Machining Centres
HELLER solution competence:
Efficiency for your production. Worldwide.
Setting standards in 5 axis
www.heller.biz
The F series
Some of the options shown are not included in the basic configuration. Design and scope of supply are subject to
technical changes. © 08. 2012 Gebr. Heller Maschinenfabrik GmbH
Content
5-axis competence
5-axis competence in HELLER quality
5-axis competence
in HELLER quality 3
The F Series:
Machine concept 4
Your investment in a new machining centre has to pay off.
A plus in flexibility:
To make your production future-proof, you need reliability,
Cutting costs through complete machining – the F series provides
precision and high productivity. We are here to help you.
the response to this trend in the machine tool industry. Being able
to perform as many tasks as possible with the same machine
Innovative spindle technology:
Process stability times three The workshop machine:
FT 4000 for table loading
The production machine:
FP 200 / 4000 with pallet changer
Control:
The choice is yours
CAD/CAM integration:
From idea to finished product
Tool management:
Fast, precise, flexible
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Our answer: the new F series.
5-axis machining centres designed to offer more than their
­competitors.
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­provides flexibility now and in the future.
A plus in availability:
The F series was specifically designed for robust processes. This
A plus in sturdy engineering:
means: not chasing after peak values but providing adequate
HELLER has been synonymous with milling and high-quality
speeds, proven components, truthful characteristics. What are the
­machining since 1894. The F series embodies our complete
benefits to you? A machining centre with staying power offering
­know-how gained from the development of the 5-axis MCH-C
unparalleled opportunities.
­series and its predecessors. The F series is a safe investment:
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it offers productivity and precision from the very first minute.
A plus in service:
The HELLER service concept is designed to accompany you from
A plus in process experience:
process design, machine installation through to the purchase of
Our extensive process experience forms the basis for this 5-axis
new equipment and to ensure constant productivity. What is so
machine series allowing you to respond swiftly and flexibly to
special about it? We are wherever you are. All it takes is a phone
changing machining tasks, whilst ensuring maximum output and
call.
optimum quality.
Optimised life cycle costs:
HELLER services:
Availability and maximum
performance20
At a glance:
HELLER Machining Centres
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A plus in productivity:
The running costs of a machine over its complete lifecycle are
Highest productivity in continuous operation – that is what the
easy to calculate from the cost of investment and the cost of
F series has been designed for: the FT type for ergonomic table
­operation. Keeping these costs at a minimum, without compro-
loading, the FP type with pallet changer for compatibility with
mising on the quality and reliability of the machine, is the quint­
all HELLER automation systems, 5-sided and simultaneous 5-axis
essence of what we do. This is exactly what we have achieved
machining, robust machine design, powerful spindles.
with the innovative manufacturing concept offered by the F series.
The savings are directly passed on to you.
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The F series sets the standards in 5-axis machining providing productivity
and precision from the very first minute.
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F Series
The machining concept
The F Series: machine concept
Strong basis for high cutting capacity
Customised coolant treatment
ƒƒ Bed manufactured from epoxy resin concrete:
ƒƒ Paperband filter system
ƒƒ Proven axis kinematics of the tool: X, Y, C and A
ƒƒ Programming in the familiar system environment
ƒƒ Vacuum rotation filter system
ƒƒ Workpiece provides 2 axes: Z, B
ƒƒ Siemens SINUMERIK 840D sl or Heidenhain iTNC 530
ƒƒ Linear axes covered with tried and tested concertina covers
ƒƒ Flexibility of choice according to individual requirements:
efficient damping of machine movements, reduced
emissions, optimised overall weight
ƒƒ Steel column with optimised topology in Y axis with
minimal deflection
ƒƒ Statically and dynamically optimised by means of
structural mechanics simulation
ƒƒ Optimised feedback control
Precise dynamics
Flexible installation
with automation for high-volume output or for manual loading
ƒƒ Installation without anchoring
Ease of operation you can feel
ƒƒ Quick installation, easy relocation
ƒƒ Effective safety guarding
ƒƒ High processing power and easy operation
