
3
Precision and Reliability – Made in Germany – the typical features of a UNION Horizontal Borer Ram with Main Bearing System The hardened and hydro-static guided ram carrying an integrated main bearing system for the axial travelling boring spindle incorporates auto-
matic droop compensation appropriate to ram extension and weight of attachments. This ensures optimum cutting performance even with large RAM extensions by keeping the guaranteed machining accuracy. The system is prepared for coolant through the spindle.
PR / PCR 150 Power – torque diagram Machining with most modern tooling requires a much higher cutting performance from today’s machine tools. A high torque on speeds below 100 rpm is not ideal for milling operations. UNION offers high torque at a range where it's really necessary for the cutting process – at speeds larger than 200 rpm.
NAS - test piece
Achievable accuracy's Deviation from a straight line (reference traverse 630 mm) Diameter accuracy (internal boring) Deviation from true circle (internal boring ) Ø 160 mm Deviation from true circle (external milling, circular) Ø 300 mm Coaxiality of above mentioned circles Positioning accuracy against VDI / DGQ 3441 Axes X, Y, Z guaranteed values Positioning uncertainty P 0.020 mm Positioning uncertainty P for X>5m 0.030 mm Positional scatter Ps max 0.010 mm Reversal error U max 0.005 mm Positional deviation Pa 0.008 mm
4
< 20 µm IT 6 < 8 µm < 20 µm < 20 µm achieved values (average) 0.011 mm 0.015 mm 0.007 mm 0.003 mm 0.004 mm
Machining on UNION Boring Mills keeps you ahead of your competitors CE approved operations
CNC contouring control
Portable Rotary Tables
• Traversing operating cabin – with swivelling control panel and electronic hand wheel which can be optionally adjusted vertical and in spindle direction • Automatic mode only after closure of the cabin window • Safe guarding with safety fences around remaining areas of machine – electrical interlocked
• 4 axis for standard machine
For increased versatility our RAM-type boring mill can be equipped with different rotary and traversing as well as tilting tables. UNION offers you portable tables with own controls as well as NC tables controlled from the CNC of the machine. Table positioning 0.001° - 360 000 positions and automatic clamping of the table
5 side machining The machine is ideally suited for multilateral machining when using adaptable vertical- and universal millling heads. The heads as well the tools can be changed automatically from a pick-up station
• 6 axis for a machine with NC table, • 2 additional axes for a NC milling head • Controls: Siemens 840 D, Heidenhain iTNC 530 or Fanuc 16 i MA • Digital interface for the drives • Controlled axes X, Y, Z, and W (B and V for table; A and C for milling head) • Linear, circular and helical interpolation • 10" resp. 15" TFT colour screen with graphic functions • Conversational programming in different languages • Operator guidance, external programming, test run with graphic simulation, display of actual program blocks • Setting up from portable panel with electronic hand wheel • Program memory on hard disc with up to 6 G Byte • Feed and speed-override, tool compensation, datum point shift on all axes • Operating modes: manual operation, positioning with MDI, background programming, single block and automatic operation • Canned cycles: machine cycles for pecking, thread cutting, groove milling, pocket milling, frame milling, mirror image, co-ordinate system shift and rotating • Polar co-ordinate- and parameter programming • Tangential contour approach and departure • Serial data interface V 24 according RS 232-C and V11 RS422 • Failure diagnosis for the machine, control and measuring system • Teleservice, tool breakage control, torque monitoring as well as other technological aids on request
Size of tables: DV 10 1250 x 1600 and 1600 x 2000 mm 48 x 63 and 63 x 78 inch longitudinal traverse 1250 mm (49") max loading 12 tons DV 20 1800 x 2000 and 2000 x 2500 mm 71 x 79 and 79 x 98 inch longitudinal traverse 1600 mm (63") max. loading 25 tons DV 40 2500 x 3000 mm (98 x 118") longitudinal traverse 2000 mm (78") max. loading 40 tons UNION can also supply Rotary-, Traversing- and Tilting Tables as well as high speed Positioning-, Rotaryand Traversing Tables
Positioning-, rotaryand traversing table with a torque motor and a size of 1750 x 1750 mm and max. loading of 10 tons reaches speeds up to 50 rpm. Together with our RAM design, it can be used for vertical turning operations. This combination makes your boring mill into a VTL avoiding machining operations and set ups on other machines. The table can be positioned to 0.001 degree and will be clamped automatically after reaching position.
