Machine concept

The HF-series 5-axis machining centres are the perfect combination of apparent contrasts - stiffness and dynamism. The basis is the rigid machine bed. Highly precise and fast machining cycles guarantee the unique machine structure of the HF: the fifth axis is located inside the workpiece, the directly-driven A/B-axis is supported by a counter-bearing.

Cross-bed and travelling column in gated design

  • rigid cast iron machine bed in combination with weight-optimised machine columns from steel
  • rotary indexing table with counter bearing for optimum force flow and compact design
  • horizontal spindle with lean spindle neck for perfect reach into the workpiece
  • tool changer with two NC-axes for fast automatic tool change
  • large range of tool magazines, chain or rack-type
  • pallet changer with lifting/swivelling principle and robust HF pallet interface
  • machine variant with table loading available as an alternative

5-axis kinematics with horizontal spindle and 5th axis in the workpiece

  • machine bed carries the X- and the Z-axis in a cross bed arrangement
  • the machine column traverses in the X-direction and carries the machining unit
  • machining unit traverses in the Y-direction, compactly integrated into the machine column in a stable manner
  • rotary indexing unit with counter bearing traverses in the Z-direction and executes the feed movement
  • NC rotary indexing table (B rotary axis) turns the workpiece continuously (360.000 x 0.001°)

Roller bearing-mounted linear guides and stable YRT bearings in the rotary axes

  • linear axes with roller guides, driven by ball screws for a high dynamic
  • direct, absolute measuring systems for optimised precision and low position tolerance
  • power axis dynamics (option: speed)
  • A and B rotary axes with large YRT bearings and automatic clamping for maximum stability and high tilting moments
  • swivelling NC rotary table with counter bearing and lowest moments of inertia for fast positioning
  • direct drives in both rotary axes for a high dynamic

Spindle units

5-axis machining requires all components of a machining centre to deliver a top performance. The spindle must be particularly efficient: highly flexible,with torque characteristic curve adapted for the task in hand and suitable for a range of materials. The HF-series 5-axis machining centres offer 4 robots and powerful versions, so you work with a spindle that best suits your requirements.

Robust machining units with HSK-A 63 or HSK-A 100

  • horizontal spindle for optimal chip fall
  • HSK-A 63 or HSK-A 100 tool shank optionally available for both machine sizes
  • lean spindle neck for perfect reach into the workpiece
  • rigid cast iron guide slide with high dynamic stiffness and damping
  • optimised performance in action with compact overall design and robustly dimensioned spindle bearing arrangement
  • thermal stability and precision thanks to permanent cooling: Precision cooling unit and thermal growth compensation for the spindle

2 machining units with HSK-A 63 tool shank

  • high-speed motorized spindles with speeds of up to 18,000 rpm
  • torques up to 201 Nm (S6 40 %)
     

2 machining units with HSK-A 100 tool shank

  • speeds of up to 12,000 rpm
  • high-torque motorized spindles up to 354 Nm (S6 40 %)

HELLER attachment head support (MSK)

  • for use with adapter heads, e.g. angular heads
  • enlarged location base with three-point location
  • integrated torque absorption and media transfer
     

Torque support

For absorbing torque when using adapter heads.

Tool management

If you have to work with a broad range of tools and respond flexibly to new production requirements, our HF-series 5-axis machining centres are the ideal solution for you. Powerful tool magazines and a precise high-speed tool changer for optimum chip-to-chip times guarantee you constantly short non-productive times.

