Hermle UWF 902 H User manual

Universal -
Toolroom Milling and
Boring Machine
Operating Manual
UWF 902 H

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UWF 902 H
1 All-round protective enclosure
2 Quill feed cross handle
3 Vertical milling head
4 Quill clamping
5 Spindle slide
6 Operator console
7 Spindle start key
8 Swivelling arm
9 Cooling lubricant level indicator
10 Cooling lubricant tank
11 Machine table
12 Protective bellows
13 Tool-changer sliding door
14 Compound slide rest
15 Machine light
16 Pull-out writing desk
17 Main switch

Control TNC 426

Introduction
Universal Toolroom Milling and Boring Machine
UWF 902 H
Machine No.
Year Construct.
Control
Introduction
These operating instructions are aimed at helping you becoming quickly,
selectively, and comprehensively familiarized with the new HERMLE
Universal Toolroom Milling and Boring Machine.
Please pay particular attention to the safety instructions
marked by the danger symbol.
We wish you every success with the HERMLE UWF
Universal Toolroom MIlling and Boring Machine.
Yours Sincerely,
Maschinenfabrik Berthold Hermle AG
B. 129.H426.10.0196.E
The machine in this operating manual conforms to the norm.

Introduction
Note
This handbook is aimed primarily at machine operators.
It should always be kept near the machine as a reference and
as a source of maintenance information. Wiring diagrams, etc. can
be kept for safekeeping in the pouch which is found in the left-hand
inside door of the electrical cabinet.
The following symbols are used in this operating manual:
Danger - Extreme care and prudence called for.
Mistakes could lead to injury of
the machine operator or third-parties.
Note - Ignoring this remark can lead to
damage of the machine, the tool
or the workpiece.
Publisher’s Note
Published by: Maschinenfabrik Berthold Hermle AG
Post Box 1240
D-78556 Gosheim
Federal Republic Of Germany
This document may not be altered, reproduced, or given to
third parties, nor used in contravention of our due interests.
Copyright: Berthold Hermle AG
The company reserves the right to make design changes and technical alterations.
Printed in the Federal Republic of Germany
B. 129.H426.10.0196.E




Service-Organization
Hermle - Service-Organization
Phone-Number: ++/7426 / 95 - Extension
Technical problems - Hotline
After Sales Service Tel. 3723
Fax.3709
Programming Problems Tel. 6185
Tel. 6187
Spare Parts Tel. 6221
Tel. 6222
Tel. 6223
Head of Service and Assembly Mr. Betting
Head of After Sales Service Mr. Koch
Hotline Service Mr. Seemann

Table of Contents
Section Topic Page
1 General Information
1.1 Description of the Machine ............................................ 1-1
1.2 Speed-Torque-Power Curves........................................ 1-2
1.3 Operating Range ........................................................... 1-3
1.4 Technical Details ........................................................... 1-4
1.5 Machine Dimensions - Space Needed .......................... 1-6
1.6 Base Plan ...................................................................... 1-7
2 Installation
2.1 Safety Precautions Transport ........................................ 2-1
2.2 Transport Instructions .................................................... 2-2
2.3 Installation Instructions .................................................. 2-5
2.4 Cleaning......................................................................... 2-7
2.5 Removal of the Transport Safeguards .......................... 2-8
2.6 Electrical Connection ..................................................... 2-9
2.8 Preparation for Initial Start-Up ....................................... 2-10
2.9 Initial Start-Up ................................................................ 2-13

