TK 442/3

Technical SpecificationTK 442/35 Axis machining centresEnglish | 10 / 2008

5 Axis machining centresTK 442/3

5 Axis machining centresTK 442/3TEKNA was established in 1964 to produce efficient aluminum machining systems.The major role played by this material in the building industry has led TEKNA to develop, over the years, a vast range ofproducts for manufacturers of window/door frames, curtain walls and coatings.The increasing use of aluminum components in the automotive and transport industries as well as in the consumer industriesand in other industrial branches has encouraged the search for new solutions: TEKNA has seized this opportunity andinvested into it in order to meet the new demands of the market.The experience gained in the window/door frames industry and the know-how accumulated in the field of machinery have allowedTEKNA to expand its product range, including 3-,4- and 5-axis machining centers for the machining of panels and profiles.Over the past 15 years we have designed several models that have been customized according to the machining needs ofour customers. TEKNA has developed different profile clamping systems for the machining processes, the movement controlsand the suction systems of chips and dust.Nowadays our company receives and answers to feasibility study requests every week, for this reason we can state thatTEKNA is extremely qualified to provide effective responses to the most diverse problems.Thanks to its vast experience, TEKNA can offer effective systems to be used in the manufacturing of window/door frames,curtain walls, industrial doors, garage door and panels, accessories for commercial vehicles, components for trains andunderground trains, parts for the automotive industry, for telecommunication booths and many other applications.

5 Axis machining centresTK 442/35-axis CNC vertical machining center equipped with an electric spindle that can rotate around the B and C axis, this allowsfor machining on five sides of the profiles with just one clamping operation and with no aggregate heads.The rotation is powered by a brushless engine. The precision reducer that is provided allows both for a rotation from 0° to360° along the vertical axis, with increments of 0.01°, and for angle adjustments between +90° and -90° along an axis on thehorizontal plane.This machining center is designed for drilling and conventional milling processes and also for copy-milling operations onaluminum extruded profiles and other materials, including steel profiles up to 5 mm thick, steel reinforced PVC, compositematerials and various other plastics or wood. When the machine is provided with a special circular blade it is also possible toperform butting, trimming and composite cutting operation.The TK 442/3 model can be implemented in every industry and its flexibility and robustness allow to efficiently machine componentsthat require high performances, such as aluminum profiles produced by the largest extrusion press all over the world.Standard versions are available in 3 machining lengths: 3500, 6600 and 8200 mm. Upon request the machining center can bemanufactured in different lengths in order to meet the special needs of each customer.

5 Axis machining centresTK 442/3

5 Axis machining centresTK 442/3Machinability316.0184.5168298.5125.514612630030090.0640.0700.0725.0339184.52993554354040160220734346

5 Axis machining centresTK 442/33500 - 6600 - 8200 mm2900 mm (L = 6600 mm)3700 mm (L = 8200 mm)2900 mm (L = 6600 mm)3700 mm (L = 8200 mm)3500 - 6300 - 7900 mm2900 mm (L = 6600 mm)3700 mm (L = 8200 mm)2400 mm (L = 6600 mm)3200 mm (L = 8200 mm)

5 Axis machining centresTK 442/3Technical featuresMachinabilityAxis XAxis YAxis ZMax displacement speedAxis XAxis YAxis ZAxis BAxis CMovements of the electric spindle axesAsse BAxis CControl of axesAxis XAxes Y - ZAxes B - CElectric-spindleCone attachmentMax power (S1 service)Max torque (S1 service)Max rotation speedCooling systemMotor-driven tool magazine (L=6600 - L=8200)3500 mm6600 mm8200 mm725 mm300 mm80 m/1’55 m/1’30 m/1’5000 deg/1’5000 deg/1’360 deg in 0,01 deg+90 deg to -90 deg in 0,01 deg incrementsBrushless motor, truck on ball linear slideways, double precision rackBrushless motors, ball linear slideways, precision rack and pinionBrushless motors with reduction gear driveHSK F6310 kW12,7 Nm22.000 rpmLiquidN° tools 14 toolsTool change time 5’’ - 10’’Fix tool store (L=3500 - L=6600 - L=8200)N° tools1 or 2 x 14 tools (L=3500)2 x 14 tools (L=6600 - L=8200)Tool change time 5’’ - 10’’AccuracyRepetition on linear positioning+/- 0,1 mm

5 Axis machining centresTK 442/3Machining limits with electric-spindle on 0°Drilling from solidAluminuim AL99 Ø 20Steel FE370 D FF Ø 14Rectilinear milling (maximum thickness)Aluminuim AL99 15Steel FE370 D FF 5Tapping from solidAluminuim AL99 M 12Steel FE370 D FF M 12Flowdrill: max screw threadsCutting tap M 10Rolling tap M 8Notes: The drilling and milling tools are the hard metal ones. Wider diameters can be obtained with the axes interpolation. Larger tappings can be obtained with the helical interpolation. The reported maximum screw thread sizes obtained with flow drill are valid for both aluminium and steel.

