MAG's high-torque T-Rex spindle, available on 4-axis HMC 1250/1600 machines, can deliver up to 2,600nm (1,918 lb/ft) torque into a cut to produce extreme metal removal rates on large workpieces of hard materials, such as titanium, Inconel, and Carpenter 465. Developed for the machining needs of aerospace, energy, and heavy equipment manufacturers, the T-Rex spindle is engineered with 130mm (5.1”) ID bearings to handle the 42.3kN (9,500 lb) cutting thrust capability of the HMC 1250/1600 series horizontal machining centers. The T-Rex spindle is currently available on 4-axis machines, configured with 80kW (107.3hp) driving power and two speed ranges up to 5,000rpm.
The T-Rex spindle recently demonstrated triple the metal removal rates over previous spindle designs for an aerospace customer machining Carpenter 465 hardened to 50-52 Rc. The demonstration utilized a 75mm (3”) diameter Harvi inserted endmill with five flutes and 13 inserts per flute. The cutting parameters were 100mm (4”) axial depth of cut, 24mm (0.95”) radial depth of cut, and 0.5mm/rev (0.020ipr) feed rate.
The HMC 1250/1600 is engineered to make short work of large parts, such as pumps, valves, turbines, off-road equipment, and rail or aerospace parts. Major machine components, including the X-bed, Z-bed and column, are cast ductile iron, with pallets up to 1600mm x 2000mm, headstock and rotary table housings of gray cast iron. The 360,000-position full-contouring rotary table provides a rigid work platform, while a rugged worm gear drive with clamp securely holds axis position. Rotary table positioning accuracy is 10aps, repeatable to 5aps.
Meeting industry needs for tighter part tolerances and greater machining accuracies, the HMC Series comes standard with linear scale feedback in X-, Y-, and Z-axes, providing 8µ (0.0003”) positioning accuracy and 5µ (0.0002”) repeatability. Heavy-duty hardened and ground roller guide ways enable a rapid traverse rate of up to 40m per minute (1,575ipm) with high acc/dec rates, double the load capacity, and nearly 10 times the wear life of ball-type ways.
Eight spindle options include: 6,000 and 8,000 rpm/46kW (61.6hp) tilt-spindles with +90°/-120° A-axis travel; a 10,000rpm/46 kW (62hp) spindle; high-speed 24,000rpm spindle; T-Rex high-torque 2,600Nm/80kW (1,918ft/lb) spindle and two live spindles (110mm or 130mm diameter). The high-torque T-Rex spindle is specially engineered for hard-metal cutting, while the live spindles extend W-axis reach by up to 800mm (31.5”), enabling deep cavity milling to high precision with shorter, more rigid tools. Standard on the live spindle, MAG's exclusive Z-axis thermal compensation system dynamically offsets spindle growth to maintain correct axial position regardless of spindle temperature.