Precision and performance in 5-axis machining

In the realm of advanced manufacturing, precision and performance are paramount. This is especially true in industries where even the slightest deviation from exact specifications can lead to significant challenges, whether in aerospace, automotive, or other high-tech sectors. To meet these demanding requirements, companies like HELLER have continually innovated their machining technologies, ensuring they stay at the cutting edge of the industry. One of the most significant developments in recent years is the evolution of 5-axis machining centers, which offer unparalleled accuracy and versatility.

HELLER has expanded its F series of 5-axis machining centers, first showcased at EMO 2023 in Hanover, with the introduction of the F 6000 model. Following this, the F 5000 was unveiled at the HELLER Open House 2024, offering a smaller footprint while maintaining the high performance and precision for which HELLER is known. These machines are designed to meet the demanding requirements of industries like aerospace and automotive, where accuracy and efficiency are paramount.

Modular design for versatility

The new F series is built on a modular platform, allowing for customisation to suit a wide range of applications. The F 6000 features a work envelope of 1,000 x 1,000 x 1,400 mm, while the F 5000 offers 800 x 850 x 1,100 mm, making it ideal for smaller spaces without compromising on capability. Both models share key components, such as motor spindles and tables, ensuring consistent performance across different setups.

Advanced swivel heads and spindles

A key feature of the F series is the advanced swivel heads, which incorporate motor spindles developed in-house by HELLER. These heads are available with both HSK-A 100 and HSK-A 63 tool interfaces, catering to various machining needs. The dynamic swivel head with a 5th axis ensures maximum machining performance, while the backlash-free drive concept provides impressive precision.

HELLER offers a variety of spindles tailored to different applications. The Speed Cutting Unit (SCU) reaches speeds of up to 15,000 rpm, ideal for high-speed tasks, while the Dynamic Cutting Unit (DCU) offers versatility with speeds up to 12,000 rpm and torque of 400 Nm. For ultra-heavy machining, the Power Cutting Unit (PCU) remains a reliable choice, offering 146 Nm at 8,000 rpm.

Robust kinematics for precision

The F series machines feature robust kinematics, including a revised drive concept with a twin ball screw drive in the Z-axis and a reinforced X-axis. These enhancements increase the dynamics of the linear axes and reduce positional tolerances to just 5 μm. The rotary B and C axes have also seen improvements, with standard tolerances reduced to 7 arc seconds. These advancements ensure top-tier workpiece accuracy and reduced machining times.

User-friendly design

Ease of use is a priority in the F series. The machines provide convenient access to the work area and are equipped with LED lighting for better visibility. The SETUP-Assist function actively supports the operator during the machining process, preventing collisions between machine components and tools. The machines also come with the latest SINUMERIK ONE control system from Siemens, featuring a 24-inch touch screen and an intuitive interface.

Efficient chip management and compact footprint

HELLER has improved chip management in the F series, with features that ensure free chip fall and efficient removal. Steep stainless-steel covers and a wide chip conveyor help keep the work area clean, enhancing the quality of the finished workpiece. Additionally, the compact design of the F series, which is only about 3,700 mm wide, makes these machines suitable for space-constrained environments. The new rack-type tool magazines offer high storage capacity while occupying less floor space, further adding to the machines' efficiency.

Flexibility in automation

The F series is designed for easy integration with automation systems. The F 5000 and F 6000 are available with an automatic pallet changer (APC) as standard, while a FLEX version without the integrated pallet changer offers greater flexibility when combined with external automation solutions. This flexibility allows manufacturers to maximise machine utilisation and adapt to different production requirements.

Conclusion

HELLER's F series represents a significant advancement in 5-axis machining, combining precision, performance, and user-friendly design in a compact, versatile package. Whether for small to medium batch production or specialised applications, these machines are designed to meet the most demanding requirements, setting a new standard in the industry.