Giddings & Lewis Horizontal Machining CentersHMC Series

Automated Large Part Machining

• Rugged construction with sub-stantial workpiece swing

• Choose from eight different head-stocks including high torque, live and tilt spindles

• High performance drive/way system for the ultimate in speed and performance

• Superior accuracy capabilities produce high precision parts

Metal Cutting | Composites

Designed and Built to Meet Customer DemandsDesigned with extensive Six Sigma “Voice of the Customer” input HMC Series horizontal machining centers meet the needs of today’s manufacturers. Cast iron construction for rigidity, speed to reduce cycle times and the capacity to handle a wide range of parts are features demanded by customers doing large part production.

The modular design of Fives Giddings & Lewis horizontal machining centers makes it possible for OEM manufacturers and job shops to match the machine features to the part size, material and operations required. Among the configuration choices are: travels, controls, tool magazines, attachments, coolant systems and several different headstocks.

Large Capacity/Solid ConstructionCapable of swinging and shuttling up to 7,000 kg, (15,400) the HMC Series is a productive choice for large part production. These rugged machining centers are able to carry heavy loads and take deep cuts due to the design elements that make them a rigid, accurate machining platform.

— Cast iron construction with reinforced columns and beds— Standard linear scales— Hydrostatic rotary tables— Part swings to 3000 mm (118.1 in)

Giddings & Lewis HMC SeriesHorizontal Machining Centers

Aerospace, Oilfield, Construction, Mining, Shipbuilding, Job Shops, these are just a few of the industries relying on the capacity, rigidity, versatility and precision of the Giddings & Lewis HMC Series

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High Performance Drive/Way SystemThe high performance Fives Giddings & Lewis system produces faster positioning speeds, enhanced contouring performance, increased thrust and dependable accuracy. This all starts with the hardened and ground preloaded roller guideways. The result is reduced friction and faster traverse rates, up to 40 m/min (1575 ipm). The design of the roller trucks optimizes way surface contact and rigidity. The way system efficiency results in reduced oil and energy usage.

— Hydraulically preloaded ballscrews provide superior axis stiffness via constant preload which is unaffected by heat— Large, zero-backlash ballscrews supply smooth axis motion and high thrust performance. The stiffness of the larger screws enhances load carrying capacity— Special geared AC digital drives maintain high torque and impressive stiffness even at high traverse and feed rates – 35 kN (7,870 lb) Z-axis thrust – 29 kN (4,500 lb) X and Y-axis thrust— Digital servo drives are sized to handle the headstock

positioning and weight influences— Unsurpassed positioning accuracy is provided by the standard linear scale feedback system

– Positioning accuracy 0.008 mm (0.0003 in) – Repeatability 0.005 mm (0.0002 in)

Hydrostatic Rotary Table A built-in contouring rotary table is standard on the HMC Series.

— The table design features tapered roller radial bearings and preloaded hydrostatic axial bearings. The hydrostatic bearings add dynamic stiffness for heavy-duty, precise cutting— For contouring, the robust worm gear drive includes servo clamping. For conventional machining operations, the design includes a non-influencing mechanical clamp— Standard rotary scale feedback provides unmatched positioning accuracy

Peripheral Ring Clamp

Robust Design Provides Superior Customer Value

High performance drive/way system capable of high thurst and up to 40 m/min traverse

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Spindle ChoicesWhether machining aluminum, cast iron or titanium, the HMC 1250 has the spindle to do the job. In addition to the standard 10,000 rpm spindle, choices include high-speed, high-torque, three tilt and two live spindles.

The live spindles add reach and increase productivity by accomodating the use of multi-functional attachments such as programmable boring bars and contouring heads. The 210,000 position A-axis tilt spindles facilitate five-axis machining of large parts thereby reducing the number of required setups. The larger bearings, motor and drive train of the high torque spindle make light work of heavy cuts and hard metals.

Feedout Tools Reduce Cycle TimesContouring heads and programmable boring bars, useable on an HMC with live spindle, maximize spindle utilization, reduce setups and tooling requirements with their ability to perform multiple operations, including turning, on various size part features. Operations include grooving, threading, contour bores, back spotfacing, chamfers and more. Attachments maybe stored and changed from the tool magazine or optional attachment rack.

