The design of the INDEX R200 allows it to machine equivalent workpieces almost twice as fast as commercially available turning/milling centers that use only a motorized milling spindle. One motorized milling spindle and one work spindle each are assigned to one another in two subsystems located one above the other permitting highly productive and flexible machining, including simultaneous and independent 5-axis machining on both spindles.
The innovative axis arrangement produces directional kinematics, which in turn enables comprehensive and complete machining. Within the machine design the main spindle moves in Z, the sub-spindle in X and Z, milling spindle 1 (top) in X/Y/B, and milling spindle 2 (bottom) in Y/B. The result is a machine with two independent subsystems, exceptional stiffness, and impressive dynamic response. Workpieces can be machined efficiently and in parallel on the front and reverse sides.
The R200 can accomplish full reverse side machining as well as parallel machining. Both heavy-duty roughing operations and highly-accurate fine-turning operations can be performed simultaneously on the main spindle and sub-spindle.
To assure a high degree of thermal stability and vibration damping to enable machining of difficult-to-cut and high-strength materials, the R200 has a vertical cast machine bed with a heavily ribbed, enclosed modular design.
Minimum Chip-to-chip Times
Two separate shuttle units independently load the two motorized milling spindles with the HSK-A40 tools required in each case from a common chain tool magazine. With 80 or 120 places, the INDEX R200 has an extensive tool stock. Short chip-to-chip times of approximately 4 seconds contribute significantly to the minimization of secondary processing times. While machining is performed on the main spindle, the lower milling spindle can load a new tool, protected from falling chips and coolant. The results in high productivity and improves process reliability.
Powerful Motorized Milling Spindles and Movable Work Spindles
The two quill-guided motorized milling spindles are located in the center of the machine bed. This diagonal arrangement allowed the usual cross-slide to be omitted. When combined with the play-free and wear-free hydrostatic circular guide, an overall system with exceptional stiffness is produced.
The R200 exhibits high acceleration and rapid traverse rates due to the powerful drives and weight-optimized assemblies. Impressive key data, such as 11kW power and 18,000rpm, milling spindles as well as 0.9s ramp-up time (0 to 5,000rpm) make possible the high-performance machining operations.
The machining flexibility and remarkable speed of the machine are explained by the generous B-axis swivel ranges of 270 and 230 degrees and the rapid traverse rate of 45 m/min. The data for the identically rated work spindles in synchronous design include maximum power rating of 33kW, maximum speed of 5,000rpm, and peak torque of 150Nm.
Two linear tool carriers affixed to the side of each milling spindle allow fast, high-precision access to 6 stationary tools without a tool change. The exclusive INDEX W-toothing in the base of the toolholders minimizes the associated setup effort and ensures a force-locking and form-locking tool fit: this represents the optimum precondition for precise turning operations comparable to that of a turret.
Bar stock is fed by a material guide channel mounted to be moveable in the Z-direction and permanently connected to the main spindle. The INDEX SBL (Sliding Bar Loader) is designed for bar stock with a diameter of 20 to 65 mm and a length up to 3000 mm. The large material bar stock supports unmanned operation of the machine.
The Control
The current INDEX C200-4D SL control is based on the field-proven Siemens Sinumerik S840D Solution Line and has been enhanced by INDEX with user-friendly functions. Specially developed cycles simplify the most complex machining operations. They support multi-axis milling and turning operations and provide maximum functional reliability.
INDEX VirtualMachine Programming
The INDEX VirtualLine software packages support economical use of the new turning/milling center from the very first workpiece. These packages complement each other in terms of their functions and guide the programmer and operator to the right solution for the machining task: both on the PC during the preparation stage and directly at the machine in the factory.
In conjunction with the 3D simulation of the INDEX Virtual Machine, machining programs can be created, checked, and optimized on the PC. The CNC Programming Studio provides more advanced support for programming and operating the INDEX R200.
Energy Efficiency Built-in
The INDEX R200 is also designed with advanced technologies to support energy efficiency requirements: weight-optimized components for reduction of energy consumption and for increasing the dynamic response; energy recovery by means of regenerative drives; energy shutdown of units that consume large amounts of energy after a user-defined time (standby mode); minimized friction based on optimally paired materials and low-friction bearings (hydrostatic circular guide); intelligent cooling principles for targeted cooling of the machine, economical use of waste heat, or climate-neutral heat discharge from the production hall.
The cooling concept of INDEX ensures that the spindles, hydraulics, and control cabinet are cooled constantly and that the heat can be fed to another useful application via a “water interface”, e.g., for service water heating or as process heat for other manufacturing steps.