Section Topic Page
3 Operation
3.1 Safety Instruction ........................................................... 3-1
3.2 Starting the Machine - General ..................................... 3-5
3.3 Operating Modes - CNC Control ................................... 3-8
3.3.1 Manual Operation .......................................................... 3-8
3.3.2 Electronic Handwheel .................................................... 3-9
3.3.3 Positioning with Manual Data ........................................ 3-10
3.3.4 Program Run - Full Sequence ....................................... 3-10
3.3.5 Program Run - Single Block .......................................... 3-10
3.3.6 Program Store/Edit ........................................................ 3-11
3.3.7 Test Run ........................................................................ 3-11
3.3.8 Block Advance ............................................................... 3-12
3.3.9 Compensation of the Thermal Expasion of the Y-Axis . 3-13
3.4 Tool Clamping ............................................................... 3-14
3.5 Data Transfer ................................................................. 3-15
3.6 Cooling System of the Electrical Cabinet ...................... 3-15
3.7 Horizontal Milling ........................................................... 3-16
3.8 Vertical Milling................................................................ 3-17
3.9 Swivelling of the Vertical Head ...................................... 3-18
3.10 Adjusting the Vertical Head ........................................... 3-18
3.11 Extending the Quill ........................................................ 3-20
3.12 Cooling System ............................................................. 3-21
3.13 Moving Free ................................................................... 3-22
3.14 Spindle Orientation ........................................................ 3-23
3.15 Closed Loop Oil Lubrication .......................................... 3-23
3.16 Central Lubrication ........................................................ 3-24
3.17 User Parameters ........................................................... 3-25
3.18 Changing the Machine Parameters............................... 3-27
3.19 Miscellaneous Functions ............................................... 3-29

Section Topic
4 Options
4.1 Tool changer HTC 34 .................................................... UWF 902 H
4.2 Tool changer UTC 34 .................................................... UWF 902 H
4.3 Automatic head..............................................................UWF 902 H
4.4 Tool changer HTC 34 ....................................................UWF 1002 H / UWF 1202 H
4.5 Tool changer UTC 46 ....................................................UWF 1002 H / UWF 1202 H
4.6 Automatic changeover from ver. to hor. machining ...... UWF 1002 H / UWF 1202 H
4.7 Rigid clamping table ...................................................... UWF 900
4.8 Rigid clamping table ...................................................... UWF 902 S
4.9 Rigid clamping table ...................................................... UWF 1002 S
4.10 Rigid clamping table ...................................................... UWF 1202 S
4.11 Rigid clamping table ...................................................... UWF 902 H
4.12 Rigid clamping table ...................................................... UWF 1002 H
4.13 Rigid clamping table ...................................................... UWF 1202 H
4.14 Universal clamping table ...............................................UWF 900
4.15 Universal clamping table ............................................... UWF 902 S
4.16 Universal clamping table ............................................ UWF 1002 S / UWF 1202 S
4.17 Universal clamping table ............................................... UWF 902 H
4.18 Universal clamping table ............................................ UWF 1002 H / UWF 1202 H
4.19 NC-rotary table .............................................................. UWF 900
4.20 NC-rotary table .............................................................. UWF 902 S
4.21 NC-rotary table .............................................................. UWF 1002 S / UWF 1202 S
4.22 NC-rotary table .............................................................. UWF 902 H
4.23 NC-rotary table .............................................................. UWF 1002 H / UWF 1202 H
4.24 NC-controlled swivelling rotary table .............................UWF 1002 H / UWF 1202 H
4.25 NC-Precision dividing head RWNC-125 / RWNC-160 ..All Models
4.26 NC-Precision dividing head TAWN 125 / RTWN 200 ... UWF 1002 S-H / UWF 1202 S-H
4.27 Swarf conveyor ..............................................................All Models exept UWF 900
4.28 Three-D probe ............................................................... All Models
4.29 Internal coolant supply through Spindle ........................ All H Models
4.30 Spindle taper HSK A 63............................................... All H Models
4.31 High frequency spindles ............................................. All H Models
4.32 Arbour support ............................................................... All Models