1) The live spindle intermittent rating is S6-40%

Headstock Options Standard High Torque(1) Live Spindles(1) Tilt (6,000 rpm) Tilt (8,000 rpm) Tilt (24,000 rpm Power kW 37 / 46 60 / 80 30 / 45 37 / 46 37 / 46 50 / 65 (Cont. / S6-60%) hp 49.6 / 62 80.5 / 107.3 40 / 60 49.6 / 61.6 49.6 / 61.6 67.5 / 87 Torque Nm 908 / 1,128 2,200 / 2,600 1,108 / 1,662 1,161 / 1,386 740 / 920 58.3 / 64.1 (Cont. / S6-60%) ft lb 670 / 832 1,623 / 1,918 817 / 1,226 856 / 1,022 555 / 690 43 / 47.3 Speed rpm 10,000 5,000 4,000 6,000 8,000 24,000 Spindle diameter mm 100 130 110 (130) inch 3.93 5.1 4.3 (5.1) W Axis travel mm 500 (800) inch 19.7 (31.5) A-Axis travel deg +90 / -120 +90 / -120 +90 / -120 Taper Std ANSI #50 ANSI #50 ANSI #50 ANSI #50 ANSI #50 HSK 63A Opt SK #50 SK #50 SK #50 SK #50 SK #50 HSK 100A HSK 100A HSK 100A HSK 100A

Tilt Spindle

High Torque Spindle

Live Spindle

Contouring HeadProgrammable Boring Bars

Spindle Choices

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Headstock with Integrated contouring head and live spindle

Exclusive Fives Giddings & Lewis Technology

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Exclusive Spindle Growth CompensationDeveloped by Fives Giddings & Lewis, the exclusive W-Axis thermal compensation software, which is standard on the live spindles, dynamically offsets spindle growth, maintaining tight accuracies.

Multi-Functional Integrated Contouring Head Adds Machining VersatilityThe headstock includes both a live spindle and integrated contouring head. Switching between the two is a simple control command and allows manufacturers to machine more with fewer setups and greater part precision. The contouring head adds turning capabilities such as grooving, threading, contour boring, facing and more. Both spindles use standard modular tooling; Kennametal KM 80 or Sandvik Coromant Capto C8. The live spindle also accepts 50 taper tools and with the addition of an auto-coupler, programmable boring bars.

Whether it’s the multi-functional integrated contouring head or the precision offered by the spindle growth compensation, no other builder can match the technology

Large Tool CapacityTool magazines are available with 60, 90, 120, 200 or 300 positions. The tool changer is capable of changing not only heavy tools but attachments such as contouring heads and programmable boring bars as well.

— Maximum tool weight is 50 kg (110 lb) — Maximum tool diameter: – Full magazine, 125 mm (4.9 in) – Empty adjacent position, 300 mm (11.8 in)— Maximum length, 650 mm (25.6 in)— Tool change time 18 seconds

Rack-Style Tool MagazinesThree rack-style tool magazines, 180, 315 or 540 tools, are available for parts requiring a large number of tools.

Additional Options– Tool probes– Part probes

Attachment Rack– Reduce cycle time with automatic attachment changing– Configurable for various combinations of attachments and contouring heads– Access door in enclosure for easy tool maintenance

Tooling and Tool Magazines

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Maintenance-Friendly Services AreaThe services area was designed using Visual Uptime Management principles. This design methodology improves and simplifies maintenance and while also maximizing machine and control availability.

— All services are centralized— The panel is at floor level— Labeling is clear and specific. Hoses are marked with the type of fluid or gas and the direction of the flow. Labels and noteplates are color coded. — Solenoids are lighted. Gauges are marked with normal operation ranges

Choice of High-Performance ControlChoose the control that is right for the job. Fives Giddings & Lewis offers Siemens and Fanuc controls on all horizontal machining centers. All control choices include: fast ethernet connection, rigid tapping, high-level programming capabilities, interior lighting for control cabinets and remote hand-held pendant with MPG (manual pulse generator).

W/Z Tracking, available on HMCs with live spindles and 840D Solution Line controls, offers ease of programming and operator convenience.