ƒƒ No separate foundation required
ƒƒ Optimum access to the work area for workpiece loading
ƒƒ Complete integration into the CAD/CAM process chain
ƒƒ Low operating costs
ƒƒ Linear guided, smooth opening doors provide optimum
ƒƒ Optimised resilience and thermo-symmetry
Production precision down to the micron
ƒƒ Single-handed philosophy: short-stroke doors can be opened
ƒƒ Absolute encoded, direct measuring systems
ƒƒ Z axis with concertina cover below the spindle prevents
ƒƒ High-resolution rotary encoder
ƒƒ Lowered loading sill at knee height
ƒƒ YRT bearing with integrated measuring system
ƒƒ Operating panel at the setting station with integrated
ƒƒ Steep and extremely smooth chip chutes
ƒƒ Free chip fall from rotary table
in the workshop
access for loading operations
Quick chip evacuation for higher precision
contaminants from leaving the work area
Control
with one hand
flush/air guns
ƒƒ Easy to connect to all common HELLER automation systems (FP)
ƒƒ Clean work area due to integrated flushing nozzles
ƒƒ Easy to clean due to good accessibility to work area
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F Series
Spindle technology
Innovative spindle technology:
process stability times three
The F series with swivel head
The F series with fork head
ƒƒ Swivel range from +15° to –195°
ƒƒ Axis swivel range +30°,
ƒƒ High torque due to powerful 1PH8 motor
up to –120° below centre axis
ƒƒ Robust housing in cast iron
ƒƒ Robust housing in cast iron
ƒƒ HELLER zero-spindle system
ƒƒ Motor spindle mounted in fork head
ƒƒ Media supply directly through the spindle
with bearings
ƒƒ Suitable for dry machining
ƒƒ Energy and media supplied through the
ƒƒ State-of-the-art RMP wireless measuring probe
outside of the fork head
ƒƒ New cooling system provides reduced
thermal growth in the machine and
highest workpiece precision
ƒƒ Media supply directly through the spindle
High performance cutting with Power
Speed cutting with Speed Cutting
Speed cutting with Speed Cutting
Cutting Universal PCU 63
Universal SCU 63
Tilt SCT 63
The benefits to you:
The benefits to you:
The benefits to you:
ƒƒ Transmission provides
ƒƒ Swivel motor spindle with
ƒƒ Suitable for dry machining
energy and media supply
ƒƒ For machining up to a +30°
through the centre of the
angle below centre axis
extreme rigidity and damping
ƒƒ 1 : 1 gear train
ƒƒ HSK, SK and BT spindle taper
swivel head
ƒƒ HSK, SK and BT spindle taper
ƒƒ Perfectly suited for cast iron,
ƒƒ High speed: 16,000 rpm
ƒƒ High speed: 16,000 rpm
ƒƒ High chip removal rate
ƒƒ High cutting capacity with
steel and titanium
ƒƒ Swivel head geometry de­
signed for optimum stability
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The F series provides four spindle variants offering flexibility for any
machining task whilst ensuring highest precision and performance.
ƒƒ Clearly arranged cutting
ƒƒ High cutting capacity
­geometry
PCT
ƒƒ High chip removal rate
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FT 4000
The workshop machine
The workshop machine:
FT 4000 for table loading
Outstanding accessibility: F series for table loading (FT)
Profile:
Application:
Facts:
ƒƒ Entry into HELLER 5-axis
ƒƒ For frequently changing tasks
ƒƒ Tool provides 5th axis via
Technical data
machining
ƒƒ Classic workshop machine
for manual loading
ƒƒ Flexible, powerful, highly
and prototype construction
HELLER swivel or fork head
ƒƒ Combination of highest
ƒƒ Storage capacity for up to
­cutting capacity and class-­
240 tools in chain-type
leading surface finish
­magazine or 409 tools in
precise
­rack-type magazine
ƒƒ For a wide range of parts and
ƒƒ Unparalleled ease of access to
materials produced in low
work area through three-part
­volumes
work area door
ƒƒ Table with large clamping
­surface, optionally with
­hardened surface
Model
FT 4000
Working range
X = 800 mm
Y = 800 mm (SCT 900)
Z = 1,000 mm
Table size
Ø 720
Workpiece Ø x height max.
Max. workpiece weight
Chip-to-chip time
Rapid traverse
1,020 mm x 1,500 mm
1,400 kg
3.7 s
60 m/min
Acceleration
6 m/s²
Tool Ø x length (chain)
Tool Ø x length (rack)
Spindle tapers
Spindles*
160 mm x 450 mm
188 mm x 450 mm
SK 40 / HSK-A 63 / BT 40
PCU/PCT 63:
10,000 rpm, 44/46 kW, 242/116 Nm
SCU/SCT 63:
16,000 rpm, 40 kW, 80 Nm
* S6 – 40% duty cycle
Sample workpiece Formula 1 racing car
(aluminium)
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Integral component
(aluminium)
Glass mould with cooling bores
(cast iron)
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FT 4000
The workshop machine
FT: enhanced space, user-friendly
ergonomics and precision
Safety and ease of operation have a crucial impact on
FT for manual table loading
the availability of a machine. Faster and more efficient
ƒƒ Optimum access to the work area
­operation minimises operating errors and risk of failure.
