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MAG has introduced the Hypermach GTi five-axis titanium aerospace profiler at IMTS for efficient processing of large parts such as spars, bulkheads and door-edge frames, or nested-part groups.

MAG will also showcase a Hypermach H4000 GTi at the show with hard-metal cutting demonstrations using a five-axis HSK100A 6,000rev/min/850Nm high-torque geared spindle.

Part of the larger Hypermach horizontal range of machines, the GTi series is covered by four key patents related to efficient, accurate machining.

Developed for high-output machining of large monolithic titanium aerospace parts, the five-axis Hypermach GTi series turns the typical profiler concept on its side in a fixed-column, travelling table arrangement.

The modular machine design is available with part capacities from 2 x 4m (6.6 x 13.1ft) to 2 x 8m (6.6 x 26.3ft).

The Hypermach GTi’s structural link provides lock-up between the column and X-axis table base to provide extreme stiffness for aggressive cuts at the upper limits of the workzone.

This four-point column link provides closed-loop stability, controlling machine geometry changes caused by thermal growth and maximising structural stiffness for heavy machining.

The added stiffness enables the Hypermach to consistently produce higher quality and more accurate parts, while allowing heavy cuts at any position in the workzone to reduce cycle times and achieve the lowest cost-per-piece production.

The X-axis table/pallet receiver delivers feed rates up to 50m/min (2,000in/min), while the Y-axis reaches vertical speeds up to 35m/min (1,378in/min) to minimise parasitic time out of the cut.

Water-cooled servomotors are used on X,Y and Z axes of GTi series machines to eliminate thermal influence of the motors on positioning accuracy and to maximise performance for high acceleration/deceleration and feed rates.

The spindle carrier rotates at 60deg/sec (10rev/min) in A and C axes, powered by worm/wheel drives.

Scale/encoder feedback on all five axes provides accuracy and MAG’s optional Volumetric Error Compensation package can enhance the machine’s volumetric performance by 50 per cent.

GTi series machines come standard with a 72-tool magazine, which is field expandable to 110 or 142 tools.

Hypermach GTi series machines can be configured to meet the layout and workflow requirements of most plants.

All Hypermach H-Series machines feature a full-portal, open-centre design, allowing chips to fall through to a high-volume conveyor to avoid chip re-cutting and the need for a blow-off attendant.

Programmable, variable high-pressure through-spindle and external coolant system is a standard feature.

Pallet load can be from the right or left side and the chip conveyor can be configured to discharge in either direction.

Installation is on a flat floor, which reduces the cost and time required for installation by avoiding the need for pits and multi-step foundations.

This makes future reconfiguration of the plant layout easy.

Combined with MAG’s Cincron cell automation modules, the GTi series design allows a virtually infinite number of material-handling and cell configurations for flexible multi-machine and multi-pallet part manufacturing.

The four patents covering the Hypermach machine design include one for the rigid four-column lockup between the column and table base, which provides consistent stiffness and improved accuracy throughout the work zone.

A second patent covers the ‘flight deck’ ergonomics of the operator station.

Its layout permits visual monitoring of the machine’s HMI, the work zone, the tool-change process, tool in the ready position, the tool magazine itself and the utilities panel, as well as immediate physical access to the work zone.

A third patent covers maintenance and reliability issues – motors and drives are on the exterior of the machine, away from workzone contamination, and critical drive components, such as ways, bearing, ballscrews and scales, can be accessed and serviced from the exterior of the machine.

A fourth patent covers the pallet-handling system, which allows a pallet to be loaded from either or both sides of the machine without any modification to the system, permitting a variety of work-handling configurations without modification to the machine.

MAG Industrial Automation Systems

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