Of course, in the CHIRON Group portfolio there are a range of options for machining workpieces with up to a 200 mm diameter and a length of up to 500 mm, for milling and turning off the bar, or milling off the bar or from profile. The new 715 Series, which will be in action for the first time at the OPEN HOUSE ONLINE in June, combines all these options into one machining platform. It even includes the tried-and-tested FZ 08 S mill turn precision⁺ concept. It combines speed and precision in complete machining, rounded off with an integrated automation concept. Now, it’s one size bigger.

The 715 Series is ideal for use in the medical technology, aerospace, energy, automobile and commercial vehicle industries. Matthias Efinger, Systems Engineer R&D, says the goal during development was »to create a machining center designed for autonomous processing on all six sides, rounding off the CHIRON Group bar machining portfolio and fully bridging the gap between the FZ 08 S mill turn precision⁺ and MT 733.«

The benefits at a glance:

• Multifunctional machining in one machine

• One unit comprising a base machine and workpiece automation

• Short lead times and high level of autonomy thanks to six-sided complete machining

• Full turning function thanks to rotary spindles and a clamp-able milling spindle with 20,000 rpm

• Direct-drive torque swivel head, optimized for five-axis simultaneous machining

• Opposed spindle with identical power to the main spindle for machining on the back

• Automation with bars up to Ø 65 mm or chuck parts up to Ø 200 mm, maximum workpiece weight 20 kg

• Storage capacity for up to 128 tools

• Loading and unloading of the tool magazine during machine operation

• Ready to integrate SmartLine

This one or that one? The perfect machining model
There are two versions of the new series: MT for Mill Turn, MP for Multi Profile. Both versions have four configuration stages for milling and turning operations in any order. The swivel head, rotary spindle and opposing spindle enable continuous multifunctional machining on all six sides. Both ensure high reliability and quality, for example for hip stems, turbine blades, extrusions for chassis or battery storage.

The best conditions for high levels of automation
Both versions of the machine offer integrated workpiece handling and a magazine for up to 128 tools to allow automated manufacturing of workpieces in small and medium batches. Paired with the vigor you expect from CHIRON, with additional unmanned shifts – late shift and weekends – the productivity of the system can be greatly increased while simultaneously reducing costs.

Presentation at the OPEN HOUSE ONLINE
The new series will make its first appearance in June at the OPEN HOUSE ONLINE. At the OPEN HOUSE, the CHIRON Group will go in-depth on all of the MT 715’s highlights and show the machining center live, in action.

For the last five years, the Micro5 has been leading a small revolution in the dynamic and highly precise world of machining tiny medical instruments, delicate jewelry and the most intricate watch parts. The FACTORY5 five-axis machining center is extremely compact and can be set up very quickly almost anywhere – in the production hall or right at the work station. The »5« in the name stands for the ideal 5:1 ratio of machine size to workpiece, for five times lower weight, and for maximum efficiency. Energy consumption is 50 times lower in comparison to conventional systems.

Example applications

Taking on user feedback
The prototype CNC machine was first presented »en miniature« at the SIAMS 2016, Swiss trade fair for micro-technology production tools. Two years later, Samuel Vuadens’ team tried out the first Micro5 machining center in full industrial operation with five (!) customers. Now, 25 machines are producing high-precision components and the customers are always in discussion with CHIRON Swiss, supplying valuable feedback which often leads to new functions and optimization which benefit all users.

… from 50 rounds of optimization to the current Micro5 generation
The newest generation of Micro5 has undergone more than 50 improvements, small and large, enhancing its practical reliability, efficiency and autonomy. The double-torque spindle is key for higher efficiency operation. This helps reduce the machining time, which is already considerably shorter than larger machines.

Early users were particularly keen to achieve increased autonomy – they wanted the Micro5 to allow automatic loading for higher production capacity. We responded with the Smartfactory Project. This is a complete production line which is fully scalable in all aspects to meet specifications.

The Feed5 automatic handling system
Feed5 is a six-axis handling robot which can load and unload the Micro5. The new module acts as a fully automatic guide for workpieces and tools. As compact as the Micro5, the Feed5 is particularly useful for enabling increased autonomy and productivity for bigger series. The handling system equips the machine and the tool change takes less than five seconds. The maximum workpiece size for the Micro5 is 50 x 50 x 50 mm (L x W x H).

The newest generation of the Micro5 and the Feed5 handling system are premiering at the OPEN HOUSE ONLINE from June 15 to 18, 2021. The Micro5 has been in operation at the CHIRON Group Medical & Precision Technology Center machining park since November 2020. According to Ronny Elsmann, Head of CNC Application Technology, »it’s impressively proving its quality in dynamic, high-precision micromachining.«

The Micro5 is also a highlight on the »micro on tour« show truck – stopping off at four locations in Switzerland from August 30 to September 10. On board you’ll find nine partners, who are holding video and product presentations, as well as talks and personal discussions about innovative solutions and services in precision manufacturing.

