New floor-type boring mill features powerful, long-reach ram for job-shop versatility

Full 2-meter reach ideal for “inside jobs” on pump, valve and wind-turbine bores. Heavy-duty construction of traveling column machine maximizes stiffness for accurate, fast metal removal.

October 2010 – MAG’s new FTR 3500 floor-type horizontal boring mill (HBM) is a versatile, mid-sized job-shop machine, capable of a full 2 m reach inside parts with a ram-supported spindle. The workhorse machine tool is ideal for “heavy metal” milling, as well as precision multi-axis contouring, boring, drilling and tapping on large parts for the construction, oil field and wind energy industries.

The machine’s collinear ram, made from ductile iron, adds a 1-meter W-axis reach to the spindle’s existing 1-meter extension. It provides maximum rigidity for full-power cuts by minimizing spindle extension. The ram’s 400 x 500 mm cross section is ideally sized for extended reach with rigid support to enable the machine to perform additional operations, helping to reduce time-consuming large-part setups for faster cycle times and less work-in-process. The machine’s Ram Displacement Compensation system uses a hydraulically actuated tension rod system to counteract the static loads of attachments, and control ram displacement caused by variations in ram extension and attachment weight. Like all MAG boring mills, the FTR 3500 includes W and Z-axis thermal compensation software to dynamically offset spindle growth.

The FTR 3500 is available in column heights of 2 to 5 meters (6.6 to 16.4 ft) in half-meter increments. Traveling-column design allows virtually unlimited X-axis travel for processing of large and long workpieces or multiple batch parts, while 20 m/min (787 ipm) rapid traverse rates reduce cycle times. The choice of spindle power trains includes two four-speed versions available with spindle diameters of 130 and 155 mm (5 and 6 in). Available horsepower is 56 kW (75hp).

The FTR 3500’s rigid box welded column construction, wide way spreads on the column and runway, and steel runway fabrication provide exceptional rigidity and durability for the most demanding machining requirements, resisting deflection and minimizing vibrations. Linear positioning accuracy is 0.015 mm (0.0006 in) and repeatability is 0.008 mm (0.0003 in). Precision roller packs on X, Y and W axes, provide stability, low friction, durability and maintainability for high-performance machining. The Y-axis has a 100 mm (3.94 in) preloaded, anti-friction ballscrew, while the Z and W axes use a 63 mm (2.5 in) diameter ballscrew. The X-axis is driven by an electrically-preloaded rack and pinion system.

Modular design allows economical customization of the FTR 3500, along with industry’s fastest machine build and delivery. The machine can be fitted with choice of travels, headstocks, spindle diameters and spindle power, controls, coolant systems, workholding and tool magazines. Front-end options include a range of indexing and rotary tables, auxiliary slides and floor plates. An optional attachment rack enables storage and quick change of contouring heads, programmable boring bars, right angle heads and more to speed production. Optional cartridge-style ram allows for a fixed attachment or attachment changing operations.

“Green” features of the FTR 3500 include a minimal air-oil lubrication system in the headstock, eliminating the need for chillers and ancillary equipment for lower overall ownership cost. Ergonomic enhancements include operator platforms with X-, Y- and W-travel options, and operator convenience packages that include lighting, power, air and workbench options. Custom workzone enclosures are also available.

The service areas of the machine are designed using Visual Uptime Management principles to simplify maintenance and maximize machine availability. Clear, color-coded labeling and note plates assist in accessing and maintaining key utilities for the machine and control.

About MAG
MAG is a leading machine tool and systems company serving the durable goods industry worldwide with complete manufacturing solutions. With a strong foundation based upon renowned brands such as Cincinnati, Cross Hüller, Fadal, Giddings & Lewis, Hüller Hille, Witzig & Frank, Hessapp, Ex-Cell-O, Honsberg and Boehringer, MAG is recognized as the preeminent provider of tailored production solutions based on state-of-the-art technology. Key markets served include aerospace, automotive and truck, heavy equipment, oil and gas, rail, solar energy, wind turbine production and general machining.

With manufacturing and support operations strategically located worldwide, MAG offers comprehensive lines of equipment and technologies including process development, automated assembly, turning, milling, automotive powertrain production, composites processing, maintenance, automation and software, and core components.

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