Chain-type tool magazine for fast tool provisioning

  • 4 chain-type magazines with up to 240 pockets for machines with HSK-A 63 to choose from
  • 3 chain-type magazines with up to 150 pockets for machines with HSK-A 100 to choose from
  • rigid tool holder mounted on both sides of a double chain for high chain traversing dynamic
  • tool setting station with optimum accessibility for ergonomic and fast tool setting
  • integrated tool provisioning station for provisioning of the follow-on tool during machining and short tool-to-tool times
  • tool shank in closed holders: protects against contamination and optimum hold during positioning
  • tool provisioning during machining for short tool-to-tool times


Options

  • convenient operating panel at workpiece loading station
  • setting during machining
  • tool coding with RFID chip
  • tool shank cleaning, incl. cartridge flushing and drying
  • HELLER TRP (Tool Requirement Planning): for automatic creation of loading and unloading lists
  • tool break monitoring during machining

Rack-type tool magazine with high storage capacity

  • 2 rack-type magazines with up to 405 pockets for machines with HSK-A 100 to choose from
  • rack-type magazine with 375 pockets for machines with HSK-A 63
  • tool handling with highly dynamic loader for fast tool provisioning
  • tool setting station with integrated rotary station with multiple tool pockets for setting during machining loading
  • convenient operating panel at workpiece loading station


Options

  • automatic rotary station
  • tool coding with RFID chip
  • tool shank cleaning with brush and flushing option
  • HELLER TRP (Tool Requirement Planning) for automatic creation of loading and unloading lists
  • tool break monitoring during machining

Fast tool change for short chip-to-chip times

  • two NC-axes with lifting/swivelling principle for a high dynamic and continuous precision
  • stable double gripper for secure hold with high tool weights and tool moments of weight

Workpiece management

No matter whether with pallet changer or as table loading – HF-series 5-axis machining centres are best prepared for both feeding concepts. Various table sizes or pallet dimensions and numerous options to suit different sizes. So you can configure the machine to suit your specific requirements.

Pallet changers are optimal for series production

  • automatic pallet changer with lifting/swivelling principle
  • high maximum payload through robust, hydraulic drive
  • secure force application on machine pallets via HF interface with integrated pallet pick-up monitoring
  • continuously high changeover accuracy through integrated zero point pallet clamping system
  • HF machine pallets with DIN hole pattern and standardised aligning elements for fast mounting of clamping fixtures

Setting and loading during machining

  • manual or automated loading by robot or pallet
  • wide smooth-running door to optimise access for loading and setting by crane or handling systems
  • workpiece setting station, lockable at 90° indexing with foot unlocking mechanism, without media interface, unrestricted manual rotation
  • touch control panel, as well as media guns within reach, integrated into the machine enclosure
  • low "loading edge" and short distance to the pallet for ergonomic loading


Options

  • integrated media interface for hydraulic workpiece clamping with 100 or 200 bar of pressure and multi-line clamping technology
  • additional pneumatic functions: location check and unclamping check via media interface
  • active operator support through automatic functions: automatic setting station door, automatically rotating NC setting station, automatic setting and de-setting sequence
  • machine pallets in DIN T-slot design

Table loading for workshop use

  • workpiece loaded directly onto the machine table in the work area
  • optimum accessibility to the workpiece thanks to low "loading edge"
  • short distance to the workpiece thanks to inclined protective enclosure
  • wide, smooth-running work area door opens the work area roof for crane loading
  • round machine table with large clamping surface and DIN hole pattern

Swivelling NC rotary table with counter bearing as standard

  • directly driven A and B rotary axes with a high dynamic
  • large YRT bearing for maximum stability and high tilting moments
  • integrated automatic clamping system with fail-safe safety clamping for high, reliable tangential moments during high-performance machining


Options

  • integrated media interface for hydraulic workpiece clamping with 100 or 200 bar of pressure and multi-line clamping technology
  • additional pneumatic functions: location check and unclamping check via media interface
  • automatic setting station door
  • clamping plate with DIN T-slots

Automation

Automation solutions from HELLER are individual concepts that we develop specifically for your production facility. We analyse your requirement and devise a solution that allows you to work to your maximum capacity. We use standardised solutions wherever possible. The HF-series 5-axis machining centres are prepared for pallet and workpiece automation.

