9404 - 2-Machine Specifications-En

STC 630D
User’s Manual MNo. 9404

Machine specifications Manual 1/Part: 2
2
Machine specifications
27.05.2004  Copyright V01/2 Masch.Daten_En - 1 -

STC 630D
1 GENERAL ......................................................................................... 4
2 AREAS OF APPLICATION OF THE MACHINING CENTRES ......... 5

2.1 Work processes ................................................................................. 5
2.2 Range of workpieces ......................................................................... 6
2.3 High speed machining ....................................................................... 7
3 ASSEMBLIES ................................................................................... 8
3.1 Cross-bed .......................................................................................... 9
3.2 Fixed column, guide section and support ........................................... 9
3.3 Z-slide ................................................................................................ 9
3.4 Rotary and swivelling axis ................................................................ 10
3.5 Work spindle 15,000 rpm, HSK-A100............................................... 11
3.6 Feed, guiderails, measuring systems ............................................... 12
3.6.1 Guiderails ............................................................................... 12
3.6.2 Bearing and rotary and swivelling axis .................................... 12
3.6.3 Drives: rotary and swivelling axis A and B............................... 12
3.6.4 Drives: linear axes X, Y and Z................................................. 12
3.6.5 Weight compensation ............................................................. 13
3.6.6 Measuring systems ................................................................. 13
3.7 Tool changer .................................................................................... 14
3.8 Tool-Tower magazine ...................................................................... 16
3.9 Workpiece change system STC 630D.............................................. 17
3.9.1 Workpiece holder and workpiece ............................................ 18
3.10 Workroom protection machine casing .............................................. 19
3.10.1 Working area ............................................................. 19
3.10.1.1 Visiport ...................................................................... 19
3.10.2 Protective equipment................................................. 19
3.11 Cooling lubricant supply ................................................................... 20
3.11.1 External cooling lubricant supply ............................... 20
3.11.2 Internal cooling lubricant supply ................................ 20
3.11.3 Oil skimmer ............................................................... 20
3.11.4 Chip flushing / splash shower .................................... 20
3.11.5 Flushing gun ............................................................. 20
3.12 Chip conveyor .................................................................................. 20
3.13 Devices for auxiliary processes ........................................................ 21
3.13.1 Hydraulic system ....................................................... 21
3.13.2 Pneumatic system ..................................................... 22
3.13.3 Lubrication ................................................................ 23
3.13.4 Cooling ...................................................................... 23
3.14 Control and monitoring equipment ................................................... 24
3.14.1 Workpiece measurement .......................................... 24
3.14.2 Tool measurement with laser .................................... 24
3.14.3 Signal lamps ............................................................. 24
3.15 Electrical switch cabinet ................................................................... 25
4 CONTROL SINUMERIK 840D ........................................................ 26

4.1 Operating and display components/interfaces.................................. 26

STC 630D
4.2 Control structure .............................................................................. 26

4.3 CNC functionality ............................................................................. 27
4.3.1 Special control functions ......................................................... 28
4.4 Operation and display functions ....................................................... 29
4.4.1 Tool corrections ...................................................................... 29
4.4.2 Zero offsets............................................................................. 29
4.4.3 Diagnostics ............................................................................. 29
5 TECHNICAL SPECIFICATIONS ..................................................... 30

5.1 Main axes ........................................................................................ 30
5.1.1 Travels 30
5.1.2 Feed axes ............................................................................... 30
5.2 Working areas.................................................................................. 31
5.3 Work spindle 15,000 rpm, 90 kW, HSK-A100................................... 33
5.4 Tool handling for HSK-A100 ............................................................ 33
5.5 Tower magazine HSK-A100, 240 memory locations ........................ 34
5.6 Tower magazine HSK-A100, extra-long tools................................... 35
5.7 HSK-A100, bridge tools.................................................................... 36
5.8 Cooling lubricant supply with turbo-filter ........................................... 37
5.9 Chip conveyor .................................................................................. 38
5.10 Measuring on workpiece .................................................................. 38
5.11 Tool measurement with laser ........................................................... 38
5.12 Connected loads .............................................................................. 39
5.13 Ambient conditions........................................................................... 40
5.13.1 Permissible ambient conditions in accordance with
VDI/DGQ 3441, in particular section 4.3.2 .............................. 40
5.13.2 Noise emission .......................................................... 40

STC 630D
1 General
The machining centre STC 630 is designed as a 5-axis machining centre for 5-axis
simultaneous machining of complex workpieces. In addition to 5-axis simultaneous machining,
the machine is also designed for 5-sided drilling and milling work at any angle for a
comprehensive range of workpieces.
The modern machine and control design of these machining centres ensures effective use in
single piece production, small series and medium series production with high productivity and
accuracy.
The design of the machine is based on a cross-bed construction. All main assembles are
computer-optimised and have high static and dynamic stability.
They thus provide the basic prerequisite for high machining precision and long-term accuracy.

