Pama Vertiram 2000 gt BORING AND MILLING MACHINES AND MACHINING CENTERS

 BORING AND MILLING MACHINES AND MACHINING CENTERS PAMA
the paгtner for demanding customers 

The Company's corporate credo, "A Generation Ahead by Design" has guided Holtec's business initiatives since the company's founding in the mid-eighties
Holtec lnternational has been in business for over 30 years, it is a diversified energy technology company. The company is widely recognized as the foremost technology innovator in the field of carbon-free power generation, specifically commercial nuclear energy and it is a major player in the engineering and manufacturing of large cask for the nuclear waste industry. Holtec manufactures both transport and storage casks. To
meet its expanding business needs, Holtec has built a 50 acre state-of-the art Technology Campus on the Delaware River in the city of Camden, NJ. The new Campus houses it's corporate office, a 330,000 sq. ft. (30.00Omq) manufacturing facility and a
50,000 sq. ft (5.000 mq) warehouse with future expansion to include, a reactor test
loop and several auxiliary buildings to support the ongoing development of Holtec's
small modular reactor, SMR-160.
The Company's corporate credo, "A Generation Ahead by Design" has guided Holtec's
business initiatives since the company's founding in the mid-eighties. In practical
terms, it means meeting the emerging needs of the industry through innovation. This credo has also guided Holtec in the choice of the manufacturing equipment for their new
Campus. 
Mr. Greg McGann, Holtec's Procurement Mgr.
says: "All of Holtec manufactured equipment is very large. Our cylinders range anywhere
from 8 to 12 ft (2,5 - 3,5m) diameter with an overall length of up to 240 inch. (6m). We
are also looking at sma11 modular reactors as a new product which from our initial design
will be roughly 12 foot (3,5 m) diameter by 95 ft. (30m) 1ong. The designed weight is
approximately 375 tons. We will make that in sections. So the equipment was selected
with the intent of being capable of machining the size components we have but most
important to provide Holtec with best technology for world class manufacturing operations.
All shop areas are serviced by bridge cranes ranging from 50 to 200-ton capacity. Heavy
machining is performed on CNC vertical and horizontal milling and boring machines. HMD employs the latest technology in water jet cutting, laser cutting, grit blast and painting in an environmentally controlled autonomous in-shop paint facility. Nondestructive testing capabilities include the entire gamut of inethods used in the metal fabrication industry, such as liquid penetrant, magnetic particle, radiographic, helium leak, hydrostatic, ultrasonic, load and functional testing. In addition, the factory is served by a proven array of subcontractors who provide a multitude of services ranging from laboratory testing services to laser metal cutting.
Most materials we deal with are high strength carbon steel as well as stainless 304/304L and 316/316L steel. With the wide variety of components and features we have, we
needed extremely flexible and multi-tasking equipment therefore we chose a twin column Speedram 3000 floor type HBM with 3 separate work zones, a central floor plate
(15x28ft - 4500x8500mm) fully usable by each column, with a 100T roto-traversing tab1e (13x13 ft - 4000x4000mm) on each side
and a Vertiram 3000 GT MC."
Gantry machine has followïng features: X travel 40ft. (12m), distance betwéen columns 12ft. (3,6m), clearance under the spindle 13ft. (4m), crossrail travel W 8,5ft.
(2,6m) and ram travel Z 6,5ft. (2m). A unit turning table (dia. 100 inch. - 2500mm,load capacity 18 Ton) completes the configuration to guarantee a real multitasking.
Hydrostatic support on all axes including ram and rotary tables is standard on these
machine, providing superior rigidity and vibration dampening. Both maćhines are
equipped with several automatic head attachments (all which are interchangeable
between the two Speedram columns) to provide maximum flexibility and extend machining capabilities. We purchased the universal heads, right angle heads for both machine. The Speedram also has a speciaί gun drilling attachment for future production of
the tube sheets. Almost all the head attachments come with automatic tool change capability as well as internal coolant.
To help us in effectively maxìmize the utilization of our resources we also purchased
the PR2 suite which will help manage tools & part programming for all machines, both
Pama and other machine tool suppliers in our manufacturing facilities.
Given the magnitude of the ìnvestment and the complexity of starting from a green
field, the Pama team has worked with us on all the steps of the way to insure a successful outcome of the project. The installation team has also done and is continuing to do
a great job. The people here have been very professional and efficient.

