hyperturn 95/110 hyperturn 95/110

[Workpieces][Upper tool turret]- Compact milling spindle- Speed range up to 7000 rpm- Latest spindle motor technology- High torque of up to 128 Nm- Internal coolant supply of up to 80 bar- Quick tool change- Large and easy to program travel range- 12-station tool turret available- Both spindles in use- Y axis stroke +/- 120 mmShaft(steel)[Counter spindlel]- A choice of 2 spindle solutions: A2-8, A2-11- Up to 42 kW power with high torque of up to1040 Nm (A2-11)- Large speed range of up to 3500 rpm andup to 30 KW power (A2-8)- Same connection for main and counterspindle- Partial hollow clamping- Liquid-cooled headstock- Stable and robust spindle bearings[Chip conveyor]- Slat-band conveyor belt- Integrated coolant tank 450/580 l- Turret pumps 2 x 14 bar- Flushing pumps 2 x 6 barConnection nozzle(stainless steel)Radial cam housing(tempered steel)

I.D. roller -burnishingUndercutForm E/FTappingO.D. roller -burnishingFace and O.D. turningI.D. deburringI.D. gear/slot shapingI.D. turningDrillingReamingMilling slant slotsTurn-milling of eccentricaldiameterKnurlingHyper-FlexibilityMachine flexibility is often sacrificed for the sake of productivity. Not with the HYPERTURN:with its high-performance and exceptionally mobile milling spindle and an almost inexhaustibletool magazine, the HYPERTURN can do nearly anything - and very quickly.

Thread millingGear machining(gear hobbing)Circular spitgot millingSlot millingDeep-hole drillingWobble broachingHEXAGONI.D. threadingI.D. boringI.D. undercuttingI.D. groovingEngravingContour milling (elliptical)Hole patterns centering,drilling, tappingMultifunctional workpiece

[Engineering] Highlights■ Main and counter spindle for complex complete machining■ Two tool turrets with VDI rapid change system, high pressure and/orhydraulic steady rest■ Large work area for optimal ergonomics and a wider range of parts■ Machine cover: New interior and exterior design■ State-of-the-art Siemens control unit Sinumerik 840D-sl■ Stable and precise C-axis for accurate contour milling andmilling-turning work■ Strong Y-axis with a large stroke■ Dynamic B-axis with “PowerMill” milling spindle for maximum flexibility■ Full NC tailstock with integrated quill for complete machining of shafts■ FEM-optimized machine construction for more precise results■ Made in the Heart of EuropeMain spindle view with clamping device Ø 315 mm and milling spindle. The lowertool turret is unrestricted when machining workpieces with large diameters.Counter spindle view with 6-position jaw chuck Ø 500 mm. The upper turret isreplaced by a 21 kW liquid-cooled milling spindle in the B axis version. The B axistravel range is 205°. This is infinitely variable with 0.001° resolution. In addition, theB axis can be clamped in any position with 5° indexing.The work area provides the highest level of ergonomics with excellent accessibilityto the individual components. Generous amounts of free space ensure optimalchip flow, even when machining complex materials. All guides are covered instainless steel sheets to prevent damage.The modular machine concept also enables the use of a tailstock in combinationwith an NC-controlled steady rest instead of the lower tool turret, depending onthe customer’s requirements. The steady rest can be hydraulically lowered 250mm if required.Tool turret: Fast indexing 12 station tool turret for standardized VDI40 or CDI80(CAPTO) tooling. All stations can be used with driven tools for drilling, millingand tapping operation. The turret indexing movement can be controlled by theoperator at any time. Max. turning diameter for lower turret is 650 mm.The lower tool turret can be fitted with a live center point and can act as a tailstockfor machining large workpieces.