In 2020, more than 1.2 million electric cars and plug-in hybrids were sold – around a 15% increase on the previous year. According to a recent report by the Center of Automotive Management (CAM), China is increasingly becoming the mainstay customer of the transforming automotive industry. The Electromobility Report 2021, by industry news outlet electrive.net, also says »China is not only the largest global car market, which [...] has recovered best from the coronavirus crisis. The country is also the most important market for electric cars, enabling new players to enter the premier league of global car manufacturers. Above all, the domestic players are showing enormous flexibility and dynamism with new future-focused topics.« In Europe too, the turnover from plug-in hybrids and fully electric cars is growing rapidly compared to the downward trend of the market overall. Norway is in pole position, where 87% of all new vehicle approvals in December 2020 were plug-ins. The regulatory requirements on pollutants and sinking battery costs are helping drive the development of the e-mobility sector.

Less air traffic, smaller vehicles
China is also seeing growth in the aviation sector. The country now has over 50 international airports and an additional 150 for domestic travel. The large state airlines significantly built up their fleets in 2020; the five-year plan announced at the 13th National People’s Congress, particularly demanded development and construction of jet engines. The development across the rest of the world is more complex. In 2020, consultancy firm Roland Berger drew up three different scenarios on the effects of the COVID-19 pandemic and the further development of the global aviation industry by 2030.
Scenario 1: A quick recovery by winter 2020. Scenario 2: Delayed Cure with a 27% reduced demand until 2030 and the lower air traffic density effecting the product mix. In the future, smaller models will be most in demand, to make flying on certain routes profitable even with lower passenger numbers. Scenario 3 – which is now the most likely – is a significantly recessive development. This would include the »new normal«, a low level in summer 2022, and a 50% reduction in demand. This »new normal« also presents a challenge for suppliers. Operational processes have to be reduced further and designed to be more efficient. The aviation industry also requires innovative solutions to halve the CO₂ output, as planned, by 2050. The solutions may be in new drive technologies.

With this backdrop – rapid growth in e-mobility and changed market conditions in aviation – the highly productive machining of large components is gaining significance for both sectors.

Automotive

Aerospace

Large, larger at the largest: Two spindles for maximum productivity
600, 800, 1,200 mm: With their graduated spindle clearance, the three series are precisely designed for the various workpiece dimensions and cover the whole range of sizes and complex components for automotive and aerospace applications.

The common denominators for the double-spindle machining centers include: Significantly shorter cycle times, optimum component quality, high level of flexibility and a portable-sized rigid machine board for the required precision. The large magazines ensure the productive machining of demanding workpieces or product series, and the loading and unloading takes place during regular operation. All machining centers can be configured to customer requirements, and a coolant system or chip conveyor (and more) can be added depending on the use. For increased utilization, the system can be expanded to be fully automated. All series are ready to integrate the SmartLine digital systems for optimized processes at the machine, in the environment, and in your company.

Process advantages

• Double-spindle, highly productive machining of large components

• Rigid machine base with a gantry or mobile gantry construction ensures high precision 

• Process easily visible thanks to separation of the operating and loading sides

• Lots of tool options for versatile machining

• Tool change during main operation

• Independent tool change for each spindle for short chip-to-chip times

• Compact, flexible machine layout

• Intuitive operation via TouchLine

• Easy automation via robots or gantry

With the DZ 22 W five axis with a spindle clearance of 600 millimeters, two different main spindles can be used depending on the task at hand. The quicker spindle with an RPM up to 20,000 min^-1and a torque of up to 110 Nm is ideal for aluminum or aluminum-alloy workpieces. The stronger spindle with up to 12,500 min^-1 RPM and a torque of up to 200 Nm is best for hard materials and large tools. High axle acceleration and efficient rapid traverse ensure the required dynamism. The 22 Series 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.

The spindles on the DZ 25, with a spindle clearance of 800 mm, and the DZ 28 with 1,200-mm spindle clearance, can traverse independently in X or Y direction – this makes it easy to offset inaccuracies in tool pre-settings and with the clamping devices. Operating and loading take place on separate sides with easy access to the working area, and the same is true for the DZ 25 P five axis and DZ 28 P five axis versions with pallet changer for high piece turnover and short cycle times.

At a glance

A customer survey carried out last year confirmed, that the pre-configured machines in the baseline Series are in high demand and, especially in the contract manufacturing sector, customers wanted more models. Whether being used in the aerospace, automotive sectors, mechanical engineering, medical technology, precision technology or tool manufacturing, the situation regarding orders is noticeably improving, often up to or beyond the capacity of the firm. And that’s precisely where the models come into their own, with short supply times, an attractive price and proven, state-of-the-art technology

Three strong new contenders
A new entry from the 08 Series is the FZ 08 S five axis baseline, one of the most versatile machining centers in the compact class. It’s quick to set-up, easy to operate, very stable and highly dynamic when machining. There are also two additional models from the MILL Series. The MILL 2000 baseline, with a 2,000 mm travel path along the X-axis, is ideal for machining larger components or multiple clamping positions. With its swivel head, the MILL 2000 baseline offers increased freedom and a range of application possibilities. In combination with a round-table package, it can be used for five-axis machining of large workpieces. As well as the three new models, the FZ 15 W baseline is now available with both a basket and chain magazine.

baseline »to go« – in the CNC Outlet Center
Since October 2020, the CHIRON Group has also had a hub in the CNC Outlet Center in Olching, Germany. The hub is just a three-minute drive from the A8 highway – exit 78 towards Dachau-Fürstenfeldbruck. Here, you can browse a range of machines including the FZ 15 W baseline. The demo-machine is available immediately, in top condition, and ready to operate within two to three weeks. The complete range of currently available machines can also be seen online, on the  exhibitor website.