— W/Z Tracking maintains constant zero between colinear axes— Accounts for changes in machine geometry when one of the axes in a collinear set is repositioned in the part program — After the W/Z relationship is established through part referencing, the control tracks all W and Z axis moves, displays their relationship and moves one or both axes to maintain the correct gap position

Spindle Load Monitoring SoftwareGiddings & Lewis spindle load monitoring software provides a simple operator interface and application. The operator sets cutting operation acceptance values and activates or deactivates load monitoring using M codes. Available on Siemens or Fanuc, the control retracts the tool or uses feed hold when the trip point is exceeded protecting the machine, tooling and part from damage.

Adaptive ControlThis easy-to-use feature adjusts the feedrate between programmed minimum and maximum values to compensate for changes in cutting conditions including depth of cut and hardness while maintaining the desired cutting horsepower. Giddings & Lewis adaptive control provides machine protection and enhances productivity by allowing aggressive feed rates.

Remote Diagnostics OptionBenefit from quicker response and reduced machine maintenance costs by adding remote diagnostics. This option allows the Global Services group of Fives Machining Systems the ability to access the machine tool control in order to diagnose issues. If required, files may be transferred to and from the CNC

SIEMENS SINUMERIK 840DFanuc 31i

Controls and Service Panel

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Pallet Shuttles

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Pallet Changers Reduce Setup TimeThe two position pallet system is standard on the HMC Series. An optional four position system offers three park stands and one load station.— Optional power rotation of load/unload stands— Coolant shrouding contains ships and coolant— Accessible part loading from operator platform

Multi-Level/Multi-Pallet Automation OptionsTwo options are available for added automation with the HMC Series. Using a stacker crane, the multi-level system minimizes floor space. Weight and swing capacity are not limited by the storage unit with a rail-guided multi-pallet system. Additionally, the machine load/unload area is fully accessible for off-line operations.

Chip Conveyors & Mist Collectors

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Chip Conveyors Matched to the Application Selection of the chip conveyor type and positioning may be based on the part material and machine location. Piano hinged, perforated link belt conveyors which carry chips on top of the belt are best suited for steel or general purpose applications where curly or stringy chips are formed. Scraper bar conveyors drag chips along the pan bottom and are more efficient removing granular chips often produced when cutting cast iron or hard cast aluminum. The HMC Series dual chip conveyors which run parallel to the X-axis may be discharged to either side of the machine

Coolant System Increases Production EfficiencyThe coolant system capacity, filtration capabilities and programmable pressure all combine to facilitate removal of chips and contaminants. — 1800 liter (475 gal) tank— Pressure fed dual bag filters with 25 micron filtration— Four pre-programmed pressure levels, 20 to 70 bar (300 to 1000 psi) for coolant through the spindle— 15 bar (220 psi) flood coolant — Z bed flush— Optional operator convenience packages may include: standpipe part wash, operator wash pistol, HMI fault status display, automatic filter changeover, tank-mounted oil skimmer and weekend coolant cycle

Giddings & Lewis High Pressure Coolant System Offering flood and coolant through the spindle, the Giddings & Lewis high pressure coolant system efficiently handles chips and contaminants.— 1800 liter (475 gal) tank— Coolant though the spindle, 70 bar (1015 psi)— Flood coolant, 18 bar (265 psi)— 100 micron return filtration system, gravity fed dual bag with manual changeover— Options include tank-mounted oil skimmer and operator wash wand