STC 630D
2 Areas of application of the machining centres

The machines are suitable for machining hollow or solid structural parts of all types according
to their pallet size and clamping area. Depending on the equipment of the machining centres,
the application possibilities can be altered or extended.
All metal and cast materials can be machined. For machining of other materials, it is necessary
to consult the manufacturer.
 see also: Part 1, “Designated use and inappropriate use“ 
2.1 Work processes
Standard • Face milling • Boring • Grinding

machining • Roll milling • Reboring • Countersinking
• Circular milling • Precise drilling • Tapping
Special machining
High speed machining HSC
Shaping for end facing
Profile cutting
Rigid tapping (tapping without tap holder)
Helical milling
Milling of cylinder paths
Rotary milling with rotary table

STC 630D
2.2 Range of workpieces
The machine is primarily suited to the machining of the following workpieces:
impellers and blisks
engine housings
structured parts for the aerospace industry
prismatic and box-shaped parts from general production technology
When machining workpieces on the machining centre, observe the geometry in accordance
with the workroom plan and the following features to be found in this section under 'Technical
Specifications':
max. interference diameter
workpiece clearance height
max. loading mass
With special workpiece clamping devices (with hydraulic clamping system), which can be
supplied by the manufacturer as an option, the machining process can be technologically
optimised.
 see also: Part 1, “Designated use and inappropriate use“ 

STC 630D
2.3 High speed machining
The high-speed machining of light metal and casting materials is a basic area of application of
the STC 630D.
The high performance equipment with:
high work spindle speeds

high main drive outputs
high acceleration rate
high feed or rapid motion speeds
short chip-to-chip time
provides the following advantages:
high material removal volume
high surface quality
low heat transfer into workpiece
low workpiece warping
high time-saving for precision machining.
Note:
Cutting capacity does not depend solely on the machine output, however, but is also
influenced by technological conditions such as material properties, workpiece clamping, tool
type, tool projection length, tool cutting angle etc.

STC 630D
3 Assemblies
The design of the machine is based on a cross-bed construction with the following axis
arrangement:
X-axis (longitudinal) on tool side (column)

Y-axis (vertical) on tool side (support)
Z’-axis (transverse) on workpiece side (table)
The M A C H I N E basically consists of the following main assemblies:
cross-bed
fixed column, guide section and support
Z-slide
rotary-swivelling axis
guiderails and ball screws (linear axes)
measuring systems (linear axes)
feed drives (linear axes)
lubrication system
hydraulic supply
pneumatic processing
weight compensation
cooling system
switch cabinet and installations
CNC-control SIEMENS Sinumerik 840D
work spindle 15,000 rpm for HSK-A63
tool change system (without workpiece pallets)
clamping station
tool changer
tool magazine with 60 storage spaces
workroom cabin with Visiport and emission extraction
chip conveyor
flushing installations (flushing gun, splash shower, external and internal CL supply)
cooling lubricant supply, including high pressure for internal coolant supply
mounting elements
The following sections briefly describe the individual assemblies in terms of structure and
function.

STC 630D
3.1 Cross-bed
The bed carries the anti-friction profile guiderail of the Z-axis. The 6 fastening surfaces for the
fixed column are situated behind the bed. 2 brackets are mounted at the rear of the machine
bed which carry the switch cabinet and the hydraulic unit. The chain magazine and the tool
changer are arranged on the right-hand side.
The bed is open to achieve good chip clearance between the anti-friction profile guiderail of the
Z-axis. The chips fall almost unhindered into the chip conveyor, which is inserted into the front
of the bed parallel to the Z-axis.
The Z-axis is characterised by the parallel arrangement of two inter-ribbed box sections. This
provides a high degree of inherent stability and torsional strength.
The box sections are connected by roof-shaped profiles at regular intervals to ensure chip
clearance.
3.2 Fixed column, guide section and support
The fixed column is designed as a welded steel cellular construction. The anti-friction profile
guiderails suspended on the fixed column carry the guide section, which performs the
longitudinal movement (X-axis).
The guide section is designed as a stable, light-weight welded steel construction. This provides
high machine dynamics.
The anti-friction profile guiderails mounted on the guide section carry the support, which
performs the vertical movement (Y-axis).
The support carries the work spindle and is optimised for maximum rigidity with minimum inert
masses.
3.3 Z-slide
The z-slide carries the rotary-swivelling axis and is mounted on the cross-bed via anti-friction
profile guiderails of the Z-axis and moves transversely to the fixed column.

STC 630D
3.4 Rotary and swivelling axis
The rotary-swivelling axis with direct drives is mounted on the z-slide.
The assembly basically consists of the following elements:
• table
• rotary-swivel table
• B-axis housing
The table carries the pallet and has a direct drive (A-axis). The table itself is built into the
rotary-swivel table. The rotary-swivel table also has a direct drive (B-axis) and is mounted on
the B-axis housing. The B-axis housing is in turn mounted on the z-slide.
The basic functions / properties of the A-axis are:
• Berg clamping heads as the interface to the workpiece pallet

• absolute, direct hodometry
• clamping, hydraulically operated
• brake, hydraulically operated
• compressed air for repelling dirt at the clamping heads (pallet clamping)
• sealing air between table block and housing
• system for cooling the direct drive and preventing unauthorised heating of assemblies.
• pulse lubrication on axial-radial table bearing
The basic functions / properties of the B-axis are:
• absolute, direct hodometry

