Photo: Jürgen Jeibmann / Fraunhofer IWS Dresden

Premiere in May: CHIRON Group presents first 3D metal printer

Adding material instead of removing it: Additive manufacturing processes are increasingly finding their way into industrial manufacturing. The CHIRON Group's focus is on the technology of laser deposition welding. This is the basis for the AM Cube 3D printer for producing large, complex components. The AM Cube will be presented for the first time at the OPEN HOUSE ONLINE in May.

AM for additive manufacturing, Cube for the shape: This is how the first 3D printer from the CHIRON Group got its name. According to the objective of the development, the AM Cube should be very versatile: It can be used to produce semi-finished products, repair components or apply coatings. It should also be "easy to use" and be used predominantly in mechanical engineering, tool manufacturing, energy production and aerospace.

This is exactly where the particular challenge for the CHIRON Group's Additive Manufacturing team lay. They had to design a practical solution for the industrial use of laser deposition welding, which would meet the customers' high requirements. But there is currently no magic formula for either the best possible process or the ideal materials – such as the quality of the powder or the properties of the welding wires. A further focus was the safety-technical equipment of the system. The required expertise to develop a convincing solution from the still young technology, was and is being significantly built up and further developed by the CHIRON Group.

Modular platform

To ensure that customers can use the AM Cube in a variety of ways, the team working for Axel Boi, Head of Additive Manufacturing, developed a platform: A five-axis system for the construction, coating and repair of cubic components and a four-axis system for shaft processing. All core components are fitted to the base with a modular design and are housed in a laser-proof and gas-tight cab. Peripherals such as the laser source, wire feeder, cooling system and control cabinet are positioned outside. The modular design allows for adaptation to specific customer requirements and also further variants in future too, such as with automation solutions.

AM Cube put to the test

With the Swiss company Stellba AG, the CHIRON Group was able to win a pilot customer that couldn't be more suitable: Stellba repairs and coats components of water, steam and gas turbines and has a lot of experience in the fields of coating, additive metal processing and laser welding, so it's the perfect customer to put the AM Cube through its paces under real production conditions.

… and at the OPEN HOUSE ONLINE

Who would like to know more: Axel Boi is gladly available for a consultation. On request also in direct user dialogue with Fouad Cheaitani, Customer Support and Business Development at Stellba. Axel Boi also presents the AM Cube outside the OPEN HOUSE ONLINE on site in Tuttlingen. As soon as circumstances permit, we look forward to a personal meeting. Please contact us to arrange an appointment.

Axel Boi, Head of Additive Manufacturing
Tel. +49 7461 940-3871
axel.boi@chiron.de

Axel Boi (left) and Fouad Cheaitani (right) from Stellba are looking forward to the professional dialogue with you.

Repair of a turbine blade using laser deposition welding

Technology at a glance

Wire-based laser metal deposition

With this technology, the laser steel melts wire and the base material, the melt joins together and hardens. This enables complex geometries to be created, as the workpiece is built up layer by layer. The laser is flexible and suitable both for fine surfaces and large build-up rates. The material feed in the AM Cube is performed via a coaxial process control with wire, which can function in all directions. In contrast to powder-based laser metal deposition, the material supply is clean and ensures that all of the material reaches the melting area. To prevent oxidation, the deposition process is performed in a closed system with protective gas.

Precise or dynamic machining of large components? Preferably: Both!

High precision, dynamics, and the best surface quality: The twin-spindle DZ 16 W has set new standards in the machining of complex workpieces in large quantities. This standard is leading CHIRON into a new dimension: With the new series 22 and spindle clearance of 600 mm, even large workpieces can be manufactured just as precisely and dynamically. For the first time, CHIRON will present the DZ 22 W five axis at the OPEN HOUSE ONLINE in May.

Housings for electric motors and transmissions, oil sumps, chassis components: Just like for large high-precision mechanical products, such as cooling elements or distributor housings, the following used to be true: High precision takes time. And high dynamics come at the expense of precision. The new CHIRON series 22 tackles this contradiction convincingly.

The basis for the innovative machine concept with small footprint of around 25 m2 is – like series 16 – a machine platform in a moving gantry design. The rigid machine bed and active component cooling enable the required degree of precision on the workpiece. High axis acceleration and fast inputs ensure dynamic machining as never before seen with workpiece dimensions of this size.

In addition to precision and dynamics, series 22 also offers impressive flexibility. From very complex workpieces or product series with many different tools: The magazines offer space for up to 77 pieces and, thanks to the integrated workpiece changer, the workpieces are loaded and unloaded during machining operation and therefore extremely productively.

Two spindles – one fast, one strong

Depending on the processing task, two different main spindles are used in series 22: One fast spindle with a speed of up to 20,000 rpm and a torque of up to 110 Nm for workpieces made of aluminum or aluminum alloys. And a strong spindle with a speed of up to 12,500 rpm and a maximum torque of 200 Nm for hard materials and large tools.

