The F 8000 high-performance machining centre

At HELLER, things are happening in quick succession: In the fall of 2023, the Nürtingen-based machine manufacturer presented the F 6000, the first 5-axis machining center of the new generation of its F series. Just six months later, another model, the F 5000, came onto the market. And since AMB 2024 in Stuttgart, the larger F 8000 has been available. Like its siblings, it is also suitable for use from single parts to flexible 24/7 series production for users of numerous industries – from mechanical engineering to energy technology to aerospace.

The F 8000 is based on the successful 5-axis F product line, which has been on the market for more than a decade, but surpasses its predecessors in many areas. For example, its footprint is significantly slimmer at 4.20 m wide and it requires around 25 percent less space in the basic version. In addition, the optional PRO version has the best technical data. The axle acceleration in X/Y/Z was increased by 50 percent to 6 m/s2. The chip-to-chip time has been reduced by around 30 percent. The F 8000 with PRO package also improves in terms of accuracy. The position tolerances in X/Y/Z are 6 μm, which is 25 percent better than the previous model.

Another advantage of the new F 8000 is the large working range (X/Y/Z: 1,400/1,200/1,400 mm), which allows for larger workpiece dimensions and, above all, provides even more flexibility in machining thanks to the 150 mm longer stroke in the X-axis. In addition to the 800 x 800 mm pallets, larger 1000 x 1000 mm pallets can also be used as an option. Head of Development Dr.-Ing. Manuel Gerst explains: "The maximum payload is 2000 kg. We will offer a payload of up to 3000 kg as an option from the end of 2024."

Full compatibility with the previous generation
In order to make it as easy as possible for users to switch to the new generation of the F series, HELLER paid attention to maximum consistency. This means, for example, that the pallets and tools are fully compatible with the old 5-axle series.

With the SINUMERIK ONE, the new machine uses the latest generation of control systems from Siemens. Nevertheless, the user can simply adopt all NC programs that were already used in the predecessor machines with the Siemens SINUMERIK 840D sl predecessor controller. Working with the new control system is even more pleasant thanks to the main control unit in console design with a 24-inch touch screen and numerous other features.

With the new F series, however, HELLER not only guarantees full consistency with previous generations. At the same time, the developers have ensured extensive compatibility with the new 4-axis machining centers of the H series. Pallets and tools can be exchanged at will, and standardization with regard to structural components such as beds and stands allows for the same strokes, payloads and workpiece dimensions.

Slim footprint provides more space for automated processing
The standardization of the 5-axis machine within the series goes even further. For example, the F 8000 uses the same modular system as the entire F series with regard to key components such as heads, spindles and tool magazines. The machine design is also uniform in the entire F series, which results in the aforementioned narrow footprint, among other things.

The new tool racking systems from HELLER are just as important for the slim appearance of the new F 8000. They are all almost two meters narrower than the previously available variants. This is an advantage that is particularly effective when automating several machining centres. Because where there used to be room for three machines, in the future four machines can stand in a row.

Work units with pan and tilt kinematics
The F 8000 – and the entire new F series – are highlighted by the fundamentally revised swivel heads, which ensure maximum performance in machining. HELLER produces the in-house developed motor spindles itself. Equipped with an HSK-A-100 interface as standard, the Dynamic Cutting Universal (DCU) unit achieves torques of 400 Nm and speeds of 12,000 rpm. The Speed Cutting Unit (SCU) offers 15,000 min-1 in conjunction with HSK-A 100. In addition, HELLER offers additional spindles that achieve speeds of up to 18,000 min-1 in conjunction with the optional HSK-A-63 tool holder. The Power Cutting Universal (PCU) unit with gear spindle is still available for heavy-duty machining – it delivers a torque of 1,146 Nm and speeds of 8,000 rpm.

In addition to the swivel heads, HELLER also provides a clevis variant for the F 8000. This is characterized by a particularly high degree of flexibility in five-axis machining. This is because tilt kinematics can be used to produce undercuts and undercuts that are required, for example, for the production of integral components in the aerospace industry.

Ready for any kind of automation
Whether individual parts or flexible series are to be produced – with the F 8000 5-axis machining centre, users are always on the right track. For those who are not yet sure whether they want to equip the machine with a pallet automation system at the time of purchase, HELLER offers the greatest possible flexibility with the "Automation-READY" option. This is because it allows the available, standardized automation systems to be integrated quickly and easily at a later date. The F 8000 is equipped with an automatic pallet changer as standard. In addition, extended automation with linear accumulators, rotary accumulators or robots can be ordered.

All in one – milling, turning and other technologies
In addition to automation, complete machining is playing an increasingly important role in many manufacturing companies. HELLER follows this all-in-one idea and offers an optional mill-turn function for combined milling and turning tasks for the entire F series. The core of this is the high-torque rotary rotary table DDT (Direct Drive Turning). In addition to milling and drilling operations, this means that external and internal contours can also be rotated longitudinally or flat in a single clamping operation, as well as a wide variety of free and indentation grooves. Even external and internal threads can be created. This eliminates the need to switch to separate lathes, which increases accuracy on the workpiece and reduces throughput times.