FZ 15 Sales successes reflect all the sales talk about our new FZ 15!
There’s no better reason than reduced piece part costs to invest in the latest technology. And as the recently-launched Chiron FZ 15 Series begins to make its mark in five-axis applications, a number of users have singled out manufacturing cost reductions as the particular reason for choosing the FZ 15.
Take, for example, Stewart Miller, operations manager at Rexroth’s site in Scotland. He says the FZ 15 was identified “as the most capable machine to satisfy our needs in the manufacture of rear casings for hydraulic motors”.
While Mark Watts, A P Hydraulics’ operations director, says the FZ 15 is forecast to bring cost reductions of between 25 to 30 per cent in the production of callipers at the Midlands-based automotive specialist.
With impressive spindle speeds, fast rapid traverse rates and high axis acceleration rates, the FZ 15 Series vertical machining centre has been purposely designed to offer an unmatched specification and price-to-performance ratio than competitor brands.
Features such as the machine’s 400 mm Y axis travel, spindle speeds up to 12,000 revs/min (optionally 20,000 revs/min) and a 15 kW motor that produces 90 Nm of torque enable the new models to pack power with performance - at the right cost.
Spindle motor options of 22 kW and 28 kW provide torque options of 140 Nm and 180 Nm, while rapid traverse rates of 60 m/min as standard and axis acceleration figures of 1g combine with auto toolchanger options up to 48 tools to result in a machine that will achieve both lower floor-to-floor times and reduced costs for customers like Rexroth and A P Hydraulics.
Producing approximately 150,000 callipers a year at its site in Leamington Spa, A P Hydraulics has traditionally based production around an ageing machining centre that, says Mark Watts, “was inflexible and characterised by extended changeover times”.
He continues: “As part of our continual improvements, we went through a cost reduction exercise and, from the alternative machines available, the Chiron FZ 15 was identified as the way forward.
“Importantly, the machine was also selected for its increased flexibility in enabling us to meet customer demand through its ability for rapid changeovers.
“Not only were we impressed with the machine’s specification,” he adds, “but we also knew Chiron’s reputation - the company has many spindles in the marketplace processing similar parts.”
For Rexroth, on the other hand, it was the performance of an earlier Chiron-based facility that spurred the introduction of an FZ 15.
The company has systematically introduced cell-type production routines both to reduce costs and maintain quality levels by minimising inter-operation handling at the site where the focus is on the production of hydraulic motors.
Two Chiron-based cells are currently in use, and the FZ 15 application has just been commissioned.
Says Stewart Miller: “Both cells were handled as turnkey projects by Chiron, since a series of FZ 12 vertical machining centres are at their hearts (a collection of high-speed HS and W workpiece changer models).” The five-axis FZ 15 S cell supersedes the use of several old horizontal machining centres for casing production, and the machine is of fixed-table design and has a chain-type toolchanger accommodating 48 tools.
The installation of the FZ 15 cell has, adds Stewart Miller, mirrored the way in which the initial Chiron cell - for the production of hydraulic motor cams - was implemented.
“We presented Chiron with sample parts and discussed the machining operations that were required,” he says, “then Chiron responded with a solution based around the FZ 15.
“Because we were switching from horizontal machining methods to vertical routines, we obviously paid a lot of attention to fixturing design because we were concerned about swarf clearance. In the event, Chiron’s solution is based around the use of specially-designed fixtures and automatic swarf clearance routines and, while we’ve only just commissioned the cell, there’s been no problems.”
The backdrop to Rexroth’s investments is an ongoing growth in business levels so, adds Stewart Miller, “we needed to invest to match that requirement. And the high-speed FZ 15 was presented to us as the perfect fit”.
The FZ 15 Series boasts a number of other features that elevate it above its competitors. The machine’s flood coolant and through-spindle coolant features have been enhanced, with 150 litres/min delivered at 2 bar and 20 litres/min at 30 bar, respectively, being provided as standard (optionally 200 litres/min at 2.5 bar).
Through-tool coolant application is encouraged by the use of double-walled cabins and a fully encapsulated working zone fitted with automatic extraction system.
Available in a range of variations - with fixed table (S version), with workpiece changer (W), with chain tool magazine (K) or as twin-spindle (DZ) versions - the FZ 15 boasts X and Z axes travels of 550 mm and 425 mm. Long bed versions can be provided with travels from 1,250 mm up to 2,600 mm by 400 mm by 425 mm.
The facility for up to 48 tools (HSK 63) in chain-type changer format complements the lower capacity basket-type changer, and for five-axis machining the NC rotary table can accommodate loads of up to 400 kgs within a swivelling range of +/- 100 deg.
Chip-to-chip performance across the range is 1.9 secs to 2.4 secs, and W models can change the workpiece (0 to 180 deg) in less than 3 secs.
Control system options are either Fanuc 18i or Siemens 840D.
The increasing trend towards dry machining is accommodated by the machine base design of smooth, steep sides that ensure unobstructed chip flow.
In addition, the FZ 15 range represents the ultimate in low maintenance machining through the use of digital direct drives with absolute encoders, coolant-resistant seals, life-long greasing (stick-slip free anti-friction guideways), oil/mist-free pneumatics and the elimination of limit switches.