Section Topic Page
5 Maintenance and Lubrication
5.1 General .......................................................................... 5-1
5.2 Maintenance Plan .......................................................... 5-2
5.3 Lubrication Plan ............................................................. 5-6
5.4 Selection of Lubricants .................................................. 5-7
5.5 Maintenance of the NC-Rotary Table............................ 5-12
5.6 The Tool-Clamping System ........................................... 5-14
5.7 Maintenance the Tool Changer ..................................... 5-14
5.8 Changing the Guideway Strippers ................................ 5-15
5.9 Maintenance of the Cooling-Lubricant Unit ................... 5-16
5.10 Maintenance of the Heat-Exchanger Unit ..................... 5-18
5.11 Bevel Gear Lubrication - Vertical Milling Head ............. 5-19
5.12 Maintenance of the Hydraulic Power Pack ................... 5-20
5.13 Maintenance of the Central Lubrication System ........... 5-22
5.14 Maintenance of the Circulatory Lubrication System ..... 5-22
5.15 Rigid Clamping Table Maintenance .............................. 5-24
5.16 NC-Swivelling Rotary Table Maintenance..................... 5-24
5.17 Internal Coolant Supply through Spindle ...................... 5-24
5.18 Removal Feed Motor (Z-Axis) ....................................... 5-25
5.19 Service unit .................................................................... 5-26
6 Malfunctions
6.1 Malfunctions Spindle Slide ............................................ 6-1
6.2 Malfunctions UTC 34 ..................................................... 6-2
6.3 Malfunctions Magazine .................................................. 6-4
6.4 Miscellaneous Malfunctions .......................................... 6-5
7 Accessoires
7.1 Arbour Support .............................................................. 7-2

Section Topic Page
8 User Cycles
8.1 Bolt-Hole Circle .............................................................. 8-2
8.2 Right-Angle Hole Grid.................................................... 8-4
8.3 Reaming ........................................................................ 8-6
8.4 Hollowing ....................................................................... 8-8
8.5 Peck Drilling ................................................................... 8-10
8.6 Pocket Milling................................................................. 8-14
8.7 Groove ........................................................................... 8-18
8.8 Slot ................................................................................. 8-20
8.9 Circular Groove.............................................................. 8-22
9 Appendix
List of equipment for the chain magazine and UTC 34
10 Control
HEIDENHAIN Programm Instructions

1-1
UWF 902 H
Standard
• All-round protective cabin
• 5-axis continuous control
• Composite structure of cast iron/epoxy concrete
in the machine´s foot and in the compound slide
• Heat exchanger
• Brushless AC motors
• Work area lighting
Options
• Tool changer
• Swarf conveyor
• Rigid table
• Universal table
• NC rotary table
table plate Ø 500 mm
table plate Ø 650 mm
• Measuring probe
• NC indexing device
• Internal coolant supply
• Hydraulic quick clamping of vertical head
Accessories
• Chucks
• Arbour support
1. General Information / 1.1 Machine Description
1. General Information
1.1 Description of the Machine
The Hermle UWF 902 H is an efficient numerically
controlled milling machine tool designed for
machining both the largest and the smallest work-
pieces.
Equipped with a rigid clamping table, the machine
can deal with workpieces of a maximum weight up
to 450 kg, and a maximum mounting area of 900 x
528 mm.
The most complicated workpieces, weighing up to
300 kg, can be machined on the numerically
controlled rotary table.
A tool-changer with a total of 34 magazine places
and an integrated swarf conveyor are also available
as options.
As standard features, each machine is provided
with an ergonomically designed splash guard and
with a removable, generously proportioned
170 litre cooling lubricant container.

1-2
150 150
900
130
500
458
16
10
195
65
450
600
1.2 Speed - Torque - Power Curves
1.2 Speed - Torque - Power Curves

1-3
1.3 Operating Range
1.3 Operating Range
The operating range of your HERMLE UWF has the
following values:
X-axis 600 mm
Y-axis 450 mm
Z-axis 500 mm
Note
When using a tool-changer, or before the dry-run of
a new operator-program, or after any change in
program, check to see whether the tool-changer
arm clears the outer edges of the workpiece and / or
the workpiece-holding device.
The need for free movement of the changer-arm
should be taken into consideration when
programming.
Where there is danger of collision, rearrange
workpiece.
Note
If you incline the vertical milling head from its zero
position into an angular position +/- in order to
produce inclined surfaces or borings, the working
range of the Y-axis is reduced from 450 mm to 410
mm. Caution: collision danger with tool changer
flap.