HS-DIE
The SPEEDMILL it is not strictly a milling machine we can use it as an all-around and a finishing machine also.

H.S. Die is one of the premier tool & die manufacturers in Michigan, Harold Steele founded the company back in 1968. He started it out of the garage ìn his back yard and
progressed up to current size. H.S. Die now comprises of 3 facilities with about 150.000
square feet: a main and a satellite machining facility and a stamping trial facility.
Mr. Terry Carr, P1ant Supervisor, says "this configuration allows us to provide our customers with a complete product. We design it here, we machine it here, we set it up and we can sample it here. So we can do everything for the customers and that's
great."
He continues: "We have had a lot of machines in here - over 100 machines. We used
to have an old FPT machine, similar to the
SPEEDMILL which has now taken its place.
Amongst the most important reasons which made us decide to buy the SPEEDMILL are:
that fact it has a great dynamic control and that it has an enormous configuration flexibility, in our case we specified it with three separate automatic attachment heads, a 20k rpm high speed full 5 axis contouring head with extended spindle nose for deep
pocketing, a 50kW 3+2 continuous universal head and a 70kw straight milling extension
that allow us to do pretty much everything on the machine. We also specified a 50ton
(3000x3000mm with V=2000mm) fu11y hydrostatic roto-traversing table, to minimize
set up and streamline our workload. Also to be noted, the fully hydrostatic large size ram
(440x480mm) with a 73kW [S1] -6000rpm Direct Drive spindle. On our SPEEDMILL we
can do almost every tool or die from the start to finish, and being able to carry out at
a minimum of 80 % of the operations on a part on a single machine helps us to achieve
extremely high quality. It is also more efficient, we do not need to move from machine
to machine. That helps us a lot, we can start out with a raw block, rough it, semi finish it
do all the ancillary work to it, and with the five-axis head we can push it to the limit and
finish it.
The SPEEDMILL it is not strictly a milling machine we can use it as an all-around and
a finishing machine also. It is completed by a Heidenhain CNC control. It's a very sophistìcated control, we like it for finishing, especially for 5-axis operations. Again to
maximize flexibility, the SPEEDMILL is also configured with a 120 pockets tool changer
capable of handling both CAT50 and HSK63 type holders allowing automatic tool change
on every head attachment, which is again a great feature covering both roughing and
finishing. We have put a very experienced operator with solid craftsmanship to take
advantage of the machine capabilities, we are still learning, but we are sure planning to utilize the machine at the fullest of its possibilities.
Being a fairly recent installation, we don't really have sufficient data yet to confirm what we think is going to be a much more efficient and productive machine based on the results we have experienced so far. To complete the configuration, there is also a
floor plate that was incorporated in the machine from the previous installation since we
were able to reutilize the existing machine foundation with just minor changes. The
combination of rotary table and floor plate allows us to machine any size parts that we may run in this plant irrelevant of the industry they may be for: automotive, etc.
The load capacity and the work envelope (X=10000mm, Y=3000mm and Z=1600) of
the SPEEDMILL are also putting us in a very enviable position since not many shops have
large capacity machining this providing us with extra opportunities to do subcontracted work for other corporations which we did
not necessarily have before.
For the most part our production is molds: stack molds, blow molds, compression
molds and structural foam molds. We do a
Lot of plastic injection molds, a lot of panels, a lot of door handles, a little bit of ATV personal vehicle, a little bit of everything, but mostly in the automotive field. In general
parts we do require a lot of 5 axes work for 5-axes but also a lot of other boring, drilling, reaming etc. operations.
Our typical process follows these steps, first we rough the part, then we set it up and stress relieve it, continuing with heat treat, the part is then brought back to the machine, where it is checked and finished.
In the past at this point going to the next phase we were forced to move it on another machine to complete all ancillary operations. Now with the SPEEDMILL we can finish it right in the same set up, we can do all the boring, reaming, drilling and tapping right there, we don't have to waste the time to unclamp it, and move it around the shop.
It is a huge advantage in terms of precision and saving set-up-time. This is unique.

"Every new machine we have to desígn is a complex and challenging experience.
We create a unique machine forevery customer."
We design and build machines and equipment such as moulding and mechanical presses and machine tools for various types of processes.