ƒƒ Quick and easy handling of workpieces
With the F series you can profit from our application
ƒƒ Exceptionally well suited for workshop operation
experience day in and day out.
ƒƒ Ideally suited, e.g. for tool and die manufacturers with
frequently changing tasks and small batch sizes
Well-designed workpiece management allows you to machine
workpieces with a wide range of geometries and weights whilst
Robust rotary table for high workpiece weights
ensuring high process stability and perfect machining precision.
ƒƒ Maximum speed: 30 rpm (F 2000/4000)
The loading concept of the F series is based on the experience
ƒƒ Workpiece support plate in optional design (slots, threads)
gained from the H series. The result is impressive: more space,
ƒƒ Hydraulic workpiece clamping (optional: 5-point services
less chip accumulating surfaces, higher precision able to take
workpiece weights up to 1,400 kg.
interface with 60 or 200 bars oil pressure or 200 bars with
proportional technology)
ƒƒ Ball screw drive arranged in the centre
ƒƒ Hydraulic supply via bored holes in support plates
ƒƒ Component maintenance can be performed from outside
the work area
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Convenient manual loading of the FT is guaranteed enabling you to benefit
from our application experience every day.
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FP 2000/4000
The production machine
The production machine:
FP 2000/4000 with pallet changer
Highest productivity: F series with pallet changer (FP)
Profile:
Application:
Facts:
ƒƒ State-of-the-art 5-axis
ƒƒ Prepared for unmanned
ƒƒ Cutting capacity for a wide
Technical data
production machine with
­pallet changer
ƒƒ Designed for highest
availability and productivity
for machining of large
workloads
operation using pallet and
range of tasks from 5-sided
workpiece automation
machining through to
ƒƒ Flexible for short-term job
Model
Working range
­machining of complex free-
changes
form geometries
ƒƒ Perfect for production-oriented
ƒƒ Simple and cost-effective
users with high output
pallet automation solutions
ƒƒ Fully compatible with HELLER
H series
FP 2000
FP 4000
X = 630 mm
X = 800 mm
Y = 630 mm (SCT 730)
Y = 800 mm (SCT 900)
Z = 830 mm
Z = 1,000 mm
Pallet size
400 mm x 500 mm
500 mm x 630 mm
Workpiece Ø x height max.
720 mm x 850 mm
900 mm x 1,000 mm
800 (600)* kg
1,400 (1,000)* kg
Max. workpiece weight
Chip-to-chip time*
3.5 s
3.7 s
Rapid traverse
60 m/min
Acceleration
6 m/s2
Tool Ø x length (chain)
160 mm x 410* mm
160 mm x 450 mm
Tool Ø x length (rack)
188 mm x 410 mm
188 mm x 450 mm
Spindle tapers
Spindles**
SK 40 / HSK-A 63 / BT 40
PCU/PCT 63: 10,000 rpm, 44/46 kW, 242/116 Nm
SCU/SCT 63: 16,000 rpm, 40 kW, 80 Nm
* Limitations see technical data
**S6 – 40% duty cycle
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Hydraulic housing
(cast iron, plastic)
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Aerospace valve housing
(titanium)
Housing component from mould
and die making (aluminium)
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FP 2000/4000
Automation
FP: efficient, universal, highly-productive
HELLER machining centres are synonymous with productivity.
FP with pallet changer
They provide precise and reliable operation over many
ƒƒ Compatible with horizontal machining centres from
years even under constant load. We expect the same from
HELLER H series and combines with pallet pools with
our automation solutions: maximisation of productive time
6 pallets per machine, pallet handling via turntable
and throughput, increase of production and flexibility in
ƒƒ Integration into various pallet magazine systems:
terms of modifications. From swift and easy manual loading
PMB: basic design with 10 to 24 pallets per machine,
to the setting station through to a fully integrated flexible
handling via stacker crane
manufacturing system – the F series is ready for any solution.
PME: extended version with 8 to 42 pallets per machine,
handling via rotary fork
PMF: flexible design from 16 pallets per machine,
handling via telescopic fork
ƒƒ Robot automation with standard robot cell or individual
solutions
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Fully automatic: the FP provides high productivity even
under constant load.