HMC 1250 HMC 1600 Capacities X-Axis travel mm 2100 (2700) 2700 (3300) inch 82.7 (106.3) 106.3 (129.9) Y-Axis travel mm 1500 (1800) 1800 (2100) inch 59.1 (70.9) 70.9 (82.7) Z-Axis travel mm 1750 2050 inch 68.9 80.7 Maximum workpiece swing mm 2400 3000 inch 94.5 118.1 Maximum workpiece height mm 1850 2150 inch 72.8 84.6 Min. spindle centerline to pallet mm 45 45 inch 1.8 1.8 Min. spindle nose to pallet centerline mm 300 300 inch 11.8 11.8 NC Rotary Table Clamping surface, Standard mm 1250 x 1250 1250 x 1600 inch 49.2 x 49.2 49.2 x 63 Clamping surface, Optional mm 1600 x 1600, 1600 x 2000 inch 63 x 63, 63 x 78.7 Allowable load kg 5,000 7,000 (15,000) lb 11,000 15,400 (33,000) Index rate rpm 6 6 Number of positions (full contouring) 360,000 360,000 Feeds/Traverse Rates m/min 40 35 ipm 1575 1378 Thrust X and Y / Z S3-40% kN 29 / 35 29 / 35 lb 6,560 / 7,870 6,560 / 7,870 Accuracies Bidirectional accuracy A mm 0.008 0.008 (ISO 230-2-97) inch 0.0003 0.0003 Bidirectional repeatability R mm 0.005 0.005 inch 0.0002 0.0002 Reversal B mm 0.0025 0.0025 inch 0.0001 0.0001 Tooling Number of tools 60 (90, 120, 150, 200, 300)) 60 (90, 120, 150, 200, 300) Tool change time (chip-to-chip) sec 18 18 Coolant System Capacity liters 1,800 1,800 gallons 475 475 Machine Length x width x height m 11.2 x 7.4 x 4.8 12.4 x 8.6 x 5.4 Dimensions ft 36.8 x 24.3 x 15.8 40.7 x 28.2 x 17.7 Weight kg 45,000 52,165 lb 99,000 115,000 Technical data subject to change without notice

Technical Data

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Global ServicesComplete Life-Cycle Support

Global Parts SupportAs the OEM, Fives Machining Systems Global Services not only has the parts but the drawings and documents as well for all our legacy brands including Giddings & Lewis. Parts are made to the same exacting specifications as the original machines.

Global Services has a world-class call center with 24/7 operation and highly qualified parts specialists.

Contact us at 1-800-934-0735 or use our Parts Online application at www.fivesgroup.com

Preventive MaintenanceReduce the cost of machine ownership with preventative maintenance and reliability assurance programs. Critical, consumable parts are replaced and maintenance data supplied. Our factory-trained technicians provide professional, turnkey service.

Health ChecksConcerned about the status of a machine you own or are considering buying? Get a machine health check.

Machine CertificationRequalify your machine tools to original factory specifications with a turnkey certification.

Complete CareTurn your machine maintenance concerns over to Global Services. Develop an individualized complete care package based on your needs.:— On-site service— On-site parts management— Training— Asset management— Unit repairs— Machine certification— Preventative maintenance

Machine RenewalReturn your machine to the original O EM specifications with a complete mechanical rebuild. Using genuine Giddings & Lewis parts and documentation, we have the expertise to do the job right.

Control RetrofitIncrease production while reducing installation time with a control retrofit. Choose a Fagor, Fanuc or Siemens control along with upgrade packages for drives and motors.

Contact Us:Fives Giddings & Lewis142 Doty Street, Fond du Lac, WI 54935, Ph: +1-920-921-9400, F: +1-920-906-2522, fivesmsi-sales@fivesgroup.com www.fivesgroup.com

• Rugged construction with substantial workpiece swing

• Choose from eight different head-stocks including high torque, live and tilt spindles

• High performance drive/way system for the ultimate in speed and performance

• Superior accuracy capabilities produce high precision parts

Advanced Operator TrainingFives Giddings & Lewis applications specialists can help you improve efficiency by using control features and options more effectively — Develop macros to handle repeat operations— Implement tool management

Part Processing AssistanceNew or existing parts will benefit from process review and optimization by Fives Giddings & Lewis runoff technicians. — Quickly get new parts into production— Optimize part programs— Set up process monitoring options such as adaptive control— Part fixturing assistance

Learn Probing TechniquesUnderutilized by many manufacturers, tool and part probing are options that can significantly reduce cycle times.

Benefits:— Automatically calculate fixture alignments, workpiece positions and rotary axis setup— Reduce manual errors— Improve part quality by performing in-process measurements— Speed production and prevent compound problems by using tool probe capabilities to measure worn tools and detect broken tools

Machinist / Capacity SupportUtilize skilled machinists or programmers to launch your new machine into production. Whether it’s one week or six months, Fives Giddings & Lewis can support you with skilled machinists or programmers during your peak production times.

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Giddings & Lewis Application Support