1-4
1.4 Technical Details
1.4 Technical Details
Main Drive
Power of the spindle motor (AC-motor 1 PH6) at load factor 100% 8,6 kW
Spindle speed range:
speed infinetly variable within 3 gear steps 20 ... 6300 rpm
Tool holding, horizontal and vertical ISO 40 DIN 2079
Hydromechanical tool clamping, clamping force(vertical) 10 000 N
Hydromechanical tool clamping, clamping force(horizontal) 12 000 N
Spindle diameter at front, horizontal/vertical 75 / 55 mm
Quill stroke, vertical 75 mm
Feed Drive
Feed motor for each axis - AC, brushless
Feed range in X, Y, and Z axes (manual/programmable) 1 ... 2000 / 10000 mm/min
Feed force in all axes (at 80% load factor) 6 000 N
Rapid traverse in all axes 10 m/min
Noise Level
Machine noise - place of emmission value (according to German machine
noise regulation 3. GSGV, paragraph 1 section c and d) 78 dB (A)
Working Range
Longitudinal X-axis 600 mm
Transverse Y-axis 450 mm
Vertical Z-axis 500 mm
Measuring System
Direct maesurement in X, Y, and Z axes:
Resolution 0,1 µ
Input resolution 0,1 µ
Display steps 0,1 µ
Resolution, fourth axis 0,001°
Resolution, fifth axis 0,001°

1-5
1.4 Technical Details
Tables - Clamping Surfaces
Rigid clamping table 900 x 528 mm
Universal table, swivelling range towards the machine 30°, away from the machine 15°
Round plate, tilting range of +/- 25° Ø 420 mm
Round plate, tilting range of +/- 30° Ø 650 x 395 mm
NC-rotary table:
Round plate, tilting range of +/- 30° Ø 500 mm
Round plate, tilting range of +/- 4° Ø 650 mm
Control System
HEIDENHAIN contouring control system (with screen) TNC 426
Cooling Lubricant System - Lubrication
Capacity of the cooling lubricant tank 170 Liter
Rate of delivery / pressure 40 L/min / max. 3 bar
Lubrication, automatic - central
Electrics
Operational votage 400 V; 3-phase; 50 Hz
Control voltage 220 V AC; 24 V DC
Total connection valve 16 KW
Total connection valve with IKZ 19 KW
Dimensions - Weight
HERMLE UWF 902 H - including all-round protective cabin
(length x width x height) 2,95 x 2,20 x 2,30 m
Space Required (length x width) 4,55 x 3,60 m
Total weight - including rigid table, all-round protective cabin,
tool-changer and swarf conveyour ca. 6000 kg
Tool-Changer - Tool Magazine
Type UTC 34
Full technical details: see section 4
Pneumatic:
Compressed air supply p >/= 7,0 bar
Compressed air consumption at 7,0 bar approx. 0,5 Ncbm/h
Compressed air consumption with optional spindle blow-out device approx. 8,0 Ncbm/h
The compressed air should be processed with a chiller to a dry dew point of 5°C. This ensures the best
conditions for long life of the pneumatic components.

1-6
1.5 Machine Dimensions - Space Needed
1.5 Machine Dimensions - Space Needed for UWF 902 H with UTC 34

1-7
1.6 Base Plan
1.6 Base Plan for UWF 902 H with UTC 34
Complete installation surface of the machine 5,4 m2
Supporting surface of the machine 1,1 m2
Floor load related to the complete installation
surface of the machine approx. 1235 kg/m2
Max. load on the front points of support F1
or F2 when the angle table is positioned
eccentrically approx. 2080 kg
Max. foundation pressure of F1 or F2 approx. 11,0 kg/cm2
Complete installation surface of the machine
Supporting surface of the machine
Electric Pneumatic
Cabin
support

2-1
2. Installing the UWF / 2.1 Safety Precautions Transport
2. Installing the UWF
2.1 Safety Precautions - Transport
Danger
• People must never be allowed to stand under
heavy loads!
When selecting lifting tackle, chains, hawsers,
etc. make absolutely sure that the maximum load
carrying capability is sufficient to lift the transport
weight of the UWF.
Transport weight of the UWF: 5500kg
(weight of the heaviest configuration)
The maximum load carrying capability of lifting
tackle is normally clearly marked.
• Only lift the machine evenly, vertically, and with-
out any jerky movements.
• When transporting the machine by truck, secure
the machine to the loading space and ensure that
slippage cannot occur.
• Only use fork-lift trucks and other lifting trucks with
sufficient lifting power, i.e. capable of supporting
the transport weight of 6000 kg.
• Affix lifting tackle only to the orange-coloured
lifting devices provided, screwed to the side of the
machine.