Storage of machine pallets and automated setting of one or multiple machines

  • standardised linear storage systems with up to 15 storage locations depending on type and size (optional)
  • standardised machine interface available for numerous machine sizes (option)
  • everything from a single source: complete solution for short installation time and commissioning
  • optimal capacity utilisation with continuous pallet feed to one or multiple machines
  • consequently, increased cost efficiency and more flexibility in the production facility
  • specific advantages for production tasks with a large part mix and series production with small batch sizes
     

Options

  • standardised host computer interface for optimal connection to the host computer
  • high number of functions and options for automated production control
  • media interface for hydraulic workpiece clamping

Automatic loading and unloading of workpieces

  • workpiece handling by robot relieves the operator
  • ideal solution for series production
  • machining centre works to capacity thanks to continuous material feed
  • standardised machine interface for robot loading onto the setting station (option)


Options

  • media interface for hydraulic workpiece clamping
  • location check and unclamp check

Supply and disposal

Thermal stability is one of the decisive factors for reliable and highly-precise machining processes. The heat input into the machine structure and workpiece as a result of hot chips can impair accuracy. Our aim is therefore: fastest-possible chip disposal and coolant supply directly through the spindle.

Central supply areas at the rear of the machine

  • simple maintenance with optimum accessibility, all supply units at a glance
  • compressed air and flushing gun at the workpiece setting station integrated into the machine enclosure; additional flushing gun at the operating station
  • centralised oil/air lubrication for the key components
  • seal air and selective blow-out of interfaces for permanently smooth machine operation
  • media interface for hydraulic workpiece clamping at 100 bar or 200 bar (option)

Effective cooling lubricant supply and filtering

  • coolant units: paper band filter or vacuum rotation filter with high tank volume optionally available
  • internal coolant supply (IKZ) through the tool at high pressure 50 bar (option: 70 bar)
  • internal coolant supply with up to 7 pressure stages freely programmable via the NC program
  • external tool cooling with flushing nozzles integrated into the spindle
  • integrated work area flushing with adjustable nozzles for optimal work area flushing and workpiece cooling


Options

  • coolant cooler for high thermal stability and precision
  • automatic filling of the coolant unit
  • oil skimmer for removing foreign oil from the cooling lubricant tank by oil separation

Fast chip removal from the work area

  • free chip fall below the spindle and fast disposal from the work area with central chip conveyor
  • chip conveyor as either scraper conveyor or hinged conveyor, depending on the application (option)
  • steep side walls and stainless steel lamella covers with self-cleaning effect prevent chip deposits
  • interior work area enclosure made from electrolytically galvanized sheets provides long-term resistance against dirt and coolant
  • work area flushing and work area shower support fast chip disposal for machines with coolant units
  • optional: exhaust unit for exhausting cutting fluid mist from the work area

Operation and maintenance

When you work with HELLER HF-series machines, just how much machine construction has gone into these 5-axis machining centres will be tangible. No matter whether on the workpiece setting station, during tool setting, programming or maintenance – your comfort and safety and, above all, the productivity of your manufacturing facility is paramount at all times.

Optimal accessibility to all work areas for simple operation and maintenance

  • operating comfort and ergonomic design increase productivity
  • spatial separation between operating and maintenance areas
  • robust operating elements with touch function for tough everyday production conditions
  • smooth-running doors and easily removal metal enclosure elements

Maximum operating comfort during setting and production

  • main operating unit designed as a double-swivel console
  • 24" screen with multi-touch function and HELLER Operation Interface
  • good view into the work area thanks to large safety screen
  • smooth-running work area door with linear guide opens the work area roof in the operating area
  • operating modes 2 and 3 included in standard scope of supply
  • additional flushing gun within reach, integrated into the machine enclosure
  • LED work area lighting


Options

  • HT8 and HT2 handheld operating units
  • screen blow-off device for a clear view when machining with cutting fluid
  • LED status lamp with machining progress display