• clamping, hydraulically operated
• brake, hydraulically operated
• sealing air between table block and housing
• system for cooling the direct drive and preventing unauthorised heating of assemblies.
• pulse lubrication on axial-radial table bearing

STC 630D
The installations for supply, actuation and control of the rotary-swivel functions are located at
the following points:
• rotary-swivel table, below the casings in the upper section and on the back
• z-slide, below the workroom protecting trough, on the tool changer side
• at the interface A-trailing cable installation / workroom cabin
• console cooling unit / hydraulic unit
• electrical switch cabinet
3.5 Work spindle 15,000 rpm, HSK-A100
The work spindle is designed as a unit and is mounted on the support in horizontal position via
a flange connection. Additional fixing on the back of the support gives the assembly
considerably greater installed rigidity.
The installations for supply, actuation and control of the work spindle functions are situated on
the back of the support on the jib and on the hydraulic unit or in the electrical switch cabinet.

STC 630D
3.6 Feed, guiderails, measuring systems
3.6.1 Guiderails
Pre-loaded, exactly aligned anti-friction profile guiderails ensure high precision of the assembly
guiderails and therefore high machining quality and high long-term accuracy.
3.6.2 Bearing and rotary and swivelling axis
Pre-loaded axial-radial table bearings ensure high precision of the rotary and swivel axis
movement. The powerful dimensions are the basis for high long-term accuracy and high
rigidity of the machine structure and therefore high machining quality.
3.6.3 Drives: rotary and swivelling axis A and B
Axes A and B are driven by powerful direct drives. The drive motors (torque motors) are
directly flanged onto the rotary or swivel axis. This drive design does not require any gear parts
in the drive train and therefore ensures play-free operation over the entire service life.
3.6.4 Drives: linear axes X, Y and Z
The axes X, Y, Z are driven by digital AC servo motors via V-belts on preloaded ball screws for
the assemblies:
pilot carriage X-axis (2 synchronised AC servo motors)
Z-slide with mounted rotary-swivelling axis
support with work spindle
The pre-loaded ball screws together with the two-sided bearing provides high rigidity of the
linear movement axes.
The drive motors are positioned on the outside for easy servicing. They are located at the top
and bottom on the right-hand side of the fixed column for driving the
pilot carriage X-axis, at the top or bottom on the right-hand side of the fixed
column,
supports on the pilot carriage (X-axis)
Z-slide on the front of the bed
The travels of the linear axes are limited by software limit switches and monitored by the safe
limit positions SI of Safety Integrated.
All profile guiderails, axis drives and measuring systems which are fitted in or on the workroom
are protected by covers and sealed against cooling lubricant and chips.

STC 630D
3.6.5 Weight compensation
The complete vertically travelling weight of the Y-axis is compensated via a closed, hydraulic
handling system with hydraulic cylinder, pressure accumulator and charger pump.
The hydraulic cylinder for the weight compensation is attached to the guide section (X-axis)
and acts on the support (Y-axis) via the piston rod.
3.6.6 Measuring systems
The length measurement in the axes X, Y and Z is carried out by means of the direct absolute
length gauge. They are sealed in an aluminium housing and are pressurised with compressed
air. The scanning carriage and its guide are thus ideally protected against chips, dust and
splash fluids.
The angle of the A-axis (rotary axis) and B-axis (swivel axis) is measured by the angle
measurement system by means of absolute, direct angle measurement systems. These are
encapsulated designs.
The angle of the spindle (Q-axis) is measured by the angle measurement system via an
incremental gear encoder. This axis positions the angle position of the tool (tool change,
tapping, shaping, angle-defined moving out of the workpiece).

STC 630D
3.7 Tool changer
This assembly changes tools fully automatically between the tool magazine and the work
spindle.
In teach mode, tool change on the work spindle is also possible by hand, as described in the
section Operation.
The tool changer consists of the assemblies:
Tool gripper
Double gripper
Swivel arm
Cross slide (slide)
Longitudinal slide (cross slide)
Frame
The tool changer is mounted on the machine bed via the frame on the right. The frame carries
the longitudinal slide.
The tool changer moves to the work spindle via the longitudinal slide. The tool gripper is
inserted into the gripper groove of the tool or extended from it, or moved away from the
spindle with the gripped tool.
When changing tools in the feeder of the tower magazine or in a chain magazine, the tool is
removed from the feeder/magazine or inserted there with the longitudinal slide.
The longitudinal slide in turn carries the cross slide.
When changing the tool in the work spindle, the tool is removed from or inserted into the
work spindle with the cross slide.
The double gripper moves via the cross slide to the feeder of the tower magazine or to the
chain magazine. The tool gripper is inserted into the gripper groove of the tool or extended
from it, or moved away from the tool space with the gripped tool.

STC 630D
The swivel arm is mounted on the cross slide.
The swivel arm presents the double gripper at the work spindle or at the feeder of the tower
magazine or at the chain magazine in the required home position. This is done via a 90°
swivel.
The double gripper is mounted on the swivel arm.
The double gripper performs a 180° swivel during changeover
Two tool grippers, consisting of gripper tongs and clamping levers, are mounted on the double
gripper.
The tool is gripped by the tool gripper in the gripper groove.

