The hydrostatic Z-Axis extends the turning length of the 5-Axis “UniCen 1000″ Turning/Milling Centre to 2500 mm, so that it can also machine large axles and shafts without any problems. In Dusseldorf, Monforts is showing a first operational prototype. A second “UniCen 1000″ with 1500mm turning length is in operation. The most versatile machine of Monforts can turn, mill and bore with up to 90 tools in a swivelling range of 190°. It is especially suited for machining hard to machine materials such as e.g. Nickel base alloys, which are used typically for turbine components. Monforts is demonstrating the production of so called blisks (blade integrated disks) for turbines, which create especially high requirements for rigidity and accuracy in the machine.

Complete machining in one set-up

Complete machining including hardening is shown by Monforts at the Metav with the “RNC 400 LaserTurn”. Conventional soft machined parts are hardened with a laser, which sits in a standardised VDI-40 interface llike a conventional machining tool. Finally, hard turning is performed in the same set-up – it is no problem for the Monforts machines thanks to the especially rigid and vibration dampening hydrostatic column guide.  As a rule, the part removed from the machine is complete and requires no further machining. The advantages: shorter production cycles, lower logistics costs, better machine utilisation and, last but not least, a higher product quality as all processes run automatically without changing the set-up.

The laser can also be used to even machine ceramic materials such as silicon nitride, which until now were only able to be ground. In this process the laser softens the component directly prior to machining to the point that the material can be machined. With surface roughness of Ra = 0.2µm it is therefore seldom necessary for further machining. Compared to grinding it saves substantial time and costs.

High precision large components

A typical application for Monforts machines, with their rigidity and longterm accuracy, is the manufacture of wind turbines. As a result, many machines of the “RNC 700″ type are already in use, on which the Belgian wind turbine manufacturer Hansen Transmissions manufactures the bearing seats of their gear shafts. The seats are so exact that they are even used as the reference point for further shaft manufacturing processes. Monforts will also demonstrate how these shafts are machined at the Metav.