State-of-the-art

Five Axes Technologies

Five Axes Horizontal Machining Center

with integrated Universal Head

Bharat Fritz Werner

 ORION Fx

High Performance Five Axes Horizontal Machining Centers

Series: ORION Fx5500 | ORION Fx8000 | ORION Fx10000
FX series has been developed on proven platform of ORION series Horizontal Machining Centres.
Innovated to meet the configuration for the Balance of Precision & Speed for Complex Precision
Parts Machining. Import Substitution, Introduced to meet the demand for World-class HMCs for
the Indian and global market.

ORION Fx series extensively applied to the industries of Aerospace, Automotive, Medical, Energy
and further moreé

Z B

ORION FX series includes three models covering work envelope range from 0.64 cubic metres to
2.5 cubic metres in pallet sizes 500 to 1000

Model Fx 5500 Fx 8000 Fx 10000

Pallet size (mm) 500 x 500 630 x 630 (800 x 800) 1000 x 1000

Spindle taper HSK A 63 HSK A 100

Axes traverse (X/ Y/ Z) 800/ 1000/ 800 1250/ 1250/ 1000 1600/ 1400/ 1250

B axis .-30 deg to +180 deg

C axis 360 deg

ø800 ø1250 ß1600

1000

1400
1200

Job Swing
Dia x Ht (mm)
Weight (kg)

700 1500 3000

 The new generation FX series meets contemporary global benchmarks of specifications
& performance.
Gantry Loading Wide Machining Area

Precise & Complex 5 axes geometries

High rapid feed rates
Productivity through cycle time reduction
Advanced manufacturing & eliminates
extra setups

Orion FX engineering philosophy is based on five strong pillars

Productivity | Precision | Ergonomics | IIoT Enabled Sensors

Sectors
Aerospace Automobile Energy

Tooling Medical Mould Making

 ORION Fx
Precision
- Linear glass scale for X,Y,Z axes

- Direct encoder for Swivel head (B axis)

- Direct encoder for Direct Drive Rotary Table (C axis)

- Thermo friendly design

- Thermo symmetric structures

- Spindle bearing and coil cooling

- Ball screw core cooling

- Axes drive flange cooling

- Swivel head (B axis) coil cooling

- Direct Drive Rotary table (C axis) coil cooling

- Bed temperature sensor for PID control of cooling oil temperature

Axes motor flange cooling Direct drive rotary table (C-axis)

coil cooling & Direct encoder

Linear glass scale -standard

Swivel head (B-axis) coil
cooling & Direct encoder

Ball screw core cooling

Motorised Spindle cooling

 ORION Fx
Precision
- Heavily ribbed cast iron structures

- Single piece stepped cast bed for rigidity

- Comprehensive FEM analysis

- Optimum weight and stiffness for enhanced natural frequency

- Higher spindle bearing dia for robust cutting performance

- Roller type precision LM guide-ways

- Double anchored double nut ball-screws

- Reduced spindle overhang for enhanced rigidity

- Static and dynamic compliance validated by AMTTF

Maximum rigidity with FEM

optimized and
structural parts for high precision
 ORION Fx
Orion FX Universal Machining Centers are designed and manufactured to deliver excellent machine
precision with use of high precision components Roboust structural parts made of cast iron for high
rigidity and damping High precision roller type LM guideways and DIN standard ground ball screws
Spindle cooling, Direct drive rotary table cooling, Swivel head cooling, Ballscrew core cooling and
motor flange cooling with linear scale for higher precision.

This has resulted in high static and dynamic accuracies of Orion FX series.

(GA tests, values as per ISO, BFW) Machine geometrical accuracies within 25% to 50% of ISO 10791-1 values

Machine geometrical accuracies within 25% to 50% of ISO 10791 - 1 Values

As per ISO 230-1 ISO Value (mm) ORION STD (mm)

Straightness 0.020 0.005

Squareness 0.020 0.010
Spindle run out @300 mm 0.015 0.006

Linear axes Bi directional positioning accuracy 0.008 mm and repeatability 0.005 mm

as per ISO 230-2 (Example FX8000)

As per ISO 230-2 ISO Value (mm) ORION STD (mm)