Facts and figures

  • Travel distances X-Y-Z max. 620-650-600 mm
  • Spindle clearance 600 mm
  • Spindle speed 12,500 rpm / 20,000
  • Spindle torque up to 200 Nm / 110 Nm
  • Axis acceleration X-Y-Z max. 10-10-17 m/s²
  • Rapid traverse speeds X-Y-Z max. KGA 75-75-75 / LDA 120-120-90 m/min
  • Number of tools max. 2 x 77 pieces
  • Automatic tool replacement 3.5 s

Workpiece dimensions

  • Four-axis version (per working field) Dia. 680 mm x 1,330 mm, up to 600 kg
  • Five-axis version (per working field) 2 x Dia. 599 mm x 340 mm, up to 150 kg

Impressive on all counts

The working areas is easily accessible, and the process easy to see thanks to the large glazed doors. The control panel is located directly next to the working area, making set-up easier. The new machines are operated easily and according to context via the TouchLine operating system.

On the back, the tools are inserted in the chain magazine, and the tool data can be entered here directly via the operating console.

Tool replacement is carried out during machine operation; the new tool is clicked into the magazine with a single movement of the hand.

Modular design for application-oriented configuration

Series 22 is available with two drives: A ball screw drive or a linear direct drive. You can also choose from two plate variants: A suspension plate for four-axis machining or two face plates for five-axis simultaneous machining. All models can also be supplemented according to the application – e.g. with a cooling system, suction unit, chip conveyor, individual tool packages. To increase the degree of use, the specialists at CHIRON develop individual automation solutions together with the customer.

Even better with SmartLine

To tap the full potential of digitalized production, series 22 is prepared for the integration of various SmartLine modules – for a clear plus in terms of productivity, product quality and machine availability.

ConditionLine: Early detection of non-typical operating behavior and targeted planning of maintenance and repair

ProcessLine and ProtectLine: Reliable protection against machine crashes with a digital twin, both in preparation and during running operation

Presentation at the OPEN HOUSE ONLINE

The new series celebrates its premiere in May in a new way - at the OPEN HOUSE ONLINE. Here, CHIRON will inform you about the highlights of the DZ 22 W five axis and demonstrate the machining centre live under cutting.

You want to know more about the precise and dynamic machining of large components in advance?

Kristoffer Siegmann, Head of Global Account Management Automotive is looking forward to your call or e-mail.

Kristoffer Siegmann
Tel. +49 7461 940-3074
kristoffer.siegmann@chiron.de

FZ/DZ 25: The new standard for large components

The new CHIRON 25 series is designed to be compatible with the high-productivity machining of complex, large-volume structural components for the automotive industry and aviation. The entire process is easily accessible and completely viewable – a novel feature for workpieces of these dimensions.

»The new FZ/DZ 25 series combines productivity, precision and flexibility at previously unknown levels. With a spindle clearance of 800 millimeters, the DZ 25 P five axis is predestined for the twin-spindle machining of vehicular and structural components made of aluminum for electromobility,« says Bernd Hilgarth, Sales Director at CHIRON.

Click below for the full interview with Bernd Hilgarth on the 25 series at EMO:

The benefits at a glance:

  • Twin-spindle machining of large-volume components
  • Optimum dynamics
  • Best access to the working area
  • Independent X- and Z-axis compensation
  • Process clearly viewable thanks to separation of control side and loading side
  • Compact, flexible machine layout
  • Intuitive operation via TouchLine
  • Automation via robots or gantry

Product-video

Six-sided milling and turning in one set-up: MT 733 one plus

Machining all six sides in one working cycle and completely milling and turning the workpiece at just one center: This is what STAMA's MT 733 series is all about. The MT 733 one plus for the flexible and precise complete machining of chuck parts had its world premiere at EMO.

Better complete machining: Based on this principle, STAMA developed the MT 733 series for complex components and materials that were difficult to machine. The MT 733, built with a portal design as all other models in this series, one plus could be seen in live operation. Equipped with real-time tool monitoring, linear direct drive on the Y-axis, a 20,000 milling spindle and integrated automation via H portal loaders, the MT 733 one plus, in live operation, carried out simultaneous five-axis machining of toothings using with a 55% milling ratio and a 45% turning ratio on a stainless steel workpiece, and of high-precision spherical shapes. A convincing performance for a successful first-part good-part strategy.

Gerhard Ulmer, Sales Director at STAMA, explains the strengths of the new machine platform:

STAMA MT 733 one plus in the variation for chuck parts with diameters up to 250 mm. Good for the complete machining of complex components and materials that are difficult to machine.
STAMA MT 733 one plus in the variation for chuck parts with diameters up to 250 mm. Good for the complete machining of complex components and materials that are difficult to machine.