VEMARO
The largest vertical gantry machining center in Belgium is in Estaimpuis
AFC is a young and dynamic company belonging to the Vemaro group, offering subcontractor machining services. For its operations, AFC has purchased a large PAMA
Vertiram vertical gantry machining center.
The large multitasking Vertiram 4000 GT MC has a work envelope of 35m in length,
7.6m clearance between columns and 5.35 of clearance under the spindle; a 590mm
square ram with 100kw spindle drive and a crossrail with 2500mm stroke. It is also
equipped with a 6m diameter turning table with 150 tons net load capacity and 11 automatic head attachments.
For twenty-five years Vemaro, based in Estaimpuis not far from Mouscron near the
French border, has provided contract machining services mostly but not exclusively for machine manufacturers. From the time
Vemaro was originally started in Roulers, Marc Vereecke has expanded the company
four times: the latest with the purchase of the largest vertical gantry machining center
in the country, for its AFC satellite company.
This allowed for expanding group offering with turning services for components up to
8m diameter and 150t weight and for prismatïc structures that can exceed 200t and
30 metres in length.
The push behind such an important step like the acquisition of an impressive and
expensive machine was determined by the conviction that the large part contract machining was in an expansion phase, as Marc Vereecke confirmed: "There is a market for the milling of heavy, large components. Our extensive experience in this field and the
growth of the market towards even larger and heavier components led us to buy this
machine and now we are ready to satisfy any kind of machining request".
The installation of this multitasking gantry milling center has allowed AFC to become
a potential supplier not only for traditional machinery manufacturers but also for other industrial concerns in the energy, wind power, naval and transportation fields. The
machine in fact, is equipped not only with a turning table which can be switched to function as a standard rotary table for milling, but also with a mechanical universal head
that provides full five-axes capability, used as an example for machining of hydraulic turbine impellers or ship shafts.
The machining of all these components is extremely critical due to high precision required, their long procurement time and the very high costs of the raw materials. The
machining has therefore to be perfect: on one hand rework would be extremely difficult, on the other hand scrap would be very expensive and substantially affect the end
customer program, for whom the component being machined is a crucial part.
The expertise of the personnel, then, plays an equally important role as the reliability
and precision of the machíne, as also the close collaboration and the continual talks
with the customer, as Marc Vereecke confirms:" You have to start out on the right foot. We are talking about enormous pieces of raw material where the smallest mistake could immediately cost huge amounts of money. We do everything to avoid that.
Our operators and our customers carry out rigorous controls of the parts, not only after
but also during the processing. What counts ultimately is customer satisfaction."
The configuration of the machine has been carefully thought out.
Firstly, the decision was made for a travelling gantry machine that provides maximum
operating flexibility and the opportunity to integrate in the installation heavy turning.
The VFRTIRAM 4000 GT MC model was chosen amongst the PAMA Vertiram line,
fully meeting the work volume requirements and also power and spindle speed requirements: in fact, a 100kW motor is housed in the ram, which with a four-range speed
change providing a maximum torque of over 10,000Nm and a speed of 4000 rpm, making the machine ideal for both roughing and boring operations but also for small drilling
and tapping, which are requested for fully finished pieces. The travelling gantry, with a
movable crossrail, comprises of two work areas, one equipped with 180m2 of floor plate
surface (30x6mt) with 25t/m2load capacity, for milling operations and one equipped
with a milling and turning table with a 6m platform and a capacity of 150t, where the
machine can turn pieces with a diameter of up to 8m. The machine is completely hydrostatic, both for the linear movements as also for the turning table.
There is a high degree of automation: a shuttle than can hold up to 12 head attachments
runs independently to the machine parallel to the X axis and can change a head attachment in any position thanks to the electronic synchronisation with the position of the machine gantry. The ram of the machine has all the electric, hydraulic and pneumatic connections for providing the automatic coupling of the head attachments and that they operate correctly. The heads can, in fact, have motors and measuring systems for any CN axes (like in the case of the TW2-AC universal head with two with continuous orthogonal axes or for the U axis of the D'Andrea facing heads), be lubricated wth recirculation of thermo-stabilised oi1, have the tool coolant through and outside the spindle
and automatic clamping of the tool. The ram also has an integrated C axis for positioning
the head attachments to 720 positions.
Completing machine automation is the automatic tool change system, which consists of
a static magazine with 270 1S0 50 pockets for the milling tools and a 30 place Sandvik
Capto C10 for the turning tools. An anthropomorphic robot with movement para11e1 to
the X axis of the machine changes the tools to any position of the X stroke. The robot
has a gripper for IS0 50 tools and a gripper for C10 tools: to reduce the change time
on the shuttle that moves the robot along X there are buffer housings that make up for
the lack of the double gripper.
The machine also has a video camera to provide the operator with better view of the
machining operations.
To sum up: a truly impressive installation and at the same time flexible and automated that
makes AFC/Vemaro a more than credible supplier for the most demanding customers
of the most challenging markets.