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F Series
Control
Control: the choice is yours
The new F series is equally suited for machining of individual
Simply choose the type of control that suits your require-
parts in tool and die manufacturing and for the requirements
ments best: Siemens or Heidenhain.
of high-volume production using 5-axis machining.
Heidenhain iTNC 530
Siemens SINUMERIK 840D sl
CAD/CAM integration
From idea to finished product
For manual operation in the workshop
For high output with automation
ƒƒ Highly precise control of speed and acceleration
ƒƒ Precise control of speed and acceleration
ƒƒ Highly adaptable for precision and surface finishes
ƒƒ Highly adaptable for precision and surface finishes
ƒƒ Short block processing time of 0.5 ms
ƒƒ Exceptionally well suited for machining of sculptured
ƒƒ Free contour programming
surfaces
ƒƒ DCM – dynamic collision monitoring
ƒƒ Graphical cycle support
ƒƒ User-friendly setup functions
ƒƒ Remote diagnostics via ePS
Workpiece and pallet management
Tool management
ƒƒ Clearly arranged graphical and tabular visualisation
ƒƒ Extensive tool tables
of pallets and programs
ƒƒ Easy allocation of NC programs
Fast, highly precise machining without unnecessary correction loops – that is what is required of a 5-axis machining
centre. Benefit from maximum flexibility by programming at the machine combined with innovative technology and
machining cycles or use the existing CAD/CAM chain at your facilities. Be a master of your processes at any time with
the F series. If you are dealing with frequently changing tasks or complex shapes, the machines provide the precision
and efficiency you need.
ƒƒ Cutting data tables for automatic calculation of spindle speed
and feed from workpiece-specific data
ƒƒ Preparation of pallet data for pending jobs
ƒƒ Replacement tool strategy
ƒƒ Clearly arranged display of machining status
ƒƒ Monitoring of tool life and usage
ƒƒ Tool loading during spindle operation and in automatic mode
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F Series
Control
Tool management:
fast, precise, flexible
What do you require in terms of tool management from a
ƒƒ Tool axis moves along the chain path
5-axis machining centre made by HELLER? You might wish
ƒƒ Optimised tool provisioning time
to utilise your existing stock of tools, use a wide range of
ƒƒ Magazine only fixed to console
tools and large tool geometries; you require a flexible solu-
ƒƒ Tool loading parallel to machining
tion that will meet your production requirements in the
most efficient way. At the same time, tool loading times
Rack-type tool magazine
and downtimes as well as idle times should be minimised.
ƒƒ 409 magazine places
No problem: the new F series can provide all of this!
ƒƒ Max. tool diameter: 188 mm
ƒƒ Max. tool lengths: 410 mm on F 2000, 450 mm on F 4000
Tool changer
ƒƒ Reduced space requirements due to double-sided arrangement
ƒƒ Motor arranged outside of coolant and chip area
ƒƒ Magazine access
ƒƒ Optimised accessibility for belt tensioning
ƒƒ Loader axes with NC technology
ƒƒ Torsionally stiff housing due to enclosed design
ƒƒ Leakproof floor pan, no leakage of coolant or lubricant
(only assembly openings)
ƒƒ Easy exchange of motors on the ZT1 axis due to use
of elastomer coupling
ƒƒ Manually operated rotary station, optional: automatic rotary
station
ƒƒ HSK, SK and BT spindle tapers
ƒƒ Proven basic structure: tools aligned in Z direction,
Chain-type tool magazine
storage and retrieval unit moves in X, Y and Z direction
ƒƒ Max. tool diameter: 160 mm
ƒƒ Short tool selection path
ƒƒ Max. tool lengths: 350 mm on F 2000, 450 mm on F 4000
ƒƒ Compact, space-saving layout
ƒƒ Chain-type tool magazine with 54, 80, 160 or 240 storage
­places
ƒƒ Max. chain speed: 32 m/min
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F series ensures short loading times, short downtimes
and short idle times.
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Services
Services
HELLER services: availability and maximum
performance
When you invest in a machining centre today, you expect to
Relocation Service
get a solution that delivers highest availability and maximum
ƒƒ Complete relocation of your machining centres from one source
performance. That is why HELLER services are practically
ƒƒ Upgradable with production support on site
inextricably linked to the machine. From remote service
ƒƒ Planning, professional preparation for transport,
equipment, commissioning and training through to predictive
­implementation and re-commissioning from one source
maintenance and spare parts supply. HELLER ­provides a
(HELLER and other brands)
complete range of services to ensure long-term cost-­
effective operation of advanced high-tech machining
ƒƒ Additional options: inspection by manufacturer, overhaul of
main assemblies, training, acceptance
­centres incorporated in efficient manu­facturing solutions.