For complex, complete machining, the system uses a modular, building block system with two base lengths (1700 or 2300mm),twospindle sizes,with a milling spindleand a B-axis or with two turrets.Tool magazine with 80 pockets integrated to machine layout.Turret steady rest: Hydraulically operated steady rest for diameter 8 – 125 mm toguarantee highest flexibility when machining shafts.Versions EMCO HYPERTURN 95/110HT 95/110 with two turning spindles andtwo tool turretsHT 95/110 with two turning spindles,a swivelling milling spindle and a YaxisHT 95/110 with two turning spjndles,two tool turrets and a Y axis in upperslide systemHT 95/110 with turning spindle, tailstock,a swivelling milling spindle andan Y axisHT 95/110 with two turning spindles, aswivelling milling spindle, a Y axis andan additional tool turret.

The Esprit CAM system offers high flexibility and process security, a comprehensive selectionof machining cycles, maximum tool control, and cross-machine technology for yourentire production facility.[CAD]Direct CAD data import- AutoCAD (DWG)- Parasolid ®- Solid Edge ®- Solid Works ®- ACIS® (SAT)- Optional interfaces: CATIA ® ,Pro/ENGINEER ® , STEP, STL,...[CAD][CAM]- 2-22 axis turning- 2-5 axis milling- Multi-tasking of turning and milling- 3D machine space simulation- Certified post-processors

The Virtual MachineA 1:1 mapping of the real machine for defining and testing processes, optimizing machiningsequences, and training new operators.[Process chain][CPS]- 1:1 simulation with collision detection- Direct connection to CAM ESPRIT- Process optimization- Reverse simulation of existing NC codes- Reduction in scrap rates- Training on the virtual machine- Simulation of loading systems(e.g. EMCO gantry loader)[CAM] [CPS] [Production][Production]- Reduction in set-up costs- Reduction in downtimes- Reduction in repair costsOPTIMUM MACHINE UTILIZATION

Automaticreturn on investmentAs a highly productive industrial machine, the EMCO Hyperturn needs high-performance automation peripherals.The LM 1500 short bar loader is the perfect solution for automatic feeding and loading of cut-to-length bars. Witha small footprint and short loading times this loader can be used immediately as a plug-and-play solution. A dedicatedcontrol unit guarantees the perfect connection to the machine interface. The LM 1500 offers comprehensive cyclesupport and is aligned to the machine spindle length. It may also be used to load individual workpieces.The benefits■ Small footprint■ Easy to operate■ Short feed times■ Fast, straightforward changeover■ Option to load individual workpieces■ Central diameter adjustment■ Dedicated control unit■ Bar stock is placed and stored at front sideInfeed belt with prismatic rollersTechnical dataBar diameterMax. bar lengthMin. bar lengthMaterial supportFeed rateBar change timeDimensions (L x W)WeightLM1500Ø 16 – 95 mm1550 mm150 mmapprox. 550 mm0 – 60 m/minapprox. 14 sec2500 x 1140 mmapprox. 550 kgParts catcher with conveyor: Finished parts areejected with a coolant fed part ejector into the partscatcher and transferred with a conveyor to a storagearea.

Machine layout HT95/110 SMB2311210137861114135Space for operationand maintenance: app.12000 x 4200 mm91010aDoor openingng1 .... Automated machine door2 .... Tool magazine 80 Pos.3 .... Tool magazine 40 Pos.4 .... Hydraulic aggregat5 .... Tool magazine door6 .... Pneumatic connection7 .... Elektric connection8 .... Cooling unit for el. box9 .... Operating panel10 .. Chip conveyor10a Pull out chip conveyor forcleaning11 .. Recooling unit12 .. Oil mist seperator13 .. Spindle axis14 .. Coolant pump* .... dimensions for bed length1700 by 600 mm shorter