FEDEGARI
A vocation for exceiience
Using the Pama Speedmill machining centres, the Fedegari group based in Pavia is able to achieve high quality levels in machining the strategic components of its sterilizers, designed
for multinational pharmaceutical companies.

Passion, technical competence and far-sightedness in understanding the real needs of
the market on a time to time basis, trying to anticipate them via research and creation of ad hoc solutions for each individual customer. These are the cornerstones of a
philosophy that guided the brothers Giampiero and Fortunato Fedegari when they set up their company over half a century ago;
over time it grew from a small artisan metal fabrication firm into an established name
operating in the design and production of plants for the pharmaceutical sector. The
company ίs part of an international industrial group and has been operating in the
manufacturing sector since the '50s; it has made product uniqueness its strength, designing and producing systems purposefully conceived for each customer. Actively collaborating with the customers and catering to their specific needs to the fullest extent, transforms these systems into special solutions like autoclaves, washers or decontamination systems, obtaining an end
product with a high added yalue. To do this, Fedegari had to organize itself extremely efficiently, starting with the creation of a technical office, split into mechanical, electrical/electronic and software development departments comprised of highly qualified
technicians and engineers, able to design in-house all different solutions, acquiring
and maintaining over the years a complete know-how of the entire production process.
«This process starts from the design of core components (all made of AISI 316L stainless
steel) like the sanitary valves installed on our machines, which must have certain characteristics, or like the pressure body, designed using finite element mathematical models to verify correct design, through to the calculation of average system life, which is now a vital piece of information for the majority
of pharmaceutical companies - says Paolo Fedegari, CEO of Fedegari -the work of
the technical office essentially boils down to programming production and the via CADCAM systems, the machining centres in the manufacturing department for performing
lathe turning and milling operations, and machines for MIG, TIG and orbital welding, fully certified in terms of the quality of the operations carried out, in compliance with
the most stringent standards on welding of pressure bodies». Production of the autoclave sterilization chamber, on the other hand, starts from cutting, bending and welding of the sheet metal, up to milling, an extremely important step because it is largely responsible for the success of the Fedegari machines. This success is based on a patent developed by the founder of the company, in which hermetic sealing of the sterilization chamber is obtainéd by means of a special dynamic gasket operated by compressed air. «Looking at these requirements, we recently realised that we needed a machining centre able to provide the power and speed that would enable us to perform problem-free milling operations throughout the day, even 14 hours - he continued - We therefore carried out a detailed market analysis, aimed at identifying machine manufacturers able to supply dependable high performing systems capable of working in three unmanned shifts. We soon pinpointed Pama, due both
to the reputation it has built in the field and the solution it proposed, providing not only
the machine tool but also the fixturing for machining the frame of our pressure body
door, housing the gasket where the door runs and closes». This is a key element for
guaranteeing a pressure of three bars and, above all, enables us to operate safely, for
long periods, without air leakage problems which would compromise the sterility of the
product treated.
The ríght solutíon Established in 1926, Pama boasts almost a century of experience in the field of boring and milling, and today is a reference point for machine tool manufacturers, thanks to manufacturing in-house all of its machining centres. These include the two Speedmill floor type horizontal milling machines purchased by Fedegari (and housed in a
dedicated building), representing the ideal solution for all high-speed machining work,
combining high 1evels of precision and power, with the added advantage of guaranteeing efficient chip removal. This innovative milling machine, offers great flexibility, and has a direct drive spindle, which allows use of the latest tooling technology and it
is ready for the adoption of future improvements. 1t is equipped with a 2 meter diameter dual rotary table, able to house one part being machined and a further three ready for processing. The Speedmill has an X axis stroke of 8000 mm, a Y axis stroke of 3000
mm and a ram travel of 1600 mm. The spind1e speed is 6000 r.p.m., with a power of 75
kW and torque of 1800 Nm.
The rapid traverse is 40 m/min, with an acceleration of 3 m/s2, and is controlled by a
Heidenhain 640 iTNC numeric control. The machining centre is completed by a chain
style tool magazine with 60 tool capacity
and is able to change tools with maximum diameter of 420 mm, length up to 600 m
and weight of 35 kg. «For us, both the tolerances to be achieved and the high surface
finish inside the chamber (essential to guarantee effectiveness of the seal system) are paramount, and we are now able to obtain these directly with the Speedmill machining centre, which offers great production quality, dependability and rigidity - says
Tiziano Valli, (Purchasing Manager) of Fedegari - Pama has also supplied us with all
the fixtures for clamping the pieces in the machine, taking account of our needs and
proposing a complete solution which we are very pleased with, enabling us to achieve
the goals we set for ourselves».
The technical support provided by Pama was of utmost importance, in both the study
and testing phases, enabling the company to finish its components directly in the machine and to clamp them in background with a considerable reduction in down times.
Right from the beginning, PAMA supported
Fedegari following a «turnkey» policy.
It offered and supplied the equipment, appropriate tooling and the machining methods, all validated by the performance of a series of tests on the products to be manufactured, useful also for training the operators, enabling them to use the characteristics of the two milling centres to their full advantage.
«The Pama milling machines are enabling us to achieve the quality level we are seeking in
all our machining work, resulting in an end product with very high performance - added Fedegari - We certify this quality by controls on the incoming material, and on critical
features also during the intermediate phases of the production process; the final control
evaluates the quality of the end product and compliance with the design requirements,
via various testing sessions, initially in-house and then at the customer's premises, prior
to system start-up».