The clamping lever of the tool gripper features mechanical locking.
The movements on the changer are carried out via hydraulic cylinders.
The control and monitoring elements are all mounted on the tool changer. Machine control unit
is used for the control itself.

STC 630D
3.8 Tool-Tower magazine
This patented tool magazine for
240 storage spaces (4 towers)

is an assembly which is installed next to the machine and oriented towards it.
The tower magazine is a particularly space-saving arrangement for a large number of tools.
The tower magazine consists of the following assemblies:
- Base frame
Depending on the version, the base frame contains two, three or four rotating
tool towers. The guideways and the drives for the feeder are also mounted in
the base frame.
- Tool towers:
Each tool tower holds 4 tool holders (combs) with 15 tool spaces each.
- Tool feeder:
This transports the tools from the tool holder to the tool changer. The drive is
carried out with a toothed belt drive via axes “TLZ” and “TLY”. The feeder arm
carries the tool and enables the transfer to the tool changer or to the
corresponding magazine space.
- Loading station
On each tower, one comb is accessible from the outside through a door for
loading/unloading tools.
- NC-operating panell

STC 630D
3.9 Workpiece change system STC 630D

Workpiece changer, consisting of:
5
1. Changer bed
4 2. Longitudinal slide
6
3. Swivel frame
3 4. Gripper unit
2 5. Bearing block
6. Loading rocker
7. Support plate
1 8. Pallet
7 9. Chip trough
8
9
The workpiece changer is installed on the foundation plate via separate installation elements
on the right next to the machine. The changer bed forms the supporting structure of the
changer assemblies.
The bearing block with the loading rocker is mounted on the front side of the changer bed. The
support plate is integrated in the loading rocker. The support plate can be rotated and indexed
every 90°.
The loading rocker moves to two positions driven by the hydraulic cylinder:
- Pallet horizontal, for set-up work by the operator.
- Pallet vertical, for transfer / acceptance of the pallet between loading rocker
and gripper units.
The longitudinal slide is mounted on the top of the changer bed via guiderails.
The longitudinal slide moves to four positions via the NC auxiliary axis PCX:
- position “transfer/acceptance at loading rocker“
- position “ready for pallet change“
- position “move swivel frame“
- position “transfer / acceptance at rotary-swivelling axis“

STC 630D
The swivel frame is mounted on the longitudinal slide is via a cross roller bearing. The swivel
frame moves to two positions (travel = 180°) via the NC auxiliary axis PCB:
- position 0°
- position 180°
Gripper units are mounted on the swivel frame. The gripper units are arranged in pairs and
carry the pallet. The gripper is moved by a lever gear via hydraulic cylinder.
The elements for actuation and monitoring are all mounted on the tool change system.
Actuation itself is carried out from the machine control.
3.9.1 Workpiece holder and workpiece
The workpiece holder (pallet) is equipped with the interfaces necessary for the tool change
system.
These are:
• holder taper for Berg clamp, for clamping of the pallet on the rotary-swivelling axis or on
the support plate at the set-up station
• connecting links for the grippers on the workpiece changer

STC 630D
3.10 Workroom protection machine casing
The workroom of the machining centre is a cabin closed on all sides. This provides:
• protection of the operator

• protection of the environment against chips and cooling lubricants
• noise protection.
3.10.1 Working area
The workroom has a lifting gate to the set-up station, which is automatically opened during a
pallet change. The set-up station is also surrounded by a protection equipment. Access is via
two doors.
Another lifting door separates the workroom from the tool changer.
A locked sliding door with inspection window separates the workroom from the main operating
station.
In set-up mode, this sliding door can be opened by hand. This facilitates observation of the
functional processes.
3.10.1.1 Visiport
Rotating inspection glass in the workroom cabin door on the main operating area.
3.10.2 Protective equipment
All protective guards which have to be opened during operation are locked, dividing fences
with tumblers, which are equipped with safety switches with mechanical tumblers and can only
be opened when potentially dangerous movements are switched off.
Next to the left-hand column wall, in the tool change area and in the rear machine area there
are locked, dividing protective guards which allow access to all maintenance points of the
machine.
These guards are to be opened with the aid of a tool and secured by a personal protection
switch. The bottom of the machine is separated by the closed machine bed.

STC 630D
3.11 Cooling lubricant supply

The cooling lubricant supply handles the entire cooling lubricant supply for the machining
centre and cleaning of the cooling lubricant (CL). The CL-supply is only intended for the use of
emulsion (water-oil mixture).
The CL is supplied to the chip conveyor on the machine and pumped back from the chip
conveyor to the CL-supply.
3.11.1 External cooling lubricant supply

The external cooling lubricant is supplied via 8 nozzles integrated in the work spindle.
3.11.2 Internal cooling lubricant supply

The internal cooling lubricant is supplied through the spindle and the tool. The pressure of the
cooling lubricant supply can be programmed via M-functions from the CNC.
A follow-on of cooling lubricant is prevented by blowing out and by a non-return valve situated
in front of the spindle.
3.11.3 Oil skimmer

The oil skimmer is integrated in the clean water tank for maintenance of the cooling lubricant
(removal of oils and contamination).
3.11.4 Chip flushing / splash shower

The chip flushing for workpiece and workroom is controlled via a separate circuit. The cooling
lubricant is distributed via nozzles in such a way as to cover all main areas of the workpiece
and workroom cabin when flushing.
3.11.5 Flushing gun
The flushing gun is used to clean the workpieces before and after machining.
3.12 Chip conveyor
The chip conveyor is a scraper belt conveyor with a vacuum slotted hole screen. Chips are
ejected approx. 1050 mm above floor level to allow a chip collector to be placed underneath.