Setting and loading during machining thanks to the pallet changer

  • large smooth-running door to optimise access for loading and setting by crane or handling systems
  • workpiece setting station lockable with 90° indexing, with foot unlocking mechanism
  • operating elements, as well as media guns within reach, integrated into the machine enclosure
  • low "loading edge" and short distance to the pallet


Options

  • automatically actuated setting station door
  • automatically rotating NC setting station
  • software options: automatic setting and de-setting sequence

Optimal accessibility for fast tool setting

  • ergonomically arranged operating elements
  • insertion location at optimum height and with integrated unclamping function for simple handling
  • tool setting at the magazine when spindle is running


Options

  • convenient operating panel at workpiece loading station
  • setting during machining
  • tool coding with RFID chip
  • HELLER TRP (Tool Requirement Planning): for automatic creation of loading and unloading lists

Supply units and maintenance points concentrated at just a few locations

  • smooth-running doors and easily removal metal enclosure elements
  • simple and direct access to the control cabinet
  • quick-response HELLER spare part service


Options

  • maintenance manager for maintenance planning and operator support on the machine itself
  • HELLER TPS (Total Productive Services) – Service Agreements for inspection, service and maintenance measures

Control

Speed is always of the essence during the daily working routine. The Siemens SINUMERIK 840D sl, a state-of-the-art high-performance controller with HELLER Operation Interface, makes your work easy through efficient support: with intuitive operation, simple programming, cycle support and all important information at a glance.

 

Siemens SINUMERIK 840D sl

  • high-performance control for machining centres that have to meet the highest requirements when it comes to performance and machining precision
  • digital drive technology and state-of-the-art system architecture
  • SINUMERIK Operate user interface for efficient machine operation
  • optimally integrated and adapted specifically to the requirements of HELLER machining centres
  • real-time communication via Profinet
  • IO-Link for direct diagnostics and parameterisation of sensors

  • main operating unit designed as a console for optimum operating comfort on machines with Siemens control systems
  • 24" screen and multi-touch function, optimum for displaying documents and drawings
  • HELLER Operation Interface with 4 function areas for extra information at a glance
  • practical Xtends HELLER expansions and additional functions

  • handheld operating unit
  • convenient operating panel at workpiece loading station
  • HELLER Remote Diagnostic Services (RDS)
  • pallet management system for multiple setups
  • alternative strategy
  • order management
  • automatic setting and de-setting sequence

Technical data

Product selection HF 3500HF 5500
Positioning range
X/Y/Z
mm 710/750/710900/950/900
Rapid traverse speed
X/Y/Z | Power (Speed)
m/min 65 (90/90/80) 65 (90/90/80)
Acceleration
X/Y/Z | Power (Speed)
m/s² 8 (10/10/8) 8 (10/10/8)
Positioning tolerance Tp
X/Y/Z | VDI/DGQ 3441
mm 0,005 0,005
Tool shank Size HSK-A 63(HSK-A 100)HSK-A 63(HSK-A 100)
Chip-to-chip time
t₂,₃ | VDI 2852 | Power (Speed)
s 2,7 (2,4) / (7,2)1)(3,3 (3,0) / (9,5)1))2,9 (2,6) / (7,2)1)(3,5 (3,2) / (9,5)1))
Clamping surface
Nominal size
mm 400 x 500Ø 630 (Ø 710)2)500 x 630Ø 810 (Ø 880)2)
Workpiece dimension
Diameter x height
mm Ø 7103) x 630Ø 710 x 690Ø 9003) x 800Ø 870 x 900
Clamping load
Power (Speed)
kg 550 (400)550 (400)750 (500)750 (500)
Machine control
Siemens Sinumerik 840D sl
SiemensSiemens

( ) = optional values
- = not available
1) in conjunction with rack-type magazines
2) clamping plate
3) consider limitations

Downloads

heller-5-axis-machining-centres-hf_en.pdf
Product brochure
5-axis machining centres HF
3.3 MB

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