UNION PDV 10
5
Special accessories / Options Compact coolant unit 1
Chip/swarf conveyor
Die coolant is supplied via remote controlled and swivelling nozzle block. Coolant return via the chip conveyor into the compact unit for filtration and piped back into the system. Flow volume 25 l/min
A chain type conveyor takes the chips away. Length and conveyor height has to be adapted to the machine’s specification. Coolant circulation is ensured by means of collector trays.
Compact coolant unit 2
Safety precautions
Increased flow volume 50 l/min at 3 bar with adjustable pump and 3 nozzles on a swivelling block adjustable from operator panel. Coolant return as unit 1 but with appropriate filtration.
The machine will be supplied with a CE approved operator cabin with safety door – electrically interlocked. Further necessary safety equipment has to be defined in line with the local conditions and the safety regulations at the customer’s site and has to be installed before commissioning. An access to the working area of the machine for setting-up is ensured.
Universal milling attachment V4 Manual setting of certain angles in both planes in accordance with a calculation table. Length to the vertical spindle 800 mm.
Milling heads with automatic positioning On request UNION can supply vertical and universal milling heads with Hirthcoupling as well as a 2-axes NC-milling head with continuously swivelling axes.
3D-measuring probe Touch trigger probe with radio-transmission to the machine control incl. software and measuring cycles.
Field of floor plates Compact coolant unit 4 (through boring spindle) The compact coolant unit 2 will be additionally equipped with a high pressure coolant circuit and the boring spindle modified with the specific equipment for this system. A paper band free fine filter cleans the coolant. Flow volume 30 l/min at 20 bar (higher pressure possible)
according to the size of the machine a total floor plate size is recommended which is 1 m longer than the X traverse. Basic size is 2 x 5 m, special sizes available.
Universal milling head with automatic positioning (2 x 144 x 2.5°) and powered tool clamping, max power 25 kW. This milling head is also available in orthogonal version .
Vertical milling head with automatic positioning (144 x 2.5°) and powered tool clamping, max power 30 kW
2-axis NC fork type milling head GFK 50
Adapter for special accessories To accommodate vertical and universal milling heads, facing heads and other accessories. Can also be supplied for automatic head changing.
6
Swivelling range A-axis +/- 95° Swivelling range C-axis +/- 180° Closed loop axis drive by AC motors including clamping device. The milling spindle is driven from the spindle of the machine in the same speed range. Max. power transmission 25 kW with a max. torque of 800 Nm
150 years of UNION – The driving force behind boring and milling Layout of a PCR 150 with X = 5000 mm, Y = 3000 mm; floor plate 6000 x 2000 mm
Technical Data PR / PCR 150 Boring spindle Diameter RAM section Driving power Spindle taper according DIN 69871 Speed range - spindle 150 mm Traverses Column transverse Extensions in steps of up to max. length Headstock vertical optional in steps of 500 mm RAM longitudinal Boring spindle axial Feeds / rapid traverses Feeds in all axes Rapid traverse Max. feed force on the main axes Automatic tool changer Number of tools in magazine Max. tool diameter Max. tool length Max. tool weight Net weight of the basic machine
UNION provides general recommendations for the height of the machine in relation to the floor plates. The exact floor plates height to floor level and the lowest boring spindle position to the top of the floor plates can be modified according your machining task and has to be defined with the order.
metric
X X X Y Y Z W
inch
mm mm kW ISO min-1
150 450 x 550 51 50 5...2500
inch inch HP ISO rpm
5,91 17.7 x 21.7 68 50 5...2500
mm mm mm mm mm mm mm
4000 1000 25000 2500 3000, 3500, 4000 1000 700
inch inch inch inch inch inch inch
157.5 39.4 984,2 98.4 118.1, 147.8, 157.5 39.4 27.6
mm/min mm/min N
1...6000 15000 25000
ipm ipm N
0.04...236 590 25000
mm mm kg kg
40 (60, 80) 250 500 30 44500
inch inch lbs lbs
40 (60, 80) 10 20 66 97900
7
You will find our machines and our activities all over the world
Innovation The early concentration on the development and construction of horizontal borers made UNION a world renowned manufacturer producing leading machine tools for boring and milling operations. Our new unit construction system will convince you in every way.
Flexibility Of course, we can’t do everything, but in the field of horizontal boring and milling UNION can offer satisfactory solutions. We will adapt our technique to your machining problem and to the benefit of our customer. Allow us to assist you.