VOSS coat is much more than just a símple coating.
- Maximum corrosion protection, tried and tested under extreme real-life conditions
- Proprietary ín-house electroplating plant specifically designed for VOSs products
- Provides maximum process and application reliability
- Under continuous optimisation in the VOSs coat competence centre

To achieve quality solutions, however, we also need "quality" people. In this regard,
personnel training is of primary importance, carried out directly in the field, with young
employees working alongside experienced
technicians able to pass on all their knowledge, it is essential for the manufacture of
highly technological products.
95% of these products are sold to the big pharmaceutical multinationals operating
in a hundred or so countries worldwide;
Fedegari guarantees these multinationals a direct and comprehensive presence, and over the years has opened operating branches in United States, Singapore, Germany, Switzerland, U.K. and Belgium, proof of the company's desire to ensure proximity to its customers.

5-axis Technology
FANUC CNCs provide the answer to demanding machining operations involving multiple axes and multiple paths.
Sophisticated 5-axis applications can be achieved using
simultaneous 6-axis transformation, with up to 24 axes being simultaneously programmable.
FANUC 30i-B series controls aгe ideally suited to sophisticated, high-speed precision machines equipped with multiple axes and multipath functionalities.

complex large components machined with high precision.
Boring and milling centre for the production of roller presses

When the manufacture of hard coal briquettes was developing into an industrial
process towards the end of the 19th century, mining company director Wilhelm Köppern purchased the "Berninghaus smelter" in Hattingen on the Ruhr in 1898 to build roller
presses for briquette production there. He refined the original Belgian design of those
presses. That is how target-oriented innovation brought about the success of Köppern
- a family-run Group - and it continues to do so to this day. Today, Köppern manufactures
modern, high-tech products in the form of machìnes and systems, for a range of different treatment processes. Köppern roller presses are widely used across a number of
industries, for example for the comminution of clinker and slag for cement production
and of a variety of ores and minerals, including iron ore, gold, copper, nickel, bauxite, vanadium, molybdenum and diamondiferous ore. Köppern machines work on the basic
principle of two counter-rotating rollers. Image 1 shows a high-pressure grinding ro11 for
high-pressure comminution of ores. In total, Köppern has already sold several hundred
roller presses in more than 60 countries for briquetting, compaction and comminution.
ln the company's own pilot plants processing
of more than 2000 different materials has already been tested.
Seventeen years ago, the Köppern Group built a new plant on the new Hattingen industrial estate on the river Ruhr, opposite from the old factory site, to be equipped with suitably modern equipment for efficient and reliable high-quality production and assembly
of its own products. One of those machines
was a SPEEDRAM floor type horizontal boring mill from the Italian company PAMA. The
original intent of the new project was to retrofit the existing Pama machìne to bring it
up to modern components and a higher performance. However, it soon became apparent that it was not worth the cost measured against the technological advantages of an
entirely new machine. "What is more," stresses Jörg Ehrkamp, authorised representative
and Head of Production and IT, "with a new machine, you are simply better prepared for
the requirements of production of future components. That is why we decided to purchase a new machine."
Trust in PAMA technology
"Over the almost 16-year period that our first PAMA machine was in operation," says Production Manager Bodo Struck "we did not just come to appreciate the quality of the
machine, but also built up excellent personal relationships with the PAMA employees. We
knew that PAMA, with its expertise in manufacturing, production and assembly, would
be able to meet our technical and scheduling needs. To begin with, we had to find out
whether the new machine, configured as we required, could be placed on the foundation
of the old machine. The result was that the
foundation could bear all the loads of the new machine and it was also geometrically
suited to it." "PAMA's task", explains Thomas Ulrich, Branch Manager of PAMA GmbH
in Mainz," was to produce a modified X Axis bed for the new machine, designed to fit perfectly onto the locators already in place in the existing foundation. In addition, we kept the
old machine's 3 x 5 m floor plate area. That meant that the new machine could not be assembled as normal, but had to be aligned to the existing floor plate. The excellent cooperation during assembly and commissioning was remarkable. The on-site Maschinenfabrik Köppern employees assisted us, with the result that the assembly and commissioning work was completed within just nine weeks,
rather than the usual 12, and the machine could quickly be incorporated into the production process." Bodo Struck adds, "The same PAMA project manager worked with
us from the beginning stage right through to completion of the commissioning work. That
guaranteed an excellent level of support, which eliminated any gaps in communication."

