Machine concept

Structural dynamic examinations as early as the development phase are key to a milling-turning machining centre achieving an equally high performance in both the milling and turning machining strategies. Both the machine concept and the entire process design of our C-series 5-axis milling-turning machining centres are the result of a comprehensive simulation process. For you, this means: reliable productivity and precision in two fully-fledged production processes.

Cross-bed and travelling column in gated design

  • high stability and damping in the flow of forces through topology-optimised structural components from cast iron
  • thermo-symmetrical design and optimized flow of forces
  • broad range of machining units in a robust design
  • tool changer with two NC-axes for fast automatic tool change
  • large range of tool magazines, chain or rack-type
  • machines with integrated pallet changer (CP) and high payload for fast automatic pallet change
  • machine variant with table loading (CT) available for selected sizes

5-axis kinematics with horizontal basic alignment and a 5th axis in the tool

  • 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 table 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°)
  • swivel head (C) or tilting head (A) – the 5th axis is in the tool (max. C 345.000 x 0.001°/ A 175.000 x 0.001°) (swivel range with optional swivel range expansion)

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

  • linear axes driven by roll guides with ball screws for high feed forces
  • direct, absolute measuring systems (glass scales in linear axes) for optimised precision and low position tolerance
  • rotary tables with large YRT bearings and automatic clamping for maximum stability and high tilting moments
  • directly driven DDT (Direct Drive Turning) for high speeds and dynamism

Spindle units

The requirements for a spindle in milling/turning machining centres could not be more different. Milling in full operation on the one hand, vertical, horizontal and positioned turning on the other. For our C-series, we have found a solution that allows you to reliably convert power and torque into action.

Broad range of powerful 5-axis machining units

  • machining units with two kinematic variants for the 5th axis in the tool: Swivel head or tilting head
  • rigid cast iron guide slide with high dynamic stiffness and damping
  • thermal stability and precision thanks to permanent cooling: Precision cooling unit and thermal growth compensation for the spindle
  • automatic clamping of the 5th axis during machining with positioned rotary axes
  • tool shank HSK-T for maximum precision during turning
  • integrated, automatic spindle locking for maximum stability during turning operations

Swivel head kinematics

  • maximum performance in action thanks to stable swivel head kinematics
  • compact design through 45° swivel head geometry
  • high rigidity thanks to short distance between swivel head mounting and tool holding fixture
  • swivel range between C +15° to C-190° (optionally expandable with swivel range expansion)
  • energy and media routing integrated: No lines in the work area

 

Tilting head kinematics

  • maximum flexibility with complex workpiece geometries
  • simple programming and operation thanks to simple head geometry
  • A-axis driven by two swivel motors and a braced power train
  • swivel range between A +30° to A-120° (optionally expandable with swivel range expansion)
  • energy and media routing integrated: no lines in the work area

3 machining units for machines with HSK-T 63

  • speeds of up to 16,000 rpm
  • torques of up to 242 Nm (S6 40 %)
  • integrated spindle locking for turning operations
     

4 machining units for machines with HSK-T 100

  • torques of up to 1,146 Nm (S6 40 %)
  • speeds of up to 12,500 rpm
  • integrated spindle locking for turning operations

  • spindle exchange without complex adjustments
  • reduces the repair time
  • cost-effective service solution

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
     

Swivel range extension

  • swivel head from 205° to 345°
  • tilting head from 150° to 175°

* not available for all machining units

Tool management

Complete machining with one milling/turning machining centre significantly reduces the part costs. However, combined processing presents a challenge for the tool management system: an extensive range of milling and turning tools must be available and loaded precisely and safely in the process. No problem for HELLER C-series 5-axis milling-turning machining centres.

Chain-type tool magazine for fast tool provisioning

  • 4 chain-type magazines with up to 240 pockets for the CP 4000 machining centre to choose from
  • 3 chain-type magazines with up to 150 pockets for machines with HSK-T 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 terminal at the tool setting 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 425 pockets for machines with HSK-T 100 to choose from
  • rack-type magazine with 409 pockets for machines with HSK-T 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
  • convenient operating terminal at the tool setting 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

You can of course configure the C-series 5-axis machining centre to suit your particular requirements: as a workshop machine with large work area, ideally suited for single part production or as a production machine with pallet changer and the corresponding automation solution for series production.

