Multitasking at its best.HYPERTURN 95/110The new generation of ‘multitasking machines’ for the highest levels of productivity and flexibility

E[M]CONOMYmeans:[ ]

HYPERTURN 95/110

The Hyperturn 95/110 was designed to enable further increases in productivity in mass production. Whether rod, shaft, flange, orcubic parts, the modular design of the many Hyperturn 95/110 models enables them to cover a wide range of machining tasks.They are particularly suited to the series production of workpieces in the automotive industry, mechanical engineering, plain-bearing technology, and aviation.

[Control unit]- Sinumerik 840D-sl- USB interface on the control panel - Emco diagnosis- Pivotable and mobile- Clear arrangement of function keys- Large monitor and PC keyboard, optional

[Main spindle]- A choice of 2 spindle solutions:

A2-8, A2-11- Main drive power of up to 52 kW (A2-11)- High torque of up to 2480 Nm (A2-11)- Large speed range of up to

3500 rpm (A2-8)- Bar capacity diameter 95 mm (A2-8)- Liquid-cooled headstock - Stable and robust spindle bearings

[Lower tool turret]- 12-station tool turret- Max. turning diameter of up to 650 mm- Fully covered guides- VDI40 quick-change system- 12 driven tool stations- Servo-controlled - short indexing times- Both spindles in use

[Tool magazine]- Integrated tool magazine with

40/80 positions- Easy access for inspection and

manual magazine loading

[Machine cover]- All-round protection- Optimum accessibility- Large work space opening- Suitable for top-loading- Chip conveyor and HD coolant pumps

as standard

[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 mm

[Counter spindlel]- A choice of 2 spindle solutions: A2-8, A2-11- Up to 42 kW power with high torque of up to

1040 Nm (A2-11)- Large speed range of up to 3500 rpm and

up to 30 KW power (A2-8)- Same connection for main and counter spindle- 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 bar

Connection nozzle(stainless steel)

Radial cam housing(tempered steel)

Shaft(steel)

[Hyper flexibility]

Machine flexibility is often sacrificed for the sake of productivity. Not so with the Hyperturn. With its high-performance andexceptionally mobile milling spindle and an almost inexhaustible tool magazine, the Hyperturn can do almost anything - andvery quickly.

Thread cutting

Groove milling

Knurling or diagonal knurlingEccentric turning/milling

Bore reaming

Boring

Internal contour turning

Internal gear teeth slotting

Internal deburring

Facing and longitudinal turning

Surface rolling

Ejection Form E/F turning

Bore rolling

Multifunctional workpiece

Threaded journal milling

Groove milling

Gear teeth milling (hobbing)

Circular journal milling

Deep-hole drilling

Hexagonal pendulum broaching

Internal thread turning

Bore finishing

Inside turning

Internal recessing

Boring pattern centering,boring, tapping

Contour milling (ellipse)

Engraving

[Engineering] Highlights

Main 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.

The milling spindle can be synchronized with the main or counter spindle asrequired for gear-teeth hobbing on workpieces. This enables the production ofcomponents with straight or inclined teeth.

The lower tool turret can be fitted with a live center point and can act as a tailstockfor machining large workpieces.

■ Main and counter spindle for complex complete machining■ Two tool turrets with VDI rapid change system, high pressure and/or

hydraulic 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 and

milling-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 Europe

For complex, complete machining, the system uses a modular, building block system with two base lengths (1700 or 2300 mm), two spindle sizes, with a milling spindle anda B-axis or with two turrets.

Quicker and precise NC-controlled tool changer with 40/80 positions The Y-axis machine base is at a 90° offset with widely positioned, preloaded guiderails, which keeps protruding lengths to a minimum and guarantees maximumstability for complete machining.

Versions EMCO HYPERTURN 95/110

HT 95/110 with two turning spindles andtwo tool turrets

HT 95/110 with two turning spjndles,two tool turrets and a Y axis in upperslide system

HT 95/110 with two turning spindles, aswivelling milling spindle, a Y axis andan additional tool turret.

HT 95/110 with two turning spindles,a swivelling milling spindle and a Yaxis

HT 95/110 with turning spindle, tail-stock, a swivelling milling spindle andan Y axis

Fully modeled HYPERTURN 95

Collision monitoring on the HYPERTURN 95 PowerMillwith milling spindle and tool turret

Multi-axis complete machining on the counter spindlein the HYPERTURN 95

The sensational CAM solution for turning and turning/milling. ESPRIT greatly simplifies theprogramming of complex machining processes and significantly reduces set-up times.

■ Complete CNC programming for up to 22 axis for turning

■ Turning/milling for single-spindle lathes■ Turning/milling for multi-carriage turning centers■ Turning/milling for multitasking machine

tools including B axis

Applications

■ Dry runs in dynamic volume view ■ Shaded in the entire working environment:

Machine tool, clamping devices, blank part and workpiece

■ Extensive collision detection: Tool, blank, workpiece clamping devices,and target/actual workpiece comparison

Simulations

■ Parasolid® ■ ACIS® ■ NURBS surface modeling ■ STL ■ 2D/3D wire-frame modeling ■ 2D drawing, dimensioning and text

Tools

CPS Pilot can be easilycombined with ESPRITCAD/CAM software for programming complexparts.

Users work as normalwith the SIEMENS control interface.