105 Axis machining centresTK 442/3Basic machine dimensionsAEFG1BG2CDBasic machine (mm)L=3600L=6600L=8200Conveyor beltA B C D E F G1 G257709070105702640 2190 2830 2750 max 2950 max 300 200IHLExternal protection net (mm)L=3500L=6600L=8200H I L58409230108801000 max 3400

5 Axis machining centres11TK 442/3Machine dimensions with full protectionABB1G1G2CFMachine with full protection (mm)Conveyor beltA B B1 C F G1 G2L=3500L=6600577090703540 max 3000 2490 3200 max 290 200Weight (Kg)L=3500 L=6600 L=8200Basic machine 4000 5500 6400Full protection 820 1300 -Conveyor belt 190 215 235

12 5 Axis machining centresTK 442/3Construction FeaturesThe structure of the machining center features an electrically welded steel bed frame where linear slideways with recirculatingballs are mounted as well as precision racks that allow the movement of the milling head along the X axis. Thanks to the bedframe design it is possible to load bars longer than the machine working length.The milling head is designed to provide a high Y and Z axis stiffness in order to minimize the vibrations that would compromisethe machine precision and would negatively affect the quality of the machining process.It is made up by a portal structure in aluminum casting that is composed of two lateral supporting elements and a top crosspiece.On this crosspiece linear slideways with recirculating balls are mounted as well as precision racks for Y and Z axis.The back side of the machine is equipped with a chute made up of metal panels mounted along the whole length of this side,whose aim is to push the chips produced during the machining towards the conveyor belt.The back and front sides of the machine are equipped with panels that can be removed to easily perform maintenanceoperations.

5 Axis machining centres13TK 442/3Linear slideways with recirculating ballsLinear slideways with recirculating balls facilitate the movement along the machining axis of the milling head and of othercomponents of the machining centre. The system comprises driving ground bars and carriages equipped with scrapers andweather strips that protects from chips and dust the two internal groups of recirculating balls.These guides can stand similar traction and compression loads while keeping a low friction coefficient, a high resistance tovibrations and an optimal smoothness.These characteristics improve the high-quality performance of machining centers: an efficient movement of the machinecomponents that enables a high-precision positioning.

145 Axis machining centresTK 442/3Electric-spindleThe machining center is supplied with electric-spindle with automatic tool change and liquid cooling system that allows tokeep a constant temperature and to avoid overheatingThis system comprises a cooling unit that dissipates the heat of the circulating liquid thus optimizing the operation of theelectric-spindle.The max power is 10 KW in operation mode S1 and with a max rotation speed of 22.000 rpm.1211.4109.597.65.54.6kWrpm x 10007.511121822S 6 60%S 1 continuous

5 Axis machining centres15TK 442/3Minimal LubricationMinimal lubrication system with micro-drop technology that optimizes the cooling liquid consumption during the machining.In order to guarantee a suitable cooling of the tool, this system allows also to distinctly reduce the quantity of the used product.The airflow passes through the nozzles installed at the end of the electric spindle and reaches the contact area between thetool and the piece to be machined; the provided air is under pressure and mixed with a small quantity of cooling oil.Thanks to this system it is possible to limit the volume of liquid remaining on the machined piece, thus obtaining a cleanermachining area.

16 5 Axis machining centresTK 442/3Pneumatic one/two-way clampsThe pneumatic clamps are mounted on linear slideways with recirculating balls that are fixed on the bed frame, therefore theycan be smoothly positioned along the X axis of the machine.The automatic movement is managed by a CNC-controlled system that positions each clamp according to the profile lengthand the machining process to be performed.The movement along the X axis is achieved through pistons mounted on the milling head and fixing points located on bothends of the clamps; the movement can also be achieved using a translator carriage (see Optional).It is possible to use both one- and two-way clamps: Using a two-way clamp you can simultaneously machine 2 profiles withdifferent dimensions and machining processes.