STC 630D
3.13 Devices for auxiliary processes
3.13.1 Hydraulic system
The hydraulic unit rests on the right-hand bracket, which is mounted on the rear part of the
machine bed. The hydraulic system has two pump circuits.
Circuit 1: E21-HP1 works in hydraulic recirculation mode

in the range 95-100 bar, minimum 70 bar monitored.
functions operated by circuit 1:
- functions on the workpiece changer
- functions on the tool changer
- functions for the optional tool magazine types for HSK-A100
- operation of the sliding door for tool change
- pallet clamp
- brakes on A- and B-axis
Circuit 2: E21-HP2 works in pump connection mode.
Functions operated by circuit 2:
- supply weight compensation
- clamping counter-bearing Z-ball screw
- clamping of A- and B-axis
- release of tool clamping in the work spindle

STC 630D
3.13.2 Pneumatic system
The pneumatic system of the machine is supplied by the compressed air supply of the user.
The compressed air is prepared for use on the machine by:
- draining and filtering
- setting the operating pressure in the pressure controller
- depending on the requirements of the individual consumer, enrichment with

lubricant is carried out for lubrication and anti-corrosion protection or another
fine filtering.
The compressed air for the machine is connected with a way-valve:
- distribution via valve combinations to the functional assemblies
- the system pressure is monitored by a pressure monitor.
Functions of the pneumatic system:
- housing ventilation for the direct drives
- sealing air for A- and B-axis
- sealing air for option “rotating inspection glass on the main operating area”
- sealing air for option “workpiece measurement with Blum laser“
- sealing air to keep the measuring systems clean
- sealing air on work spindle
- blowing out of the work spindle during tool change
- sealing air in the pallet contact and retention knob area of the pallet clamps on
the rotary-swivelling axis (machine) and on the workpiece changer
- pneumatic contact control of the pallet on rotary-swivelling axis (machine)
- functions on the tool changer for HSK-A63
- lifting gate for pallet change

STC 630D
3.13.3 Lubrication
Pulse lubrication supplies the table bearing of the A- and B-axis, the ball screws and the profile
guiderails of the X-, Y- and Z-axis.
Work spindles up to 15,000 rpm are equipped with bearings with long-term grease lubrication.
Elements not connected to lubrication systems are delivered lubricated where necessary.
Maintaining the lubricating system see User’s Manual, Part Maintenance.
3.13.4 Cooling
A cooling unit is situated on a console on the right-hand rear side of the fixed column. The
work spindle and A- and B-axis drive assemblies are connected to the cooling circuit. Heat
elimination via the cooling circuit is used to prevent unauthorised heating of assemblies.
Heat generated in the electrical switch cabinet is eliminated via separate recooling units.
These are built into the switch cabinet doors.

STC 630D
3.14 Control and monitoring equipment
3.14.1 Workpiece measurement
The basic equipment consists of:
- switching probe mounted on tool holder

- infra-red signal transmission
- calibration point with exact calibrating bore
- mounting, installation, start-up
The switching probe is placed in the tool magazine and inserted into/removed from the spindle
with the tool changer via the NC-program.
3.14.2 Tool measurement with laser

The measurement takes place on a non-contact basis using a laser. During the measuring
process the tool to be measured is in the work spindle.
3.14.3 Signal lamps
Operating state display in four colours. Order of colours from top:

blue, red, yellow and green.
Meaning of the colours:
blue: operator intervention necessary
red: dangerous state
yellow: abnormal state, imminent critical state
green: normal state, machine producing in automatic mode

STC 630D
3.15 Electrical switch cabinet
The switch cabinet of the machine, in which the most important parts of the electrical
equipment are situated, is mounted on the bracket behind the machine bed. The mains power
connection is in the switch cabinet.
The master switch is on the left-hand side of the switch cabinet, looking at the switch cabinet
doors.
The machining centre only requires a suitable mains connection, all other auxiliary voltages
are generated internally.
The main operating point

is the CNC main control panel, on which all machine functions required to operate the machine
can be started or stopped.
Additional operating stations:
- Operating point set-up station
- Operating point loading station.