SPEEDRAM 2000 as requested by the customer
The configuration and order of the PAMA-SPEEDRAM 2000 machine was based
on the morphology and material properties of the components currently beìng processed and forecast of future manufacturing tasks.
"At the moment for example," Bodo Struck explains, "we use the SPEEDRAM 2000 to
manufacture bearing housings, cover plates, frame straps, foot plates, motor consoles and
large bands which are mounted on the roller core, and also to pick up the equipment
needed for the comminution. As a rule, the materials we use are special materials, which
are always heat resistant, high strength and/or very tough. That is why we bought a machine which is characterised by high rigidity and features vibration damping."
The existing floor plate and a rotary table model TH 50 with a hydrostatic supported
V axis with 1500 mm ofi stroke, are used to set up the workpieces. The rotary table has
a plate dimension of 2500 x 2500 mm and a net load capacity of 50 t. allowing for set up of even our largest components.
The machine column moves on a 9000 mm long X axis. That enables it to reach the rotary table, the floor plate area and the head storage station installed to the right of it. The
headstock vertical travel is 4000 mm. To be able to get deep into the parts, the ram can
be extended by 1200 mm and the quill an additional 1000 mm. To achieve high productivity, the PAMA SPEEDRAM 2000 is fitted with a 93 kW motor, which drives the 150 mm
spindle using a three-speed gearbox. Another features driving productivity up is the feed
rate, up to 20 m/min in all axes.
High performance machining of special hard
steel requires adequate protection against
flying chips or tool breakage. PAMA designed
and installed an extra high enclosure. Operator access for machine maintenance or part
clamping process is controlled by the operators and can happen at their leisure.
An extra-large operator's cabin - as requested - is another feature of the user-friendly
design. To support the operator in their high
responsibility work, this cabin is air-conditioned. "We process extremely valuable components," stresses Bodo Struck. That is why,
despite automatic operation, the machining
process is closely monitored. The independent operator platform can be moved up or
down, or even forward in the direction of the
spindle, regardless of the headstock movement."
Accessíbílíty of the machíníng surfaces in addition to the machine axes, automatic interchangeable milling heads make machining the internal and side surfaces accessible in a
short time.
An automatic right angle milling head, model TS 35 360, an automatic 3+2 universal mi11-
ing head which can be adjusted to 0.0010 on each axis, model TU 25 C, a compact right
angle milling head, TS 20 144, and the cover frame are stored in the head storage unit. The
right angle milling heads enable five side machining in a single set up, "Conveniently," says
Bodo Struck, "PAMA also designs and produces the heads attachments. That means
that they match the supplied machines perfectly." Following a specific procedure, the
ram retrieves whichever milling head is needed from the storage unit.
Tools are changed out of the chain style
magazine by an automatic tool changer. The
ATC is mounted on a tilting mechanism to allow automatic tool change both horizontally
in the spindle and vertically in the heads. All tools required for machining are stored in the
magazine, which has a total of 120 pockets.
For oversize tools of up to 1200 mm in length (IS0 50), a six position tool rack is installed
on the head storage unit. "The tools required for each program;" explains Bodo Struck,
"are placed on the chain magazine's swappìng station in the manufacturing process.
Via the input panel, the controller receives the current data on the assignment of the
tool magazine. We have to input data manually in order to eliminate mix-ups. We use the
tools in different machines."
For boring, PAMA supplied a CNC-controlled facing head, model UT 5-800 S, with tool
holder CAPTO C6.
Achìevíng machíníng accuracy
"Our parts are machined to an H6 tolerance
in accordance with their accuracy requirements'' explains machine operator Wolfgang
Schweinert "This requires not just a rigid machine construction of all load-bearing components, but also accurate movement along all axes. It also involves precise manufacturing preparation."
"We manufacture according to order," stresses Jörg Ehrkamp, and he explains, "Given the
size of our machines and customer requests,
we manufacture batch sizes 1 to 2. The finalised 3D drawings are transferred from our
design department to the manufacturing engineers, who use them to draw up the part
programs. Conveniently, their office is located right next to the mechanical production
department. That means that information can be exchanged quickly and easily."
Once the machining program is loaded on to the machine control system, the operator can add any optimisations that are still needed using the Sinumerik 840 D control panel. From a mechanical point of view, precision manufacturing is based on two
things: Firstly, the workpiece must be solidly clamped to prevent vibration, and secondly,
the SPEEDRAM 2000 must be set up to minimize tool vibrations during machining. "On
the basis of construction principles typical to
PAMA,- Thomas Ulrich explains - To achieve that, our machines are produced exclusively
from cast components and all axes have integral hydrostatic support. That is true not only
for all linear axes, but also for the rotary table. The ram is also hydrostatically supported on all four sides. Moreover, the quill operates with hydrostatic support (HSS Hydrostatic
Sliding Spìndle). Hydraulic tension rods offset
the ram droop. In addition, the machine compensates thermal expansion of the ram and
quill in real time via a Pama patented system.
For thermostabilisation of the headstock and hydrostatic oil, the PAMA SPEEDRAM 2000
has a chiller.
The internal coolant supply protects the tool cutting edges and flushes out the chips. For
deep drilling process, the machine is provided with quick connection for an ejector drill
on the headstock. That way, high volume coolant can be provided to the drill bit at up
to 50 1/min. The heat dissipation protects both the drill bit and the spindle.
Of course, the coolant is more effective with cleaning and recooling. To filter the cooling
lubricants, Köppern uses a self cleaning drum filter with its own backwashing. "We have
had good experiences with it," says Jörg Ehrkamp, but he also stresses that regular
rinsing of the chip conveyor is necessary. At this point, Bodo Struck concludes by pointing out a further advantage of the new PAMA
machine: "The ancillaries such as the chiller and pumps are much quieter than those on
the old machine."
It is also worth mentioning PAMA's software package Pama Maintenance Program'
(PMP), which monitors all the head attachments and machine assemblies with regards
to their service 1ife, and any maintenance due in connection with this. This enables the user
to check the machine's maintenance conditions at a glance.

