Starrag, which unveiled its new large-machine series in November 2024, says the four planned Heckert models will be launched and presented to the market in stages throughout 2025.

The company’s HPMS (High Performance Machining Systems) business unit, which includes the Chemnitz and Rorschacherberg sites, has developed a new large-machine construction kit from which new machining centres can be derived.

Development engineers considered the latest technical aspects when redesigning the large Heckert machines. For example, the frame components, such as the beds and columns, were optimised for thermal symmetry. If the ambient temperature changes, the core components expand or contract evenly in all directions. This behaviour is predictable and correctable. The chip fall in the area between the work spindle and the workpiece has also been improved so that hot chips have minimal opportunity to transfer heat to the workpiece or the machine.

An important advantage of the new machines is the improved productivity. The decisive factor here is an increase in the diameter of the ball screws from 63 to 80 mm. A further stiffening of the structural components complements this improvement. As a result, users can achieve even higher cutting values, increase chip volumes and ultimately reduce machining times. The machine has also become faster. Instead of a 40 m/min rapid traverse rate, it now enables 50 m/min, reducing non-productive times.

The approximately 20% smaller footprint is another benefit in light of high floor space costs. This reduction is primarily due to the repositioning of an energy chain, which enables further integration of the chip conveyor into the machine.

More information www.starrag.com

Based on the robust design of DMG Mori’s DMV series vertical machining centres, the company has developed its new DMX 60 U and DMX 80 U for workpieces weighing up to 300 and 350 kg respectively. With travels of 600 x 600 x 510 mm for the DMX 60 U and 800 x 600 x 510 mm for the larger model, the competitively-priced, 3+2 axis machining centres with their swivelling rotary table are suitable for producing complex components.

The machines feature a design based on a monolithic machine bed and massive castings, providing up to 50% higher static rigidity compared with their predecessors. Combined with wide roller guideways in all axes, DMG Mori says it ensures excellent stability during operation. The design also enables dynamic machining and rapid traverse rates of up to 42 m/min, some 40% faster than predecessor machines. Moreover, the speed of the rotary B axis and C axis for positioning parts has been raised by an even higher percentage, from 6 to 10 rpm.

Comprehensive, multi-sensor temperature compensation ensures thermal stability and consistently precise production, while direct drives and linear scales in the X and Y axes guarantee high positioning accuracy.

The energy-efficient production centres are suitable for a variety of applications thanks to a choice of spindles, starting with the 12,000 rpm inlineMASTER spindle as standard. SpeedMASTER spindles with a high torque of up to 200 Nm or a speed of 20,000 rpm are optionally available.

The standard BIG PLUS face-and-taper tool-holding interface provides additional stability and accuracy during machining. Customers can choose from different tool magazine options with 30 to 120 pockets.

More information www.dmgmori.com

At the Paris Air Show earlier this month, machine tool manufacturer Schwäbische Werkzeugmaschinen (SW) presented its technology portfolio for the high-precision machining of aerospace components. Using aluminium and titanium wing ribs and blisk parts as examples, SW experts demonstrated how the combination of multi-spindle machining centres and integrated automation solutions can enable fully integrated and efficient production.

“Our customers are under pressure to maintain or even increase productivity in the face of skills shortages and tight delivery schedules,” said Markus Löhe, key account aerospace at SW. “At the Paris Air Show, we showed how our integrated machining and automation solutions help achieve exactly that.”

The exhibits were produced on the BA space 3, currently the largest machine in the SW portfolio. It was developed to meet the demands of modern aircraft manufacturing. The machine’s dual-spindle configuration allows either parallel machining of two workpieces or simultaneous operation of both spindles on a single component – suitable for high production volumes or large workpiece dimensions. Thanks to its two-axis swivel head, it is possible to machine complex components in five axes in a single set-up.

“In the aerospace industry, where structural components such as wing ribs are milled from up to 95% solid material, this machine really stands out for its high dynamics, precision machining and stable processes,” said Löhe. “This also applies to challenging parts such as blisks.”

As complexity increases – especially in large-scale aerospace projects – suppliers are seeking fully integrated solutions that cover every step from machining to process control. SW says its technology offers not only increased output through dual-spindle machining, but also seamless automation throughout the process chain.

More information https://sw-machines.com/

Heller presented its expertise in the productive and flexible manufacture of complex components at the Paris Air Show earlier this month. The accent was on the company’s F and HF series of five-axis horizontal machining centres (HMCs), which see regular use in the aerospace industry for producing various sizes of engine component, doors, landing gear and structural parts.

Especially with regard to the machining of difficult-to-machine materials, Heller says its robust yet compact machining centre solutions are configurable with a choice of automation options, all models being equally suitable for single-part manufacturing or high-volume production, 24/7.

Since the end of 2023, Heller has rolled out five-axis production centres of various sizes in the new F series. In addition to a small footprint, the machines offer acceleration up to 7 m/s² in the linear axes and positional tolerances in X/Y/Z up to 6 µm. A further advantage is the large working volume relative to the external dimensions.

With one-hit machining playing an increasingly important role in many aerospace manufacturing applications, Heller has embraced this all-in-one concept and offers an optional turning function for combined turn-milling on the F series for machines up to 1.6 m in the X axis. The facilitating high-torque rotary table delivers speeds up to 700 rpm, allowing external or internal contouring in the longitudinal or transverse direction in a single set-up, as well as the production of undercuts and recesses. Even the cutting of external and internal threads is possible.

Error prevention features include a digital twin integrated into the Siemens Sinumerik One control system, which supports virtual mapping of a production process before removal of the first chips.

More information www.heller.biz

Mills CNC has introduced a range of simultaneous five-axis machining centres into the UK market. The second-generation DVF 5000 series, successor to the original series introduced in 2018, builds on the success of its predecessor through improved accuracy, faster processing speed and greater machining flexibility.

Faster X-, Y-and X-axis rapids (42 m/min) and 0.4 g acceleration/deceleration rates combine with increased B- and C-axis rotation speeds (25 rpm) and impressive tool-to-tool changeover times of 1.3 seconds to reduce part cycle times and increase throughput.

Standard second-generation machines are equipped with a directly-coupled 18.5 kW/15,000 rpm spindle capable of processing a diverse range of materials in double-quick time. To increase machining capabilities, built-in high-torque 30 kW/15,000 rpm/230 Nm or high-speed 37 kW/20,000 rpm options are available.

Irrespective of the spindle type selected, all options feature advanced oil-cooling which, working in conjunction with strategically located sensors on/in the spindle head, column and bed, monitor thermal displacement throughout the machining process. Automatic parameter adjustment minimises the effects of thermal expansion and drift.

The incorporation of precision roller-type LM guideways and high-accuracy 0.0001° B- and C-axis rotational mechanisms, with the optional IKC (Intelligent Kinematic Compensation) system to monitor and adjust rotary axis errors, guarantees precision even over extended use and lengthy machining runs.

DVF 5000 second-generation machines can handle larger workpieces than their predecessors and feature 630 mm diameter rotary-tilting tables that accommodate workpieces up to 600 mm in diameter and 500 mm in height. There is also a 26% increase in table size, a 32% increase in the machining envelope available, and a 20% increase in X-, Y- and Z-axis travels.

More information www.millscnc.co.uk