STC 630D
4 Control Sinumerik 840D

The machining centre is equipped with a CNC Sinumerik 840D with integrated PLC. The
control in combination with the drive components SIMODRIVE 611D is designed for maximum
machining accuracy and high productivity.
The most important functions of the standard design are listed in the following:
4.1 Operating and display components/interfaces
- Flat control panel OP012 with 12.1" TFT colour display
- Full CNC 19” QWERTY keyboard
- Machine control panel 19” for operation of machine functions
PCU50 Pentium III / 560 MHz / 256 MB consists of:
• Operating system WIN-NT
• HMI-Advanced
• 3 GB on hard disk free for user data
• 2 serial ports COM1, COM2 (V.24)
• Ethernet interface 10/100 Megabit/s for RJ45-connector

• USB ports (1x internal / 2x external)
4.2 Control structure
• CPU: NCU-573.4
• 3.0 MB CNC-user memory, buffered for programs and data
• PLC S7/300 integrated in CNC
• SIMODRIVE 611D

STC 630D
4.3 CNC functionality
• Machining package 5-axis with following functions

- 5-axis transformation with tool orientation
- 5-axis tool length correction
- oriented tool withdrawal
- tool-oriented RTCP (remote tool centre point)
• Look-ahead-function
• Dynamic pilot control
• Quadrantal error compensation to reduce the marks on the quadrantal transitions
• Measuring system error compensation
• Coordinate transformation and inclined machining with frames
• Rectangular coordinate systems can be transformed very easily by moving,
turning, scaling and mirror inversion
• Acceleration and jolt restriction programmable via NC-program
• 2-D tool radius correction with start-up and shut-down strategies
• Polar coordinates
• Interpolation types:
- linear interpolation, circular interpolation, helical interpolation
• Standard milling and boring cycles with graphic support and access protection
• Tapping with and without tap holder
• Measurements given in metric and inch
• Basic system metric as standard, inch optional
• Program input and editing simultaneously for machining
• Oriented work spindle stop
• Programming language (DIN 66025 and high level language extension)
• Part program management (program names with 23 alphanumerical characters)
• Main program call from main program and subprogram
• Feed/rapid traverse override (0 – 120%/100%)
• Spindle override (50 - 120%)
• Safety Integrated

STC 630D
4.3.1 Special control functions
The following additional functions are available on the control:
• Sinumerik 840D: spline interpolation

• Sinumerik 840D: polynomial interpolation
• Sinumerik 840D: 3D tool correction
• Sinumerik 840D: mains connection via SINDNC
• Sinumerik 840D: workpiece measurement, Starrag standard cycles
• Sinumerik 840D: workpiece measurement, 3D measuring cycle
• Sinumerik 840D: software cutting edge pitting detection
• Sinumerik 840D: software wear correction (for cutters and drills)
• Sinumerik 840D: software tool breakage detection
• Shut-down and warm-up program

STC 630D
4.4 Operation and display functions
- Batch search with and without calculation
- Manual input (MDA)
- Set-up functions (JOG) for all axes and the work spindle with machine control
panel or manual control panel
- Continuously active diagnosis system with error and status display in plaintext
Diagrams for display or input of:
• Tool data
• Process data
• Data for running time regime chip conveyor
• Data for operative intervention by the user
• Display of operating hours for the machine, spindle and rotary coupling union
running time
• Service function for tool and pallet change
4.4.1 Tool corrections
Tool management with
• variable position coding
• Tool wear monitoring (time, piece number)
Tool radius correction on the plane advance detection of contour infringements
4.4.2 Zero offsets
- Zero offsets: number projectable (max. 100)
- Zero offsets programmable (FRAMES)
4.4.3 Diagnostics
- Remote diagnostics with modem

STC 630D
5 Technical specifications1
5.1 Main axes
5.1.1 Travels
Travels
 X-axis (longitudinal slide adjustment) mm 1050
 Y-axis (vertical support adjustment) mm 1000
 Z-axis (transverse table adjustment) mm 1060
 A rotary axis degrees endless
 B swivel axis degrees 245
Travel positions / travel ranges
 Travel positions in accordance with travel position sheet Drawing no. 9168.0
of StarragHeckert AG
5.1.2 Feed axes
Linear axis X / Y / Z’
 Technologically utilisable feed force at 60% ED kN 12
 Technologically utilisable feed force at 100% ED kN 10
 Feed X / Y mm/min 0 ... 40,000
 Feed Z mm/min 0 ... 40,000
 Rapid traverse X / Y / Z m/min 40 / 40 / 40
 max. acceleration X / Y / Z m/s2 6 / 6 / 3
 Input and display accuracy mm 0.0001
Rotary axis A’ / B’
 Technologically utilisable feed force at 60% ED Nm 1940
 Technologically utilisable feed force at 100% ED Nm 1500
 Feed rpm 30
 Rapid traverse rpm 30
 max. acceleration A’ / B’ r/s2 4 / 2.5
 Input and display accuracy degrees 0.0001
 Clamping: max. permissible tangential torque Nm 6000
1 For better legibility, data of vendor assemblies are also listed in this section. For binding data, see the
relevant section in the file “Vendor assemblies“.

