MAXcomputer GmbH - www.max-computer.de

General information
A clever new development meets many wishes. The manufacturing of turned objects, polygons, forks, scale wheels, threads etc... is possible not only by new mechanical but also by software functions.


The hardware is extended by the 4th. axis (U-axis), existing CNC- machines must have a relating AxisController (U-Axis).

The software is integrated since nc4/nccad4 to be comfortably used, it is being developed and supplemented steadily.

There are two versions of the turning unit:

KSZD1 Our small turning unit

Suitable for all coordinate tables and CNC-Machines.
For simple tasks and small parts.

The picture shows an equipment with chuck and tailstock, mouted to the Y-Table of a CNC-Machine A4.

KSZD2 Our big turning unit

For CNC-Machines with at least 100mm clearance.
For bigger parts and high precision tasks.

The picture shows an equipment with collets but without tailstock, mounted at right angle to the Y-Table of a CNC-Machine A3massive.

The components of the delivery can be found under "Technical data/Delivery".

The conception of the turning unit can be seen in the above pictures. It is qickly explained: the engine has a stepping motor as moving element and is fixed at the Y-table and connected to the extended interface. By the help of the software the rotating shaft is either turned steadily or brought into a certain position in which surface working is done, similar to milling.

Behind it, there is a lot of developmental work, in order to make it go so easily. But our aim has always been not only to furnish mechanics, but also comfortable software which is easy to handle.

Using a stepping motor in the engine has many advantages:

• The speed can be controlled variably without steps by the software
• It is possible to use it as dividing head
• The turning direction can be controlled by software

The turning unit is a 4th. axis that can be used with many different ways of machining that need complex movements (f.e. engraving round bodies, milling spirals a.o.m.)

You will get a real CNC-lathe by mounting it as follows:The entire turning unit is fixed on the table. Engine and chuck take the object to be turned, the tailstock and the centre point prevent the object to pass aside. The machining unit with the rotating tool makes the cutting:

2 machining methods are possible:

• If the object turns continuously, rotation bodies will be fabricated.
• If the object is fixed in a certain angle position you can work on any of its surfaces on the X-, Y- or Z-level.

You will get a universal machining unit if the turning unit is fixed to the back end of the Y-table (milling in the front, turning in the back). Then, however, not all of the Y-table can be disposed of, but you do not have to change tools all the time.

Different workpiece zero points can also be "taught in" and called up when changing the application mode since nc4/nccad4.

Notes:
All mechanical parts are made in high precision. We use high quality ball bearings for the rotation axles, the mounting plate for the tailstock is made of ground steel.
The ground surfaces and fits allow the parts to be precisely joined and mounted to the Y-table.
The turning unit helps our coordinatetable KOSY to open up to new applications and perspectives. Our application laboratory and our production team is engaged in its use. Our experience are passed on in tipps for practice. We are really enthousiastic about KOSY as lathe, and hope you feel the same way.

Functions for the turning unit are part of the functions of nccad. It is our philosophy, not only to provide hardware but also an easy-to handle software.

For direct control NC-commands must be available to allow the manual operation of speed, turning direction and angle position. The turning unit is, so to speak, a 4th axle, it was given the name U-axis. The stepping motor for the U-Axis makes e.g. 400 steps per rotation, its transmission ratio toward the turning axle is 1:3. That means that 1200 steps of the stepping motor are necessary for one rotation of the rotation axle and that one step makes the angle change for 0,3°.

Example: If you want to go to an angle position of 30°, you have to:

• Go to the zeropoint [Pos1]
• Enter the direct command U100 (You understand: 100 x 0,3° = 30°). The zeropoint corresponds to the angle position 0, there is a sensor.

The following NC-commands were newly created, they can be entered either as direct commands or integrated in a NC-program:
M02 Turning OFF
M03 Snn Turning to right, S = speed
M04 Snn Turning left, S = speed

Speed nn can be set from 1 to 400 (approx. 1 to 400 rpm).

The U-axis can be integrated into the G-commands, e.g.:
G01 X10 Y20 Z-2 U600 F100

nccad has been extended, especially for drawing a turning piece.

• This makes constructing easy,
• allows machining "turn round" and "mill surface",
• saves calculating by originating from a workpiece zeropoint,
• makes it unnecessary to convert radius into diameter
• helps to get a clear structure.

See below a series of pictures how CAD/CAM supports turning:

Construction of a contour and surface machining

First the turning contours are drawn, they get technology N°1 (down)
Then an additional X-Y-help axis is made and the contours for surface working is drawn (above), it gets technology N° 2, shown in detail in the next picture.

Technology for the example to construct

Please notice especially the machining "pocket hole" and "setting for angle positioning" in order to get the 4-edge surface.

The finished turned object belonging to it is shown in the picture below.

Different examples of turned objects

Thread milling with the turning unit:

You can make any threads, also M-threads (here M8).

In the middle picture you see the finished turned part which was constructed in the photos above. Turning contours and working the surface was done without changing tools.
By milling the turning contours you can make particularly thin parts.

The third picture shows an object (streetlamp in model construction), the thinnest part of which has a diameter of 0.8 mm - with a length of 25 mm.

For printing the table, please click on the .pdf sign