Pallet changers are optimal for series production

  • automatic pallet changer with lifting/swivelling principle
  • high maximum payload through robust, hydraulic drive
  • optimised force application to machine pallets due to the fork shape of the lifting/swivelling traverse
  • continuously high changeover accuracy through robust aligning elements and extensive blow-out of the function surfaces
  • hydraulic pallet clamping for secure hold, even with high process forces
  • 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
  • large 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, unrestricted manual rotation
  • operating elements, as well as media guns within reach, integrated into the machine enclosure


Options

  • integrated media interface for hydraulic workpiece clamping (60 bar)
  • 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 integrated platform and low "loading edge"
  • large, divided work area door opens wide to the work area for simple setting and crane loading of large components
  • round machine table with large clamping surface and DIN hole pattern
  • main operating unit designed as a console with 24" multi-touch screen, can be swivelled between operating station and workpiece setting station
  • media guns integrated into the machine enclosure

NC rotary indexing table with rotary function

  • rotary table with direct drive for high turning speeds and a high milling dynamic
  • large YRT bearing for maximum stability and high tilting moments
  • automatic hydraulic rotary table clamping for high tangential torques
  • permanent cooling with separate cooling unit
  • automatic imbalance detection during machining
  • HELLER balancing cycle for simple setup balancing and imbalance check


Options

  • integrated media interface for hydraulic workpiece clamping (60 bar)
  • additional pneumatic functions: location check and unclamping check via media interface
  • automatic setting station door

Automatisierung

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 C-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

Fast and precise chip disposal plays a key role for milling and turning in a single set-up. Because chips in the work area impair precision. HELLER C-series 5-axis milling-turning machining centres are designed to transport chips exactly where they belong: in the chip container.

Central media supply area at the rear of the machine

  • simple maintenance with optimum accessibility, all supply units at a glance
  • compressed air and flushing gun integrated into the machine enclosure at the workpiece setting 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 60 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

  • CP 4000: free chip fall below the spindle and fast disposal from the work area with central chip conveyor
  • CP 6000 – CP 10000: chip disposal using spiral conveyors and a cross-conveyor
  • chip conveyor as either scraper conveyor or hinged conveyor, depending on the application (option)
  • steep side walls and bellow covers with self-cleaning effect prevent chip deposits
  • 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

Milling and turning at the limit calls for maximum operator performance too: he must respond flexibly to new tasks at all times, change workpiece and tools quickly, yet still working safely. When developing the HELLER C-series, then, we considered simple operation, short distances and a high degree of comfort as paramount.

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 for tough everyday production conditions
  • smooth-running doors and easily removal metal enclosure elements

Maximum operating comfort during setting and production

  • ergonomically arranged operating elements and control screens
  • swivelling main operating unit with clamping function optimally integrated into the machine enclosure
  • 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
     

Options

  • handheld operating unit
  • screen blow-off device for a clear view when machining with cutting fluid
  • main operating unit in console design with 24" multi-touch screen and HELLER Operation Interface

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 at 90° indexing with foot unlocking mechanism, unrestricted manual rotation
  • operating elements, as well as media guns within reach, integrated into the machine enclosure
     

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

Central supply area at the rear of the machine

  • simple maintenance: all supply units at a glance with good accessibility
  • 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

Combined processing is multi-tasking in metal machining – for the machine, as well as for the control. A machining centre achieves combined milling and turning at the limit only with powerful boring, milling, turning and measuring cycles. That's why, for our C-series 5-axis milling-turning machining centre, we rely on the Siemens SINUMERIK 840D sl state-of-the-art high-performance control.

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
  • HELLER Operation Interface for more comfortable operation (as standard for machines with table loading, optional for machines with pallet changer)
  • optimally integrated and adapted specifically to the requirements of HELLER machining centres with the MDynamics 5-axis technology package
  • integrated HELLER balancing function

  • standard for machines with table loading (optionally available with pallet changer)
  • 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
  • machine control panel with pushbuttons and 3 overrides for optimum control in all operating situations

  • 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 CP 4000CP 6000CT 6000CP 8000CT 8000CP 10000
Positioning range
X/Y/Z
mm 800/800(900)1)/1.0451.000/1.000/1.3001.000/1.000/1.3001.250/1.200/1.4001.250/1.250/1.4001.600/1.400/1.400
Rapid traverse speed
X/Y/Z
m/min 65 65 65 50 50 45
Acceleration
X/Y/Z
m/s² 6 4 4 4 4 4/4(3)1)/4
Positioning tolerance Tp
X/Y/Z | VDI/DGQ 3441
mm 0,005 0,008 0,008 0,008 0,008 0,008
Tool shank Size HSK-T 63HSK-T 100HSK-T 100HSK-T 100HSK-T 100HSK-T 100
Chip-to-chip time
t₂,₃ | VDI 2852
s 3,75,95,96,36,37,1
Clamping surface
Nominal size
mm 500 x 630630 x 630Ø 1.000800 x 800Ø 1.1001.000 x 1.000
Workpiece dimension
Diameter x height
mm Ø 900 x 1.000Ø 1.000 x 1.200Ø 1.580 x 1.200Ø 1.250 x 1.400Ø 1.810 x 1.400Ø 1.400 x 1.600
Clamping load kg 1.4001.4001.4002.0002.0004.000
Machine control
Siemens Sinumerik 840D sl
SiemensSiemensSiemensSiemensSiemensSiemens

( ) = optional values
- = not available
1) = in conjunction with tilting head

Downloads

heller-5-axis-milling-turning-machining-centres-c_en.pdf
Product brochure
5-axis milling/turning machining centres C
3.3 MB

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