HELLER services are available around the globe offering
Fast-response spare parts concept
­unrivalled performance.
ƒƒ High availability of spare parts, flexible, global supply
ƒƒ Supply of exchange parts (reconditioned spare parts with
Global presence to serve our customers worldwide
­special savings)
ƒƒ Transnational services
ƒƒ Service kits (ready-made spare part packages)
ƒƒ Global service standards in HELLER quality
ƒƒ Fast response thanks to our own repair shop
ƒƒ Customised service concepts for global players
ƒƒ Standardised spindle repair
ƒƒ Group-wide service agreements
ƒƒ Designated contact person (responsible for communication,
technical support and implementation of ­standards at
­subsidiaries)
HELLER Academy for technical staff development
ƒƒ Customer-specific or standardised training of your staff
(at HELLER or at your premises)
ƒƒ Training for operators, programmers and maintenance staff
Service solutions and service standards
(hands-on instruction on main assemblies)
ƒƒ Industry-specific and customer-specific solutions
ƒƒ Practice-oriented, modular training materials
ƒƒ Upgrades to expand your machining centre’s task profile
ƒƒ NC simulation tools for programming courses
ƒƒ Efficient solutions providing higher availability and precision
ƒƒ Cost reduction through standardised services (rebuilds, repairs,
training, upgrades)
Direct support via teleservice and service hotline
ƒƒ Rapid troubleshooting via teleservice (RDS)
ƒƒ Dedicated contact person on site
ƒƒ Short response times and 24/7 standby service
ƒƒ Predictive planning of maintenance measures (CDS)
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HELLER services provide optimum availability of your machining centre
ensuring maximum productivity.
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Machining Centres
At a glance:
HELLER Machining
Centres
H series –
4-axis horizontal machining
F series – setting standards in 5 axis
High performance and precision from light-metal machining
­volumes, frequently changing tasks. Production centre FP:
through to heavy-duty cutting. For varying batch sizes and a
­high-­production capacity with 5-axis / 5-sided machining, flexible
variable range of parts and materials.
response to job changes.
ƒƒ Work area: 630x630x630 mm3 – 1,000x1,000x1,000 mm3
ƒƒ Working area: 630x630x830 mm3 – 800x800x1,000 mm3
ƒƒ Spindle taper: SK 40 / HSK-A 63 / BT 40 · SK 50 / HSK-A 100 / BT 50
ƒƒ Spindle taper: SK40 / HSK-A 63 / BT 40
ƒƒ Spindles: 6,000 – 24,000 rpm / 25 – 60 kW / 40 – 2,292 Nm
ƒƒ Spindles: 10,000 – 16,000 rpm / 40 – 46 kW / 80 – 242 Nm
Workshop machine FT: wide range of parts and materials, low
MCH series –
universal high-performance machining
C series – Combined Processing
Superior machine dynamics, optimum positioning and circular
with A and B axis and powerful 5-axis machining, future-proof
High-torque flexible machining from heavy-duty cutting at
­accuracy, reduced idle times. Suitable for high chip removal rates
­productivity.
822 Nm through to finish machining at max. 8,000 rpm.
as well as flexible production.
Milling/turning centre for horizontal, vertical or tilted turning
ƒƒ Work area: 630x630x830 mm3 – 800x800x1,000 mm3
MCH-C series –
flexible 5-axis heavy-duty cutting
High precision and outstanding machining quality.
ƒƒ Work area: 1,250x1,000x1,000 mm³ – 2,000x1,400x1,250 mm³
ƒƒ Spindle taper: HSK-T 63
ƒƒ Work area: 1,000x1,000x1,100 mm3 – 1,600x1,200x1,700 mm3
ƒƒ Spindle taper: SK 50 / HSK-A 100
ƒƒ Spindles: 10,000 rpm / 44 kW / 242 Nm · 16,000 rpm / ƒƒ Spindle taper: SK 50 / HSK-A 100
ƒƒ Spindles: 6,000 – 12,500 rpm / 43 – 72 kW / 460 – 1,145 Nm
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Made to work
34 kW / 68 Nm
ƒƒ Spindles: 6,000 (8,000) rpm / 43 kW / 822 Nm
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