STC 630D
5.2 Working areas
Workpiece: interference contour and loading

 max. swing diameter mm 1000
 max. height mm 600
max. workpiece clearance height (incl. pallet) from table
block (support for “Stark Speedy Tornado 2000“)
 max. loading mass kg 800
max. permissible mass workpiece on pallet, incl. clamping
equipment (centre of mass middle of A-axis)
Further conditions
WARNING
When positioning the workpiece on the workpiece holder, it is to be

ensured that the centre of mass comes to rest approximately in the
middle of the table. The workpiece fixtures are to be dimensioned
accordingly.
The workpiece holder/pallets may only be set up/assembled by

appropriately trained, authorised personnel. In the event of
incorrect assembly of the workpiece holder/pallets, the
warranty for the entire machine becomes null and void and thus
all liability claims will be rejected!

STC 630D
WARNING
Collision is generally possible between the workpiece side (rotary-

swivelling axis with housings and workpiece/workpiece holder and/or
option “Blum laser“) and the milling head (work spindle, tool and
associated housings).
Programming of the machining processes, setting up the

machine and operation of the machining processes on the
machine may only be carried out by appropriately trained and
authorised personnel. In the event of incorrect use, the
warranty for the entire machine becomes null and void and thus
all liability claims will be rejected!

STC 630D
5.3 Work spindle 15,000 rpm, 90 kW, HSK-A100

 Make StarragHeckert AG
 Model C06-4237
 Tool holder in accordance with DIN 69893 HSK-A100
 Torque / output diagram Drawing no. 5437.0
 Output S6 40 % ED, ts = 2 min kW 90
 Output S1 100 % ED kW 70
 Torque S6 40 % ED, ts = 2 min Nm 292
 Torque S1 100 % ED Nm 227
 max. speed rpm 15,000
 Bearing lubrication Grease
 Bearing sealing Labyrinth / sealing air
 Cooling Water cooling system
 Sensor system for monitoring the tool clamp
 Sensor system for monitoring entry of water into the work spindle
 Sensor system for stator temperature monitoring
 Sensor system for bearing temperature monitoring
 Sensor system for recording mechanical displacement in the spindle optional
5.4 Tool handling for HSK-A100

 Make StarragHeckert GmbH
 Model C06-4546
 Change time s 11.5 a) b)
Chip-to-chip (in accordance with VDI 2852) without
blowing out coolant
 Change time, from standby s 9.0 b)
Q-/A-/B-/X-/Y-/Z-axes in ready position for tool changer,
tool prepared in tool changer, incl. tool changer window
open/close, without coolant blowing out
a)
Using dynamic equipment (C06-7630), the change time (chip-to-chip) is reduced by
approx. 1.0 s
b)
With heavy tools or tools with excess length, the changing time increases by approx. 4.0 s

STC 630D
5.5 Tower magazine HSK-A100, 240 memory locations

 Make StarragHeckert GmbH
 Type C06-4554
 Magazine spaces (max.) Stk 240
 max. tool length mm 450
 max. tool diameter with occupied adjacent spaces mm 110
 max. tool diameter with free adjacent spaces mm 250
 max. tool mass kg 35
 max. tilting torque (at tool changer gripper interface) Nm 50
 Max. total weight of all tools per tower kg 600
ATTENTION
Observe the information in the operating instructions on the position

type and tool size.

STC 630D
5.6 Tower magazine HSK-A100, extra-long tools

 Adaptation/supplement to type C06-4552
C06-4553
C06-4554
 Magazine spaces (max.) Stk 15
Note that:
 Reduces the max. loading capacity of the magazine
by 15 pieces, as it is not possible to load an adjacent
comb with extra-long tools
ATTENTION

type and tool size.

STC 630D
5.7 HSK-A100, bridge tools

 Adaptation/supplement to type C06-4547
C06-4552
C06-4553
C06-4554
ATTENTION

type and tool size.

STC 630D
5.8 Cooling lubricant supply with turbo-filter
Overall size / model

 Make Knoll, Bad Saulgau
 Designation SF 1000 / Turbo 1
 Filter type for clean water Turbo-filter
 Volume: clean water Litres 450
 Volume: grey water tank Litres 1250
Cooling lubricant inputs
 Recirculation from chip conveyor Pcs. 1
CL outputs: low-pressure process cooling
 max. delivery rate l/min 50
 max. supply pressure bar 4.4
 outgoing lines Pcs. 1
CL outputs: high-pressure process cooling
 max. supply pressure bar 70
 pressure control Selection via M-command from
NC-program in 7 steps
CL outputs: flushing installation
 max. supply pressure bar 5.5
Option: oil separator
 Make 07.02.4-187
 Model RAPID 2.1
(Bandölskimmer)
 Year of construction 2007
 Amps 0.1A
 Volt 400V / 50Hz
 Watt 35W
 Weight 4.7kg
 Protective system IP54

STC 630D
Option: cooling lubricant heating and cooling

 Control between 20 and 25 °C
(with max. ambient temperature of up to 38°C)
5.9 Chip conveyor

Design
 Make Knoll, Bad Saulgau
 Model 450 K-1/200
(scraper belt conveyor)
 Scraper spacing mm 380
 Scraper height mm 45
 Chain feed m/min 1.5
 Ejection height mm 1050
Cooling lubricant tank
 Width mm 450
 Height mm 198
 Volume, grey water tank Litres 300
5.10 Measuring on workpiece
Probe: manufactured size / model