Simulation takes placeexclusively at the PC workstation. Machine production isnot interrupted.

Exact image.EMCO CPS Pilot displays the indi-vidually configured machine withall its functions and features 1: 1as a 3D graphic.

Optimum load.The CPS Pilot ensures that downtimesare kept to a minimum for optimiza-tions.

Rapid success.EMCO CPS Pilot provides thesame operator interface for twomachines – the virtual and the real.Retraining is not necessary. Fastand successful utilization of CPSPilot is therefore guaranteed.

The benefits for you■ Up to 80 % shorter set-up times■ 100% production safety■ Reduced processing times■ Optimum machine load■ Significant cost reductions

The EMCO CPS Pilot (Crash Prevention System) is an innovative offline programming system for the EMCO Hyperturnseries. Users work at external programming workstations with an image of the machine in Simulation mode. Unlike withmost other competitive products, they can plan, program, simulate, and optimize the next production run with CPS Pilotwhile the HYPERTURN is producing a series run. Collision and damage to the machine can be completely eliminated withthe CPS Pilot due to the virtual test run. The result: 100% production safety, up to 80 % shorter set-up times, and asignificant increase in productivity and economic viability.

The virtual HYPERTURN

Automatic return on investment

Material support and separator

Infeed belt with prismatic rollers

As 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.

Technical data LM1500Bar diameter Ø 16 – 95 mm

Max. bar length 1500 mm

Min. bar length 150 mm

Material support approx. 550 mm

Feed rate 0 – 60 m/min

Bar change time approx. 14 sec

Dimensions (L x W) 2000 x 1100 mm

Weight approx. 550 kg

■ Small footprint

■ Easy to operate

■ Short feed times

■ Fast, straightforward changeover

■ Option to load individual workpieces

■ Central diameter adjustment

■ Dedicated control unit

■ Ergonomic EMCO design

The benefits

1 .... Türautomatik2 .... Werkzeugmagazin 80 Pos.3 .... Werkzeugmagazin 40 Pos.2 3 nur für Variante mit Frässpindel

4

578

32

121

13

13

116

910

Türöffnung 2320*

1 .... Automated machine door2 .... Tool magazine 80 Pos.3 .... Tool magazine 40 Pos.2,3 . only with milling spindle

Door opening 2320*

Space for operation and main-tenance: app.9500x4200 mm

1 .... Automated machine door2 .... Tool magazine 80 Pos.3 .... Tool magazine 40 Pos.2,3 . only with milling spindle4 .... Hydraulic aggregat5 .... Central lubrication6 .... Pneumatic connection7 .... Elektric connection8 .... Cooling unit for el. box9 .... Operating panel10 .. Chip conveyor11 .. Recooling unit12 .. Oil mist seperator13 .. Spindle axis* .... Measurements with bed length

1700 are 600 mm shorter

Machine layout HT95/110 SMB

Machine area HYPERTURN 95/110 SMB

Work area HYPERTURN 95/110 SM2Y

Specifications in millimeters

Specifications in millimeters

S1

S6 (40%)

S6 (40%)S1

400020001000500

1600

3000 60005000 7000

0

40

20

80

60

120

100

140

128

0

5

15

10

20

17

30

25

21,5

M (Nm) P (kW)

(U/min)0 500 1000 1500 2000 2500 3000

Nm (60K)

Nm (100K)

Kw (100K)

Kw (60K)

Nm (S3-40%)

Kw (S3-40%)

0

5

10

20

15

22,4

2725

30

35

18,5

33,5

40

45

0

2

10,5

4

8

5,8

12

10

3,2

14

P (kW)M (Nm)

n (U/min)

PowerMill milling spindle Tool turret, upper/lower

Main spindle A2-11 Counter spindle A2-11

0

100

200

300

400

500

max. 800

0 1000 2000 3000

0

5

10

15

20

25

30

max. 33

35

700

900

600

max.3500400

min-1

kWNm

Main spindle A2-8 – counter spindle A2-8

Performance diagrams HT 95/110

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[Technical data]

www.emco-world.com

EMCO MAIER Ges.m.b.H.Salzburger Str. 80 . 5400 Hallein-Taxach . AustriaPhone +43 6245 891-0 . Fax +43 6245 86965 . info@emco.at

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 / Z2 300 / 1340 – 1940 mm

(11.8 / 52.8 – 76.4")Y travel in 240 mm (+/- 120 mm)

(9.4" (+/- 4.7"))Main and counter spindle (A2-8)Maximum speed 3500 rpmMaximum power 33 kW (44.3 hp)Maximum torque 800 Nm (590 ft/lbs)Main and counter spindle (A2-11)Maximum speed 2500 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 tools Speed range 0 – 3000 rpmTorque 40 Nm (29.5 ft/lbs)Drive performance 10.5 kW (14 hp)Driven tools 2 x 12B-axis and PowerMillTravel range 205°Tool magazine positions 40 (80 optional)Tool holder CAPTO C5 (HSK-63A)Maximum torque 128 Nm (94.4 ft/lbs)Maximum power 21.5 kW (28.8 hp)Maximum speed 7000 (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 Y 15 m/min (590 ipm)Coolant systemTank volume 420 / 520 liters

(119 / 137.6 gal)Pump capacity 14 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 weight 16000 – 22000 kg

(35274 – 48500 lb)Safety devices CE compliant