The BTU Center for Hybrid Electric Systems Cottbus (chesco) conducts research into climate-friendly mobility of the future with a focus on aerospace. It develops, tests and optimizes new, sophisticated materials and component geometries, going through a large number of development and design loops. It produces prototypes and pre-series using a combination of different processes – including 3D printing, laser cutting, punching and, as a rule, milling.

At the Hammerwerk Fridingen, on the other hand, they work on parts production for forging tools and series production with high cutting performance of components for engines and chassis. For the mobility of today, for customers from Automotive, Non-Automotive and Off-Highway.

The applications could not be more different. And yet both customers opted for the FZ 19 S five axis, the first machining center in the new 19 Series, even before it was launched on the market.

Senior Product Manager Markus Vollmer says this shows that »Our development strategy was exactly right. We wanted a machine with universal application possibilities. Flexible, of course. But that's what everyone is counting on. We have equipped the FZ 19 S five axis with the necessary power to precisely machine materials such as Inconel or titanium. And with the corresponding milling performance and dynamics to also manufacture series highly productively on a single-spindle machine in a compact space.«

Another key advantage of the FZ 19 S five axis: With 700 mm travel in Z, the working area is designed to be ideal for 5-axis simultaneous machining of workpieces with a cubic capacity of up to 580 mm or cylinders up to 820 mm in diameter and 700 mm in length. The first machine variant of the new series is also available with an HSK-A100 interface and a maximum spindle torque of 408 Nm for machining components from blanks, for example for aerospace applications.

As with all CHIRON Group machining centers, the modular design allows individual configuration exactly according to requirements. For example, with motor spindles developed and manufactured in-house, various rotary table packages and tool magazines in three sizes each for the HSK-A63 and HSK-A100 interface, with capacity for 36 to 196 tools.

The highlights at a glance

• Precise, flexible and high-performance production

• Machining a wide range of materials, from aluminum to titanium alloys

• Up to 196 tools for highly complex workpieces and parts manufacture involving a wide range of variants

• Low thermal expansion of the machine thanks to actively cooled components

• High dynamic and static rigidity – the machine bed has a mobile gantry design

• Gantry rotary axes with torque direct drive, without backlash from gearbox

• Tool set-up during operation for maximum output

• Easy access for set-up, automation and crane loading

• Established, high-performance control technology: Siemens SINUMERIK ONE or Fanuc 31iB5

• Intuitive operation via TouchLine for safe user guidance

In addition, the 19 Series is prepared for the integration of all SmartLine digital systems – keywords: advance simulation and optimization of machining operations, condition monitoring, preventive machine protection. »At BTU chesco, for example, the software systems are used to prepare the experimental processes for industrial use,« explains Till Oeschger, Project Manager at the CHIRON Group. The open platform Industrial Edge from Siemens can also be integrated.

Would you like to know more about the new FZ 19 S five axis or the FZ 19 S mill turn variant, which can also be used to productively implement turning applications for large and heavy workpieces? Get first-hand information at AMB 2024, Hall 10, Stand A51.

You can find out more about the new series here.