Bi directional positioning accuracy A 0.032 0.008

Bi directional repeatability R 0.018 0.005

Rotary axes Bi directional positioning accuracy 0.010 arc sec. and repeatability
0.007 arc sec. as per ISO 230-2 (B & C axis)

As per ISO 230-2 ISO Value (mm) ORION STD (mm)

Bi directional positioning accuracy A 0.028 0.010

Bi directional repeatability R 0.016 0.007

ORION Fx undergoes rigorous testing as below to ensure best performance

Geometrical Laser calibration for Circularity tuning Circularity test

Accuracy test positioning accuracy by CNC system using Ballbar
test

Kinematic precision Volumetric error

Test piece Machining Checking & correcting Compensation
(VEC/ VCS)
 ORION Fx

Productivity
Machines are available with Automatic Pallet Changer and without Automatic Pallet Changer

Rotary type automatic pallet changer for quick and

smooth work piece change irrespective of load. APC
arm up/ down movement is guided on LM Guides Tool Magazine
Servo driven tool magazine
with 40/ 60/ 80 tool magazine
can be offered for larger
capacity Tool loading and
unloading possible while
machining. Touch screen
HMI is available as option for
easy tool management. Option
of tool breakage sensor on
magazine side available

Automatic Tool Changer

Servo driven high speed ATC for fast tool change

can handle tool weights upto 30 kg.
ATC are provided with special tool locking
mechanism for smooth and reliable tool change
is provided as an optional feature.

Chip Conveyor

Efficient chip disposal with chip conveyor inside bed.

Direct chip disposal from stocker side.

Rear side chip disposal Ample shower wash facility

to avoid chip accumulation16/ 40/ 70 bar coolant thru
pressure with drum and cyclone filtration system

Oil skimmer to remove oil content and improve coolant life

 ORION Fx
Productivity
Swivel Head (B axis)
Swivel head considered to be vital subassembly for any 5 axis machines.
The pre-loaded precision gear box ensures best-in-class B axis torques and accuracy

Driven by Stator Rotor coil

Motorized Spindle
Direct encoder on axis

Pre-loaded
precision gear box

HSK A 63/ A 100

Tool holding options

Direct Drive Rotary Table (C axis)

DDRT
The state of the art direct drive rotary table for highest positioning accuracy, reliability and speed
 ORION Fx

Wider operator door with large window for easy access& visibility swivel type operator panel
for easy operation
 ORION Fx

IIoT Enabled Smart Sensors & User Screens

IIoT enabled smart sensors & User screens

- Spindle bearing temperature, Tool clamp/declamp positions

- Chiller oil flow & temperatures for Spindle, Ballscrew, DDRT, Swivel Head cooling
- Hydraulic oil pressures, temperatures, levels
- Coolant levels/volume in litres, flow, temperature
- Main air pressure
 ORION Fx

Spindle Characteristics
 ORION Fx
Machine Dimensions

Floor Plan
Without Automatic Pallet Changer

Floor Plan
With Automatic Pallet Changer
 ORION Fx

CNC Features

Siemens 828D for 4+1 Application

Siemens 840D SL for simultaneous

M Dyynamics - Siemens 840 D SL 5 axis ^+& M Dynamics
Advanced surface
5 axis features
Spline interpolation TCPM - Tool enter path management
Automatice measuring cycles Plane transformation
Measure kinematics TRIORI, TRANS, CYCLE 800
Simultaneous recording of 3D simulation 3D compensation
Shop mill machining STEP programing Shortest angular traverse
Residual material dettection Tool path linearization
User memory on user CF card Tool vector input
Automatic tool repositioning
Tool vector retract
5 axis Head Table Kinematics Ready Tool vector canned cycles