Quality components[Machine bases and slides]When matching components, weplace great value on high stability,good damping characteristics, and athermoneutral design. We achieve highstability through a shorter force flow,thermal stability through symmetry,and dampening through the materialsand interfaces selected.[Headstocks]The design and manufacture ofheadstocks are two of EMCO‘s corecompetencies. During engineering,the focus is on precision, robustness,high rigidity, precise rotational characteristics,and a long service life.[Tool turret]Rapid-indexing turrets with adjustableswivel speeds and milling drives representthe current state of the art. Thebacklash-free milling drive is not onlyideal for milling and drilling, but also forrigid tapping, hobbing, and polygonalturning.[Tool holder]Innovative, fully developed tool holdersystems form the basis for costeffectivemachining. High changeoveraccuracy and stability result in shortsetup and cycle times.www.emco-magdeburg.dewww.emco-magdeburg.dewww.sauter-feinmechanik.comwww.wto.de[Clamping cylinder / chuck]Hydraulically activated clampingcylinders and chucks guarantee theprecise, safe clamping of work pieces.Programmable sensors are used forstroke monitoring. There is no needfor time-consuming adjustments ofcontactless limit switches.www.roehm.biz[Hydraulic systems]Compact dimensions, quiet operation,and high energy efficiency - just someof the advantages of the hydraulicassemblies used by EMCO. Monitoredpressure switches prevent the needfor time-consuming manual pressureadjustments.[Ball screws and roller guides]Highly precise and generously dimensionedguide rails and ball screws withoptimal pretensioning form the basisfor the machining of precision parts.[Chip conveyor]Slat band conveyors allow for flexibleimplementation and the safe removalof chips. A monitored overload clutchprevents damage from improper use.[Coolant pumps]Low-maintenance immersion pumpsfor pressures of up to 25 bar and flowrates of up to 1500 l/min provide optimumconditions for machining andenable reliable chip transportation.www.hawe.dewww.boschrexroth.comwww.knollmb.dewww.grundfos.at

Minimum use of resourcesfor maximum profit.E[M]COLOGYDesigned for EfficiencyAt EMCO, we take a consistent, responsible approach to the use of resources in machine tools in orderto safeguard long-term investments. From the development of our machines through to their constructionand manufacture, we place a strong focus on the sensible and sparing use of raw materials and energy.This enables us to achieve parallel savings in two areas:1. Reduction in the basic power consumption of machine tools, e.g.assemblies are switched on and off as required and the installedconnected loads are kept to a minimum.2. Reduction in variable consumption: This can be seen in the lighter axes,energy recovery system, increased rate of good parts, and the shorter process chain enabled by completemachining.Through these measures, which are constantly being refined and further optimized, EMCO truly demonstratesthat its slogan of „Designed for your Profit“ is not just an empty promise: EMCO products help savethe environment and provide intelligent customer savings without compromising on quality and flexibility.[Regenerative drive system]Kinetic energy is converted into electrical energy andfed back into the grid.Savings of up to 10%[Compact hydraulics unit with pressure accumulator]Thanks to its accumulator charging system, the pumponly runs when required. If the pressure accumulator isfull, the pump switches over to closed loop circulation.Savings of up to 90%[Roller guides]Extremely low friction losses thanks to rolling friction.Highly dynamic performance with minimal lubricantconsumption.Savings of up to 50%5105 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%5905 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%5505 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%[Structurally optimized mechanics]FEM analysis is used to optimize the relevant componentsin terms of their rigidity while simultaneouslyreducing their weight.Savings of up to 10%[Highly efficient motors]The use of energy-efficient motors (IE2) in the coolantpreparation area guarantee highly cost-effectiveoperation.Savings of up to 10%[Synchronized chip conveyor]Programmable interval times enable optimal use ofthe chip conveyor independently of of the machiningprocess.Savings of up to 95%5105 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%5105 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%0955 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%[Intelligent standby concepts]Reduced consumption by automatically switching offancillary units and machine space/screen illuminationafter a defined period of inactivity on the control panel.Savings of up to 50%[Virtual machine]Significant reduction in the setup and running-in timeson the machine through the use of highly developedsimulation and programming software.Savings of up to 85%[Intelligent energy management]Intuitive data entry screens for activating the individualenergy-saving functions.Savings of up to 70%5505 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%0855 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%0705 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