For Matthias Rapp, Head of Area Sales for Germany, Austria and Switzerland at the CHIRON Group, the Outlet Center is »a new and interesting sales channel and a fantastic opportunity to reach a wider audience of potential customers with the baseline Series for classic machining.« As well as exhibiting the machines, the Outlet Center plans to hold lectures and machining seminars, although all events are still on-hold due to COVID-19.

More orders than machine capacity?
You can find information on all machine types in our new brochure »CHIRON baseline – Proven top technologies  available at short notice«. You can also get in touch with Matthias Rapp to discuss your requirements and orders via phone or email.

The more productive a machining center is in manufacturing components, the more economically and thus sustainably the resources of space, energy and raw materials can be used. That much is clear, at least in theory. But what does that mean in practice? When is a machine particularly productive?

When the cycle times are significantly shorter, for example. The 16 Series operates approximately 20 percent faster than the predecessor series. A customer needs fewer machines, less space and fewer peripheral devices - for example for a coolant supply - for the same output. Production is more efficient, and therefore more sustainable, if multi-spindle systems are used instead of single-spindle devices: »Our stated objective is for a double-spindle machine such as the DZ 16 W or the STAMA MT 733 to produce two workpieces in the same time that a single-spindle machine needs for one workpiece – of course with the same high quality standard. The reduced requirements for space, energy and investment costs compared to single-spindle machines are very attractive for our customers,« says Dr. Claus Eppler, CTO at the CHIRON Group. 

Automatic tool changes, workpiece changeover via a pallet changer or a tool change unit as well as loading and unloading the magazine in parallel contribute to the short cycle times which can be implemented for example with the CHIRON 16, 22, 25 and 28 Series and with the STAMA MT 733. Sustainability is also reflected in a variety of other technical solutions which add up to considerably more energy efficiency.

Automated machining opens up further potential
»The constantly increasing use of automation solutions is an important trend in manufacturing,« states Dr. Eppler. »Ideally, several machines are operated by one employee, in the best case scenario in just one or maximum two of three production shifts. The night shift - unpopular with the staff and expensive for the company - should run on its own, in a manner of speaking.« This can be achieved with an automation solution like the VariocellUno. Digital monitoring and messaging functions make it possible to have disruption-free, highly efficient production even in autonomous operation.

Digital assistance saves resources – across the board
Thanks to the digital systems of the SmartLine portfolio and SmartServices, the CHIRON Group provides the best support throughout running operation and ensures additional efficiency, availability and productivity of the machining centers. And as for saving resources cross the board: servicing procedures at one site can be combined and scheduled for a single date. Disruptions can be rectified from afar thanks to remote support, thus avoiding travel – along with the associated CO₂ emissions. The running-in times and commissioning of the actual machining centers are also decreased due to virtual machine commissioning and simulation of customer processes.

Repair instead of replace – thanks to the AM Cube
The AM Cube, the first 3D metal printer of the CHIRON Group, has so many good features, as Axel Boi explains in the following video clip.

One of these positive features is sustainability: larger components can be assembled directly and precisely in the customer's production line without the otherwise high material costs, without long procurement times and environmentally harmful transport. Components are protected from corrosion and wear if they are coated using laser deposition welding procedures, they last longer and release fewer harmful substances - for example, abrasion from brake disks - into the environment. In addition, the AM Cube is ideally suited for repairing parts – another advantage in view of sustainability with manufacturing solutions of the CHIRON Group.

Dr. Nicole Hoffmeister-Kraut, Minister for Housing, Work and Planning for the Federal State of Baden-Wuerttemberg, was extremely interested in sustainable manufacturing solutions and retrofits for longer machine service life during her visit at the CHIRON Group. The minister was a guest in Tuttlingen at the end of July as part of her transformation trip.

Preserving values, saving raw materials: retrofit instead of new purchase
Sustainability also means preserving values. A machining center from CHIRON or STAMA brand represents such a value, even if it has been in operation for many years.

The life cycle of existing machines can be increased with a retrofit solution from CMS – and not only that: all important elements such as drives, main spindles and control are reconditioned, which means the systems manufacture 30 to 40 percent faster than before. At the same time, the energy requirements decrease: the thermal energy from the cooling circuits can be fed into the customer's central water circuit, special drive motors feed any energy that has been generated but is not required back into the mains supply. The greatest potential for savings provided by a retrofit is with the raw materials at 75 percent, compared to a new purchase. The most important factor for the customers - along with the lower investment costs - is the delivery time: already modernized machining centers from the CMS portfolio are available in just two weeks, a customized refurbishment is completed in six to 12 weeks.