5 Axis machining centres17TK 442/3Fixed tool magazineIt is mounted on machine with machinable length of 3500, 6600, 8200 mm and it is installed on the end of the machiningcenter. It holds up to 14 tools. A removable enclosure protects tools from chips and dusts produced during the machiningprocess.

18 5 Axis machining centresTK 442/3Motor-driven tool magazineThis magazine is mounted on machine with machinable lengths of 6600 and 8200 mm.It is installed in the central area of the machine and it electrically moves on both sides of the TWIN area, reducing the toolchange interval.The magazine is provided with an enclosure that protects tools from chips and it can be installed together with up to 2 fixedtool magazines that can be mounted on both ends of the work table of the machine.It holds up to 14 tools.

5 Axis machining centres19TK 442/3TwinThe TK 442/3 model features the TWIN operation mode that enables the operator to divide the machine into two welldistinctmachining areas: the operator can access one of the two areas for changing the workpiece, while in the second areathe machine keeps working; in this way it is possible to perform different machining processes in the two distinct areas.An intermediate area is delimited by two safety light barriers in order to assure the safety of the operator when the machineis used in this mode.This system increases and optimizes the productivity because it eliminates the idle times caused by the machine downtimeand it gives the possibility to perform different machining processes in the two separated areas.The TWIN system can be mounted on machines with machinable lengths of 6600 and 8200 mm.Safety protectionThe TK 442/3 model is equipped with a safety light barrier system that prevents the operator from accessing dangerous zoneswhen the machine is working: the operator is allowed to access the machine only when safety conditions are met.It is provided with a perimeter protection, made up of special modular nets for robotics centers installed on three sides of themachine (back side and two lateral sides).

20 5 Axis machining centres OptionalTK 442/3Full automatic protectionThe scope of the full enclosure is to protect the operator against accidental contacts with moving components of the machineand the produced chips and to reduce the noise level.The enclosure is installed on three perimeter sides and on top of the machine, it is made up of insulating and sound-absorbingpanels that can be removed for maintenance operations. It is provided with front shields made up of two frames of extrudedaluminum with transparent shields. In the TWIN mode, it is possible to independently open and close each half of the frontenclosure, by controlling them from the CNC system.

Optional5 Axis machining centresTK 442/321Circular bladeCarbide tipped circular blade that can be used to precisely perform common cutting processes in the 5-axis machining center.It is supplied with different diameters of 250 or 350 mm.Translator carriage for the clamping systemIt can be used only in machines with machinable lengths of 6600 and 8200 mm, operating in TWIN mode. The translatorcarriage is CNC-controlled and enables the operator to rapidly reposition the clamps in the opposite TWIN area during themachine operation. This system allows to improve the productivity of the machining center by minimizing the idle time.

22 5 Axis machining centres OptionalTK 442/3Auxiliary container for cooling liquid (30 liter)It reduces the duration of the machine downtime necessary to feed the standard tank; it is the ideal solution for continuousworking cycles.Motor-driven conveyor beltIt collects chips and conveys them to the far right end of the table, unloading them in a container, if any.

Optional5 Axis machining centresTK 442/323Laser detection kitIf more profiles are located on the machine length without a precise position, this kit detects them and determines the zeropoint for the program.3D ProbeContact probe that is used to accurately inspect the workpieces with complex geometric forms. This device improves theproductivity thanks to the fast and accurate measurement of the components.

24 5 Axis machining centres OptionalTK 442/3Barcode readerThis device reads the labels applied on profiles and allows the system to automatically load the machining program and thetransfer of some parameters of use. The reader is also available in “wireless” release.Remote controlled electronic wheelIt moves the axis and performs milling operations activated by manual commands, allowing the operator to walk along themachine. Thanks to the electronic wheel it is also possible to start and run the machining program without going back to thecommand console.Voltage stabilizerIt stabilizes the machine voltage supply, even if some voltage losses occur.Uninterruptible power supply (UPS)The UPS is a device which maintains a continuous supply of electric power when utility power is not available.In case of a blackout, while the machine enters emergency mode, the CNC does not stop (because it is powered by the UPS)thus allowing the operator to save manually or with an automatic routine the already performed job.

