Bed type milling machine

Zayer 20KF 3000

The combination of the Zayer 20 KF 3000 machine, the Heidenhain TNC 426 control system, and a swivel universal head (Huron type) transforms this milling machine into a versatile and powerful production hub. The swivel head completely eliminates the biggest drawback of large machines – the need to constantly reposition and re-clamp heavy workpieces for machining at different angles. Here’s how precisely this head works with the Heidenhain system and what possibilities it offers. Kinematics and capabilities of the swivel head. The head in ZAYER machines consists of two inclined dividing planes that rotate relative to each other. This design allows for: Transition from vertical to horizontal: In a few moments, you can change the machine from a vertical machining center to a horizontal milling machine. This makes it possible, for example, to simultaneously machine the top of a workpiece and, a moment later, mill its sides. Milling at any angle: The head allows you to position the spindle in space at unusual angles, which is crucial for machining inclined surfaces, chamfering large plates, or creating converging pockets. Enormous rigidity: Although the head is movable, its design locks with tremendous force (mechanically or hydraulically). The machine does not lose any of its ability to perform heavy rough machining (so-called “hogging” with a large chip). Cycle 19 and PLANE in Heidenhain TNC 426 – The magic of software. The biggest challenge with a swivel head is the mathematics – when you tilt the tool, the zero points in the X, Y, and Z axes change. Heidenhain TNC 426 solves this automatically using dedicated geometric functions: Cycle 19 (Machining Plane): You inform the control system of the angle at which you have physically rotated the head. The computer immediately recalculates the entire coordinate system. The tool moves in the axis at an angle, and you program as if you were working on a flat surface. Coordinate transformation: You don't have to manually calculate the tool offset after rotating the head. The controller knows the exact dimensions of the machine's kinematics and automatically corrects the position of the X, Y, and Z axes. Angular drilling: After calling Cycle 19, the standard drilling cycle (e.g., deep drilling) automatically performs the feed movement in the inclined axis – the operator writes the program in the Z axis, and the machine physically moves with a combination of the X, Y, and Z axes. Production benefits in the workshop. Machining 5 sides of a workpiece from a single setup: You place a 5-ton steel block on the table. You clamp it once. By rotating the head, you machine the top and all four sides without moving the workpiece with a crane. This guarantees perfect maintenance of geometric tolerances (perpendicularity and parallelism of the surfaces). Time savings and safety: Repositioning a large workpiece on the table often takes hours and carries the risk of accidents or damage to the table. With this head, you only reposition the tool – manually using dividing plates or in an automatic version from the program.
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