Quality The cornerstone of UNION’s success. From the product quality to technical advices and after-sales-service – for UNION it is an all-embracing philosophy.
Service Installation and commissioning, technological service, overhauling and modernisation, various special accesssories for increased versatility, spare part service, repairs, re-location of machines, machining of large components.
UNION Werkzeugmaschinen GmbH Chemnitz Clemens-Winkler-Straße 5 D - 09116 Chemnitz Post address UNION Werkzeugmaschinen GmbH Chemnitz P.O. Box 1142 D - 09070 Chemnitz Phone: +49-371-87 41 -0 Fax: +49-371-87 41 -322 E-Mail: [email protected] http://www.UNION-Bohrwerke.de We reserve the right to alter our products at any time for improvement.
PCR 15-2e
UNION PR 150 / PCR 150
UNION PR 150 and UNION PCR 150 – Horizontal Boring and Milling Machines with traversing column and RAM for heavy cutting operations on large components up to a length of 25 m The newly developed UNION PR- and PCR-Series – offer our latest boring mill concept for a efficient multilateral machining of huge components. A traversing column version with a longitudinal traversing RAM which meets your total machining needs and reduces the through put times to a minimum.
General Specification Boring spindle diameter 150 mm Traverse X 4000 mm + n · 1000 mm Traverse Y 2500, 3000, 3500 or 4000 mm Traverse Z 1000 mm Traverse W 700 mm Main drive power max. 51 kW Control iTNC 530, Sinumeric 840 D or Fanuc 16 i MA Floor plate field according the X-traverse of the machine or to customer request
Main features • Hydro-mechanical compensation of the RAM deflection due to the extension and weight of attachments • 4, 6 or 8 axis control provide for contouring, NC tables or NC milling heads • Infinitely variable AC-motors employing digital drive technique, ensures high driving power • Wide range of speeds and feeds • Nitrided axially traversing boring spindle • Precise guiding of all linear traversing slides guarantees optimum machining accuracy • Horizontal and vertical adjustment of operator platform • 5-side machining by fast interchangeable milling heads as well as NC facing heads and other attachments for contouring operations • Customisation of machine specification to suit customer needs • Optimum flexibility through a multitude of available options
Machine with automatic tool changer for 60 tools, automatic accessory changer and pick-up station for angular milling heads and cover plate as well as tools, which will be automatically changed into the milling head
Highest efficiency assured on multilateral machining with UNION RAM-TYPE Boring Mills and Machining Centers 2
Design Highlights Main machine frame units
Automatic Tool Changer
• Wide 3-way bed adjusted by levelling shoes in three rows • Column transverse movement with backlash-free rack and double pinion drive • Column transverse traverse can be extended in steps of one meter up to a max. length of 25 m • Double-walled box-type column with guides for the vertical traversing head stock as well as two ball screw spindles as parallel axes • Massive saddle slide as carrier for the heavy duty column • Sturdy main components, latest design driving and guiding elements provide high power transmission and vibration-free operation • Very high machining accuracy especially on circular milling is guaranteed by means of preloaded Linear-Compact-Roller Guides for the main traverses.
Tool magazine for 40, 60 or 80 tools fitted on the rear side of the column and arched track system for the changer with double arm gripper
Machine in assembly stage with enclosure partly removed and ram, prepared for automatic accessory changer
Different versions of RAM's prepared for automatic milling head change having all electrical and hydraulic connections for the operation of a variety of milling heads
with cover plate and coolant nozzle block which can be swivelled by remote control from operating panel
Machine bed with column saddle and column
3
Precision and Reliability – Made in Germany – the typical features of a UNION Horizontal Borer Ram with Main Bearing System The hardened and hydro-static guided ram carrying an integrated main bearing system for the axial travelling boring spindle incorporates auto-
matic droop compensation appropriate to ram extension and weight of attachments. This ensures optimum cutting performance even with large RAM extensions by keeping the guaranteed machining accuracy. The system is prepared for coolant through the spindle.
PR / PCR 150 Power – torque diagram Machining with most modern tooling requires a much higher cutting performance from today’s machine tools. A high torque on speeds below 100 rpm is not ideal for milling operations. UNION offers high torque at a range where it's really necessary for the cutting process – at speeds larger than 200 rpm.