Software5 Axis machining centresTK 442/325HardwareThe CN6 hardware is made up by two processors: A processor controls the CN6 and the other controls the functionsof a common PC; thanks to this system you can use the function of the common PC even while the machining center isworking.It includes:CPU PENTIUM cardKeyboard, mouse, LCD 17’’ color screenEthernet card for the network connectionUSB and parallel portsAxis and spindle speed control cardsHard Disk with minimum capacity of 40 GbModem for the direct connection via Internet

26 5 Axis machining centres SoftwareTK 442/3CN6 Numerical ControlThe Numerical Control basic software controls all functionalities of the machining center through an interface based onwindows that includes: User graphic interface (HMI, Human Machine Interface) that displays all variables of the center (for example spindleposition, tool rotation and feed, etc.) and from which it is possible to activate some auxiliary devices (such as lubricationsystem, chips belt, etc.) User table that combines each tool with one or more performance such as rotation speed, penetration speed or millingspeed A series of table with all configuring parameters of the center

Software5 Axis machining centresTK 442/327CN6The CN6 license includes:Numerical Control management softwareISO Language EditorSLW (Self-Learning software)Formulas SoftwareSoftware for remote connectionISO language editorFor numeric-control machines the international programming language ISO is used. With this language you can createprograms to perform every kind of machining, with linear or interpolated paths, variable speeds, tapping, parameter use etc.and for managing all functionalities of the machining center.

28 5 Axis machining centres SoftwareTK 442/3SLW Self-learningTekna owns the SLW (Self Learning for Windows): a language of superior level then the ISO language . Thanks to a defaultnumber of functions (macros) that can be selected from a graphic menu, it is possible to easily create machining programs.Coordinates (values in X, Y and Z) must be assigned to each selected macro and other machining programs; each macro canbe activated both as ISO and SLW program. During the selection and the setting of the chosen macros, these are translatedin ISO language, thus creating a file that can be saved as machining program.The macro library generated by Tekna includes a large number of machining; using this library an advanced user can createseveral machining programs very easily.It is also possible to create and add to the macro library other specific macros customized by the client.The Self-Learning SLW is very user-friendly: after a two-hour training even a beginner user can use the machine.

Software5 Axis machining centresTK 442/329FormulasThis is a software that can be used with Self-Learning SLW. You can use it to define formulas based on the default variables(i.e. the profile length) and then use them in the Self-Learning macros. This function is very useful when you have to performsame machining processes on profiles of various lengths. For example, the position in X of a hole can be set as L/2-50, whereL must be correctly assigned (by inserting it manually, via a bar code reader o with a kind of automatism).Remote connectionThis functionality allows to directly update the CN6, Maintenance and Technical Support on the machine, remotely via Internetusing a telephone line (modem) or via a LAN (Ethernet card).

30 5 Axis machining centres Optional softwareTK 442/3NC ToolNC Tool is a 2D CAD/CAM software based on AutoCAD software: With the appropriate setting of the parameters, thissoftware creates ISO programs that are CN6-compatible.The main functionalities of the NC Tool software are:Drawing file importEasy setting of the desired machiningAutomatic creation of ISO programs that are CN6-compatibleAny changes to geometrical scales and to the dimensions of an existing drawing are automatically converted in a new updatedISO program.NC Tool can import/export .dxf and .dwg files, moreover it allows text editing and the subsequent generation of ISO codes.

Optional software5 Axis machining centresTK 442/331TK camSoftware package that allows the creation of ISO programs using a 3D graphic programming.With TK CAM it is possible to assign machining operation regardless of machine models and tool series and view a simulationof the running program in a 3D representation. In TK CAM it is possible to optimize tools and clamps, it provides an anticollisionfunction and the automatic generation of ISO codes for the program. In the TK CAM it is possible to import specific.dxf/.dwg drawings and to assign the corresponding machining operations. In addition, details of the described machiningprocesses can be imported in TK CAM in a generic .xlm format: This functionality allows the interaction with the managementprograms commonly used in the window and door frame manufacturing industry.

Technical SpecificationDATA AND GRAPHICS ON THIS CATALOGUE ARE PROVIDED MERELY FOR INFORMATION PURPOSES. TEKNA RESERVES THE RIGHT TO CHANGE THE CATALOGUE WITHOUT PREVIOUS NOTICE, FOR TECHNICAL ORCOMMERCIAL PURPOSES.TK 442/35 Axis machining centresBranchesTeknacentroTekna NordestTK MaquinariaTK PortuguesaTK PortoTekna DeutschlandTekna UsaSouth AmericaChinaVia Monte Bisbino, 5620021 Baranzate (Milan) • ItalyTel. +39 02356961Fax +39 023562293tekna@tekna.itwww.tekna.itEnglish | 10 / 2008