Machine simulation and postprocessor

 ORION Fx
Standard Features
ú HSK spindle taper
ú Motorised (Integral) spindle
ú Spindle cooling B & C axis cooling system
ú Ball-screw cooling system
ú AC servo drives for all axes
ú Linear scale feedback
ú Continuous Direct Drive rotary table (0.001 deg x 360,000)
ú Continuous swivel axis 0.001 deg
ú Pneumatic counterbalance for vertical axis
ú Lamella cover for X and Z axes
ú Single sheet covers for Z axis/ Telescopic cover
ú Automatic centralised oil lubrication system
ú Air blst for spindle taper cleaning
ú 60 tools, servo-driven tool magazine & tool changer
ú Slat Chip conveyor inside the machine, in the cutting area
ú Overhead shower wash
ú Basic coolant system with Scraper chip conveyor with drum filter
ú High pressure coolnat thru spindle system 40 bar with paper band filtration system
ú Coolant gun, Air gun, Ooil skimmer
ú Hydraulic powerpack with air blast oil cooler
ú Operator door safety interlock
ú 3 tier signal lamp, machine lamp
ú AC for electrical cabinet
ú USB interface
ú Energy saving function
ú Machine alarm diagnostics
ú 10.4" color LCD disply

Optional Features
ú Automatic pallet changer (Servo-driven, Rotary type)
ú High torque spindle for Fx8000 & Fx10000
ú High pressure coolnt thru spindle system 60 bar
ú Hydraulic connections through pallet with auto couplers (Fx5500 & Fx8000)
ú ATC side tool breakage sensor
ú Part probing
ú Laser measuring system for tool offset & tool breakage
ú Mist collector
ú Coolant chiller
ú Customer specified machine colours
ú 15" color LCD Display
ú Milling and Turning table, Dia 630, 700 rpm for Fx8000
ú Milling and Turning table, Dia 800, 500 rpm for Fx8000
ú Automation and SMED compatible
ú Visiport
ú Automatic centralised grease lubrication system
ú Machine Collision monitoring
ú Spindle growth compensation
ú Tool kit for checking & correcting kinamatic precision
ú Cad model post porocessor
ú IIoT 4.0
 ORION Fx

Technical Specifications
Specifications Unit Fx5500 Fx8000 Fx10000
Axes
X axis mm 800 1250 1600
Y axis (Table) mm 1000 1250 1400
Z axis (Spindle) mm 800 1000 1250

Work volume XYZ m3 0.64 1.25 2.50

Rapid traverse m/ min 60 40 40

2
Acceleration m/ S 6 4 4

Table

Rotary table - Direct Drive posn 360,000 x 0.001deg 360,000 x 0.001deg 360,000 x 0.001deg

Table speed rpm 40 20 10

Pallet size mm 500 x 500 630 x 630 (800 x 800) 1000 x 1000

Load capacity kg 700 1500 3000

Max. Job swing dia x swing height mm 800 x 1000 1250 x 1200 1600 x 1400
Spindle

Spindle taper std. HSK A63 HSK A100 HSK A100

Spindle power Ed40% std. kW 28 63 63

Spindle speed std. Nm 12000 8000 8000

Max spindle torque std. Nm 105 470 470

Spindle taper (high speed opt) - HSK A63 HSK A63

Spindle power ED40% (high speed opt) kW - 28 28
Spindle speed (high speed opt.) rpm - 12000 12000
Max spindle torque (high speed opt) Nm - 105 105
Swivelling Milling Head
Rotating speed Cont./ 50% ED mm 10 10 10
Axis torque mm 3,000 5,000 5,000
Resolution deg 0.001 0.001 0.001
Automatic tool changer

Number of tools std 60 60 60

Number of tools opt 80 80-120 80-120
Max tool diameter all places mm 80 125 125
Max tool diameter max mm 165 250 (315) 250 (315)
Max tool length mm 430 600 600
Max tool weight kg 12 30 30
Chip to chip time (min) s 4 7.5 8.7

Pallet changer

Type 180 deg swing type

Pallet change time s 10 25 60

Accuracy as per ISO 230-2

Positioning A - with Linear scale mm 0.008 0.008 0.009

Repeatability R - with Linear scale mm 0.005 0.005 0.007

B & C axis index accuracy arcsec 10 10 12

Machine Installation Data (With Pallet Changer)

Basic machine weight kg 14000 24000 30000

Floor area W x D mm 3200x5800 4250x7000 4500x9500

Compressed Air bar 5-6 5-6 5-6

Total connected load-cont/ 30 min kVA 60 90 100

Power supply 3ph, 415 V, 50 Hz

CNC system Siemens Sinumerik 1(Simultaniuos 5 axis)

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