NAS - test piece
Achievable accuracy's Deviation from a straight line (reference traverse 630 mm) Diameter accuracy (internal boring) Deviation from true circle (internal boring ) Ø 160 mm Deviation from true circle (external milling, circular) Ø 300 mm Coaxiality of above mentioned circles Positioning accuracy against VDI / DGQ 3441 Axes X, Y, Z guaranteed values Positioning uncertainty P 0.020 mm Positioning uncertainty P for X>5m 0.030 mm Positional scatter Ps max 0.010 mm Reversal error U max 0.005 mm Positional deviation Pa 0.008 mm
4
< 20 µm IT 6 < 8 µm < 20 µm < 20 µm achieved values (average) 0.011 mm 0.015 mm 0.007 mm 0.003 mm 0.004 mm
Machining on UNION Boring Mills keeps you ahead of your competitors CE approved operations
CNC contouring control
Portable Rotary Tables
• Traversing operating cabin – with swivelling control panel and electronic hand wheel which can be optionally adjusted vertical and in spindle direction • Automatic mode only after closure of the cabin window • Safe guarding with safety fences around remaining areas of machine – electrical interlocked
• 4 axis for standard machine
For increased versatility our RAM-type boring mill can be equipped with different rotary and traversing as well as tilting tables. UNION offers you portable tables with own controls as well as NC tables controlled from the CNC of the machine. Table positioning 0.001° - 360 000 positions and automatic clamping of the table
5 side machining The machine is ideally suited for multilateral machining when using adaptable vertical- and universal millling heads. The heads as well the tools can be changed automatically from a pick-up station
• 6 axis for a machine with NC table, • 2 additional axes for a NC milling head • Controls: Siemens 840 D, Heidenhain iTNC 530 or Fanuc 16 i MA • Digital interface for the drives • Controlled axes X, Y, Z, and W (B and V for table; A and C for milling head) • Linear, circular and helical interpolation • 10" resp. 15" TFT colour screen with graphic functions • Conversational programming in different languages • Operator guidance, external programming, test run with graphic simulation, display of actual program blocks • Setting up from portable panel with electronic hand wheel • Program memory on hard disc with up to 6 G Byte • Feed and speed-override, tool compensation, datum point shift on all axes • Operating modes: manual operation, positioning with MDI, background programming, single block and automatic operation • Canned cycles: machine cycles for pecking, thread cutting, groove milling, pocket milling, frame milling, mirror image, co-ordinate system shift and rotating • Polar co-ordinate- and parameter programming • Tangential contour approach and departure • Serial data interface V 24 according RS 232-C and V11 RS422 • Failure diagnosis for the machine, control and measuring system • Teleservice, tool breakage control, torque monitoring as well as other technological aids on request
Size of tables: DV 10 1250 x 1600 and 1600 x 2000 mm 48 x 63 and 63 x 78 inch longitudinal traverse 1250 mm (49") max loading 12 tons DV 20 1800 x 2000 and 2000 x 2500 mm 71 x 79 and 79 x 98 inch longitudinal traverse 1600 mm (63") max. loading 25 tons DV 40 2500 x 3000 mm (98 x 118") longitudinal traverse 2000 mm (78") max. loading 40 tons UNION can also supply Rotary-, Traversing- and Tilting Tables as well as high speed Positioning-, Rotaryand Traversing Tables
Positioning-, rotaryand traversing table with a torque motor and a size of 1750 x 1750 mm and max. loading of 10 tons reaches speeds up to 50 rpm. Together with our RAM design, it can be used for vertical turning operations. This combination makes your boring mill into a VTL avoiding machining operations and set ups on other machines. The table can be positioned to 0.001 degree and will be clamped automatically after reaching position.
UNION PDV 10
5
Special accessories / Options Compact coolant unit 1
Chip/swarf conveyor
Die coolant is supplied via remote controlled and swivelling nozzle block. Coolant return via the chip conveyor into the compact unit for filtration and piped back into the system. Flow volume 25 l/min
A chain type conveyor takes the chips away. Length and conveyor height has to be adapted to the machine’s specification. Coolant circulation is ensured by means of collector trays.
Compact coolant unit 2
Safety precautions
Increased flow volume 50 l/min at 3 bar with adjustable pump and 3 nozzles on a swivelling block adjustable from operator panel. Coolant return as unit 1 but with appropriate filtration.
The machine will be supplied with a CE approved operator cabin with safety door – electrically interlocked. Further necessary safety equipment has to be defined in line with the local conditions and the safety regulations at the customer’s site and has to be installed before commissioning. An access to the working area of the machine for setting-up is ensured.
