Now available from Hinckley-based 2D CNC Machinery Ltd (www.2dcnc.co.uk) is the German-built Alzmetall GS 1400/5-FTD five-axis bridge-type machining centre; this can undertake a complete in-cycle production sequence involving 3-D turning, boring, milling, contour milling and five-sided machining on complex components — including those with customised gear forms.

High levels of precision, contouring form and geometry are aided by the machine’s patent-pending ‘4-Guideway System’, where the bridge is carried inside the machine’s structure (the more traditional method is to mount the bridge on top of the side supports, with just two guideways).

The 4-Guideway System allows the machine to maximise the benefits of the latest control software technology.

For example, when producing customised gear-tooth forms, such as those found on compact double-helical herringbone and bevel gears, the machine can automatically compensate for factors such as residual deviation found within the workpiece material.

This compensation is achieved by means of the Heidenhain TNC640 control with its Load Adaptive Control (LAC) package. LAC can optimise control parameters and ensure that any potential deviations or minor errors in the cycle are held within 10µm.

Furthermore, while the C and A axes can be sensitive to varying machining loads and ‘moments of inertia’ that reduce contouring accuracy, by incorporating LAC parameters in the control, such as for 3-D tool radius compensation, optimised responses are provided to any variation in the loading of the rotary axes.

LAC automatically determines the load and sets the optimum parameter, from which it continuously adapts the process.

This capability not only helps to reduce cycle times but also provides a higher level of dynamic accuracy, which helps the machine to undertake turning and boring sequences — as well as the finish-milling of gear forms — in a single operational sequence.

Weighing in at 31 tonnes, the GS 1400/5-FDT has a work envelope of 1,200 x 1,300 x 800mm, a rapid traverse of rate of 82m/min in each axis, and a positional accuracy within 5µm.

The A axis offers ±140deg, while both the swivel and rotary axes are powered by direct-torque drive motors.

The spindle is rated at 82kW (500Nm of torque) and has a maximum speed of 14,000rev/min.

The tool magazine, which offers options between 33 and 250 pockets, accommodates tools up to 125mm in diameter (250mm with adjacent pockets left empty). These can be exchanged in a chip-to-chip time of 7sec.