Performance diagrams HT 95/110NmkW35900max. 33max. 80030700256002050040015300102005100000 1000 2000 3000400max.3500min -1Main spindle A2-8 – counter spindle A2-8Main spindle A2-11 Counter spindle A2-11M (Nm)14012812010080604020S1S6 (40%)S6 (40%)S1P (kW)302521,520171510533,5403530272522,42018,5M (Nm)4515105Nm (S3-40%)Nm (100K)Nm (60K)Kw (S3-40%)Kw (100K)Kw (60K)P (kW)141210,51085,843,220500 1000 200016003000 4000 5000 6000 7000(U/min)000 500 1000 1500 2000 2500 3000n (U/min)0PowerMill milling spindleTool turret, upper/lower

Machine area HYPERTURN 95/110 SMBSpecifications in millimetersWork area HYPERTURN 95/110 SM2YSpecifications in millimeters

[Technical data]HYPERTURN 95/110Work areaSwing over bed 720 mm (28.3")Distance between spindle noses 1700 – 2300 mm (66.9 – 90.6")Max. Bore in Draw Tube (A2-8) 95 mm (3.7")TravelTravel in with milling spindle X1 / Z1 550 / 1300 – 1900 mm(21.7 / 51.2 – 74.8")Travel in 2 / Z2300 / 1340 – 1940 mm(11.8 / 52.8 – 76.4")Y travel in240 mm (+/- 120 mm)(9.4" (+/- 4.7"))Main and counter spindle (A2-8)Maximum speed3500 rpmMaximum power33 kW (44.3 hp)Maximum torque800 Nm (590 ft/lbs)Main and counter spindle (A2-11)Maximum speed2500 rpmMaximum power - main spindle 52 kW (69.7 hp)Maximum torque - main spindle 2480 Nm (1828 ft/lbs)Maximum power - counter spindle 42 kW (56.3 hp)Maximum torque - counter spindle 1040 Nm (767 ft/lbs)TailstockTaper mounting (integrated bearing) MT 5Travel in 1100 / 1600 mm (43.3 / 63")Quill stroke 150 mm (5.9")Quill diameter 150 mm (5.9")Tool turret top and bottomNumber of tool positions 2 x 12Tool holding shaft in accordance with 40 mm (1.8")VDI (DIN 69880)Driven toolsSpeed range0 – 3000 rpmTorque40 Nm (29.5 ft/lbs)Drive performance10.5 kW (14 hp)Driven tools 2 x 12B-axis and PowerMillTravel range 205°Tool magazine positions40 (80 optional)Tool holderHSK63, C6, C5Maximum torque128 Nm (94.4 ft/lbs)Maximum power21.5 kW (28.8 hp)Maximum speed7000 (12000) rpmTool change time (tool - tool)2.2 secFeed drivesRapid motion speed X / Z counter spindle 30 m/min (1181 ipm)Rapid traverse speed in Y15 m/min (590 ipm)Coolant systemTank volume420 / 520 liters(119 / 137.6 gal)Pump capacity14 bar / 10 l/min(203 PSI / 2.6 gal/min)DimensionsHeight of center above floor 1360 mm (53.6")Overall height 2800 mm (110.2")Space required inclusive tool magazine 8500 / 9100 x 3150 mm(334.6 / 358.3 x 124")Total weight16000 – 22000 kg(35274 – 48500 lb)Safety devicesCE compliantEN4354 . 01/13 . Technical modifications reserved. Errors and omissions excepted.www.emco-world.comEMCO MAIER Ges.m.b.H.Salzburger Str. 80 . 5400 Hallein-Taxach . AustriaPhone +43 6245 891-0 . Fax +43 6245 86965 . info@emco.at