CN heads for boríng and facing medіum and large dimensions allowing turning
operations wíth fixed píeces on all machíne tools. Built in various models from 360
to 1600 mm in diameter, they can be applied manually, automatically, and with pallet
systems on boring machines, machining centres and special machines.
They are connected to the CNC of the machine too/ for cylindrical and conical boring and
threadings, outer, inner, and back-facing machíning, radius and spherical operatíons,
along with all types of turning operations through the interpolation wíth the other axes
of the machine tool.
Special versions of U-TRONIC are availab/e on request featuring two slides, or with
counterweights for se/f-balancing. Fixed tool holders can be applied on the slide with
manual or automatic tool change.
The various solutions proposed allow for identifyíng the best U-TRONIC applícation
on each machine too/ and offer high performance ín a consolidated period of time at
reduced costs. The introductíon of increased automation and intelligent accessories such as U-TRON/C has improved the flexibílíty of machíne too/s by reducing the tooling
and the number of placements in the princip/e of mu/ti-axis machines

U-TRONlC 5-630 BH SYNCHRO
• Grinded cylindrical gears.
• Grinded spiral bevel gears Gleason gears.
* Grinded worms and worm wheels also with "zero backlash"duplex.
• Design and costruction of integral drive units following customers requirements.
• Grinded racks up to module.
• Grinded splíned shafts.
• lnner cylindrical gears