Press report DOLittleBfast

Productive high-precision fine turning

At the AMB, Benzinger will be exhibiting turning centres from the DOLittle series for efficient and economical finishing, optimised for minimum set-up and cycle times.
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Compact, productive, efficient: The Bfast turning centres with fast, integrated loading and unloading system are ideal for finish turning (finishing) pre-machined, hardened turned parts to the highest accuracy and surface quality.
For the automated, highly productive and efficient finishing of small hardened turned parts, turning machine manufacturer Carl Benzinger GmbH, Pforzheim, is presenting its recently realised Bfast variant of the proven Dolittle turning centres. These very compact turning centres are optimised to machine pre-turned and hardened workpieces, such as gears, short shafts and sleeves, to finished dimensions and high surface quality extremely economically in medium and large series with minimal set-up and cycle times. The innovative automation concept, which has been realised for the first time, works with fewer moving machine components than previous loading and unloading systems. It considerably simplifies set-up and significantly reduces set-up times. It also minimises energy consumption due to fewer moving masses and ensures maximum availability.

Integrated loading and unloading

The turning centres are equipped with an integrated linear loader as standard. With fast linear movements, it uses its double gripper to bring blanks from a loading station outside the work area directly into the work area and from there back to the loading station with finished workpieces. This significantly reduces the non-productive times for loading and unloading compared to conventional changeover systems, as the blanks are loaded directly into the work spindle. The main spindle (spindle capacity up to 26 mm, speed up to 15,000 rpm) picks up the workpieces with positioning movements in the X and Y axes. It then positions them in front of the tool block. The latter carries out the movements in the Z direction for machining. It contains up to 19 tools in hydraulic expansion sleeves. They are adjusted and clamped outside the machine. This minimises downtimes when retooling the turning centres. Optionally, small high-frequency spindles for driven tools can also be used in the tool block. In addition, four tools with square shanks can be mounted on the upper surface of the tool block. Dieter Wentz, Sales Manager at Carl Benzinger, comments on the arrangement of the axes: ‘For the first time, we have “flattened” the axis arrangement familiar from vertical lathes, i.e. transferred it to a horizontal lathe. This enables us to realise minimum set-up and cycle times and therefore highly productive production. We have also minimised the number of moving components.The latter contributes significantly to high availability.’

Compact fine turning on 2.5 m² of floor space

Steffen Krämer, responsible for marketing at Carl Benzinger in Pforzheim, explains the concept of the turning centres: ‘The Bfast version of our Dolittle turning centres is optimised for maximum efficiency. Thanks to maximum integration, the machines are very compact. The automation and control cabinet are located within a footprint of only around 2.5 m².’

The main spindle with internal hydraulic clamping system also contributes to the compact design. This eliminates the need for a protruding pneumatic clamping unit. Workpieces up to 70 mm long and 50 mm in diameter can be machined. Dry machining, cooling with air, cooling emulsions or oil cooling or lubrication is possible. The Bfast variant has a modular design based on proven components from the Dolittle series. It therefore has the same stability, damping and temperature rigidity and realises the same high level of accuracy as the other versions in the Dolittle series.

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Automated with robot cell

An optional extraction unit is available, which is mounted on top of the machine. This means that it does not require any additional floor space. Variants for coolant oil mist and for dust, for example when machining components made of ceramic, CFRP and GFRP, are available.

A compact robot cell can optionally be attached to the side of the Dolittle Bfast turning centres for automation. It replaces the linear loader integrated as standard. The robot loads and unloads workpieces from a pallet rack directly into the work area through the predetermined opening above the mould block. This means that the work area remains fully accessible from the front for the operator to set up and monitor the machining process.

Workpieces up to 70 mm long and 50 mm in diameter can be machined. Dry machining, cooling with air, cooling emulsions or oil cooling or lubrication can be selected.

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