Universal milling attachment V4 Manual setting of certain angles in both planes in accordance with a calculation table. Length to the vertical spindle 800 mm.
Milling heads with automatic positioning On request UNION can supply vertical and universal milling heads with Hirthcoupling as well as a 2-axes NC-milling head with continuously swivelling axes.
3D-measuring probe Touch trigger probe with radio-transmission to the machine control incl. software and measuring cycles.
Field of floor plates Compact coolant unit 4 (through boring spindle) The compact coolant unit 2 will be additionally equipped with a high pressure coolant circuit and the boring spindle modified with the specific equipment for this system. A paper band free fine filter cleans the coolant. Flow volume 30 l/min at 20 bar (higher pressure possible)
according to the size of the machine a total floor plate size is recommended which is 1 m longer than the X traverse. Basic size is 2 x 5 m, special sizes available.
Universal milling head with automatic positioning (2 x 144 x 2.5°) and powered tool clamping, max power 25 kW. This milling head is also available in orthogonal version .
Vertical milling head with automatic positioning (144 x 2.5°) and powered tool clamping, max power 30 kW
2-axis NC fork type milling head GFK 50
Adapter for special accessories To accommodate vertical and universal milling heads, facing heads and other accessories. Can also be supplied for automatic head changing.
6
Swivelling range A-axis +/- 95° Swivelling range C-axis +/- 180° Closed loop axis drive by AC motors including clamping device. The milling spindle is driven from the spindle of the machine in the same speed range. Max. power transmission 25 kW with a max. torque of 800 Nm
150 years of UNION – The driving force behind boring and milling Layout of a PCR 150 with X = 5000 mm, Y = 3000 mm; floor plate 6000 x 2000 mm
Technical Data PR / PCR 150 Boring spindle Diameter RAM section Driving power Spindle taper according DIN 69871 Speed range - spindle 150 mm Traverses Column transverse Extensions in steps of up to max. length Headstock vertical optional in steps of 500 mm RAM longitudinal Boring spindle axial Feeds / rapid traverses Feeds in all axes Rapid traverse Max. feed force on the main axes Automatic tool changer Number of tools in magazine Max. tool diameter Max. tool length Max. tool weight Net weight of the basic machine
UNION provides general recommendations for the height of the machine in relation to the floor plates. The exact floor plates height to floor level and the lowest boring spindle position to the top of the floor plates can be modified according your machining task and has to be defined with the order.
metric
X X X Y Y Z W
inch
mm mm kW ISO min-1
150 450 x 550 51 50 5...2500
inch inch HP ISO rpm
5,91 17.7 x 21.7 68 50 5...2500
mm mm mm mm mm mm mm
4000 1000 25000 2500 3000, 3500, 4000 1000 700
inch inch inch inch inch inch inch
157.5 39.4 984,2 98.4 118.1, 147.8, 157.5 39.4 27.6
mm/min mm/min N
1...6000 15000 25000
ipm ipm N
0.04...236 590 25000
mm mm kg kg
40 (60, 80) 250 500 30 44500
inch inch lbs lbs
40 (60, 80) 10 20 66 97900
7
You will find our machines and our activities all over the world
Innovation The early concentration on the development and construction of horizontal borers made UNION a world renowned manufacturer producing leading machine tools for boring and milling operations. Our new unit construction system will convince you in every way.
Flexibility Of course, we can’t do everything, but in the field of horizontal boring and milling UNION can offer satisfactory solutions. We will adapt our technique to your machining problem and to the benefit of our customer. Allow us to assist you.
Quality The cornerstone of UNION’s success. From the product quality to technical advices and after-sales-service – for UNION it is an all-embracing philosophy.
Service Installation and commissioning, technological service, overhauling and modernisation, various special accesssories for increased versatility, spare part service, repairs, re-location of machines, machining of large components.
UNION Werkzeugmaschinen GmbH Chemnitz Clemens-Winkler-Straße 5 D - 09116 Chemnitz Post address UNION Werkzeugmaschinen GmbH Chemnitz P.O. Box 1142 D - 09070 Chemnitz Phone: +49-371-87 41 -0 Fax: +49-371-87 41 -322 E-Mail: [email protected] http://www.UNION-Bohrwerke.de We reserve the right to alter our products at any time for improvement.
PCR 15-2e
