Top accuracy and high dynamic performance are claimed for a new moving-crossrail, vertical-spindle machining centre called MEGAMILL from DS Technology. Despite the machine's large size, characterised by a choice of ten X-axis travels from 7.5 to 30 metres and a Y-axis of either 4 or 5 metres, linear rapid traverse rates of 30 m/min are achieved.

Ideal for manufacturing big moulds and dies, power generation components, aerostructures and other parts found throughout heavy engineering, the machine features a thermosymmetrical, fabricated steel ram of sturdy cross section. It allows rigid, high accuracy milling even at the full Z-axis stroke, which is either 1.5 or 2 metres. The need to fixture a flat component to raise it from the table to ensure accurate machining is therefore eliminated.

The water-cooled spindle motor is rated at 52 kW / 1,200 Nm and is located within the ram, together with the gearbox. The front face of the ram incorporates a rotary platform, with indexing or continuous positioning, on which a choice of milling heads is mounted. It is this design that gives MEGAMILL its wide application range, from machining of aluminium through to heavy metal removal rates from steel.

Two 38 kW, ISO 50 taper heads deliver up to 1,000 Nm of torque and provide 4,000 and 6,000 rpm maximum spindle speeds respectively. The former has a slim profile for accessing awkward areas. The latter is a universal head on which the lower part carrying the tool rotates at 45 degrees to the upper element, which has continuous positioning in 360,000 angular increments.

The third is a fork head with electrospindle rated at 22 kW / 20,000 rpm and has an HSK-63E taper for high-speed 3, 4 or 5-axis machining. Chain magazines from 24 to 100 pockets are offered and automatic head change is optional.

Various coolant delivery systems are available, as is radio-based laser tool measuring and CCTV supervision of the machining area. Control is by Siemens 840D or Heidenhain iTNC530