 Make Renishaw
 Designation MP10 GR35
5.11 Tool measurement with laser
Laser
 Make Blum
 Designation Laser system NT micro
 Laser class 2

STC 630D
5.12 Connected loads
Electrical installation
 Mains TN-C; 3 /PEN AC 400
+ 10%
 Voltage V 400
- 10%
 Frequency Hz 50 ± 1
 Total connected load kVA 130
 Recommended mains fuse A 250
Pneumatic system
 Connected pressure bar 5-1 ... 10
 Air consumption: mean value with normal pressure m3/h 10
 Air consumption: short-term peak consumption m3/min 3.5
Installation
 Foundation Drawing no. M.Nr.9404 FD
according to foundation diagram of StarragHeckert AG
 Space requirements Drawing no. MNR. 9404
according to installation diagram of StarragHeckert AG
 max. overall length mm 7295
 max. overall width, without CL-supply mm 4750
 max. overall width, incl. CL-supply and unit for CL mm 6950
cooling in standard installation
 max. overall height for mountings on X-slide (motor, mm 3370
weight compensation) or to upper edge emission
extraction (option)
 max. overall height (upper edge WPC lifting gate) mm 3800
 Net mass incl. peripheral components, approx. kg 29,000

STC 630D
5.13 Ambient conditions
5.13.1 Permissible ambient conditions in accordance with VDI/DGQ 3441, in

particular section 4.3.2
Temperature ranges
 for functional performance °C + 10 to + 40
 for nominal accuracy (standard version) °C + 20 ± 2
 for nominal accuracy (high accuracy version) °C + 20 ± 1
 permissible temperature fluctuations with nominal °C / hour 0.5
accuracy
 permissible relative humidity 20 °C % max. 90
 permissible air pollution The values of the
electrotechnical equipment
apply
further conditions
 Temperature constancy of the environment and the supplied compressed air
 Avoidance of sunlight and draughts
 No one-sided heating
 Vibration-free installation location
 No local heating of machines and controls
 Foundation complies with the foundation diagram provided
5.13.2 Noise emission

 Measuring areas sound pressure level, max. dB (A) ≤ 78
According to STARR 713D “Noise emission threshold
value of Starrag machines in accordance with DIN 45
635“
Test conditions for determination of the measuring areas sound pressure level
 Distance to measuring instrument mm 1000
 Height of measuring points above floor mm 1600
 Work spindle speed rpm 19,500
 No external noises
 No workpiece machining
 Workroom cabin closed

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STC 630D

User’s Manual MNo. 9404

27.05.2004  Copyright V01/2 Masch.Daten_En - 1 -

2 AREAS OF APPLICATION OF THE MACHINING CENTRES ......... 5

4 CONTROL SINUMERIK 840D ........................................................ 26

27.05.2004  Copyright V01/2 Masch.Daten_En - 2 -

4.2 Control structure .............................................................................. 26

5 TECHNICAL SPECIFICATIONS ..................................................... 30

27.05.2004  Copyright V01/2 Masch.Daten_En - 3 -

27.05.2004  Copyright V01/2 Masch.Daten_En - 4 -

2 Areas of application of the machining centres

 see also: Part 1, “Designated use and inappropriate use“ 

2.1 Work processes

Standard • Face milling • Boring • Grinding

High speed machining HSC

Shaping for end facing

Rigid tapping (tapping without tap holder)

Milling of cylinder paths

Rotary milling with rotary table

27.05.2004  Copyright V01/2 Masch.Daten_En - 5 -

2.2 Range of workpieces

The machine is primarily suited to the machining of the following workpieces:

impellers and blisks

structured parts for the aerospace industry

prismatic and box-shaped parts from general production technology

max. interference diameter

workpiece clearance height

max. loading mass

 see also: Part 1, “Designated use and inappropriate use“ 

27.05.2004  Copyright V01/2 Masch.Daten_En - 6 -

2.3 High speed machining

The high performance equipment with:

high work spindle speeds

provides the following advantages:

high material removal volume

high surface quality

low heat transfer into workpiece

low workpiece warping

high time-saving for precision machining.

27.05.2004  Copyright V01/2 Masch.Daten_En - 7 -

X-axis (longitudinal) on tool side (column)

The M A C H I N E basically consists of the following main assemblies:

27.05.2004  Copyright V01/2 Masch.Daten_En - 8 -

3.2 Fixed column, guide section and support

27.05.2004  Copyright V01/2 Masch.Daten_En - 9 -

3.4 Rotary and swivelling axis

The rotary-swivelling axis with direct drives is mounted on the z-slide.

The assembly basically consists of the following elements:

The basic functions / properties of the A-axis are:

• Berg clamping heads as the interface to the workpiece pallet

The basic functions / properties of the B-axis are:

• absolute, direct hodometry

27.05.2004  Copyright V01/2 Masch.Daten_En - 10 -

3.5 Work spindle 15,000 rpm, HSK-A100

27.05.2004  Copyright V01/2 Masch.Daten_En - 11 -

3.6 Feed, guiderails, measuring systems

3.6.2 Bearing and rotary and swivelling axis

3.6.3 Drives: rotary and swivelling axis A and B