G800 : GROB-WERKE GmbH & Co. KG

G800

Large machining center
GROB offers customers from the automotive sector the G800 – a large machining center variant for the flexible manufacture of large parts, including engine components and rear axle housings for trucks, commercial and construction vehicles and tractors.
GROB offers customers from the automotive sector the G800 – a large machining center variant for the flexible manufacture of large parts, including engine components and rear axle housings for trucks, commercial and construction vehicles and tractors.
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Automotive
Technical data
Working travels (5-axis version)
1,600/1,700/1,540/300
in X'-/Y-/Z-/W-axis (mm)
Max. speeds (5-axis version)
60/60/50/35
in X'-/Y-/Z-/W-axis (m/min)
Interference diameter
1,600
(mm)
All technical data
Chip-to-chip time t1 (5-axis version)
5.6
according to VDI 2852 (s) relative to speed (rpm)
Positioning accuracy
0.010
in X'-/Y-/Z-/W-axis (mm)
Table load
4,000
(kg)
Total weight (5-axis version)
48,000/51,000
without/with pallet changer (kg)
The benefits at a glance
checkboxHigh productivity
checkboxOptimized availability
checkboxHigh visibility
checkboxFlexible applications
checkboxMaintainable
checkboxCompact design
checkboxOptimized access
checkboxRound-the-clock service
Exclusive machine concept
Exceptionally large work area

Machining of large parts up to an interference diameter of 1,600 mm and a height of 1,600 mm.

Excellent chip fall

Optimized chip transport for dry and wet machining through steep machine bed slants in the work area.

Very good chip-to-chip time

Time-optimized tool changer arm for tool weights of up to 50 kg.

Maximum rigidity

Extremely wide guide distances guarantee outstanding machine rigidity.

Long tool length

Use of oversized tools up to 850 mm.

Technology for a diverse mix
Control systems

Latest generation of control systems from leading manufacturers with attractive control panel design

Motorized and gear spindle

Broad range of applications with machining spindles with up to 100 kW of output and 2,400 Nm of torque

NC rotary table

Highly dynamic and directly driven table with generously dimensioned axial radial bearing for optimized tilt resistance

Integrated disk-type tool magazine

Up to 117 tool pockets with a maximum length of 850 mm and a maximum weight of 50 kg; expandable by an additional magazine

Machine bed

Intrinsically stiff welded design for maximum machine rigidity; completely thermally decoupled from emulsion and chips

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Control systems

Latest generation of control systems from leading manufacturers with attractive control panel design

2
Motorized and gear spindle

Broad range of applications with machining spindles with up to 100 kW of output and 2,400 Nm of torque

3
NC rotary table

Highly dynamic and directly driven table with generously dimensioned axial radial bearing for optimized tilt resistance

4
Integrated disk-type tool magazine

Up to 117 tool pockets with a maximum length of 850 mm and a maximum weight of 50 kg; expandable by an additional magazine

5
Machine bed

Intrinsically stiff welded design for maximum machine rigidity; completely thermally decoupled from emulsion and chips

Typical machining operations
Crankcase
Dimensions of raw material (mm)1121x737x560
IndustryAutomotive
MaterialCast
Motorized spindle10,000 rpm
Power/torque65 kW/575 Nm   
Tool magazine drum
Dimensions of raw material (mm)Ø 500x500
IndustryMechanical engineering
MaterialCast
Motorized spindle16,000 rpm
Power/torque32 kW/206 Nm
Structural component
Dimensions of raw material (mm)380x70x120
IndustryAerospace
MaterialAluminium
Machining time40 minutes
Motorized spindle16,000 rpm
Power/torque32 kW/206 Nm
Francis turbine wheel
Dimensions of raw material (mm)Ø 800x250
IndustryEnergy technology
MaterialChromium-nickel steel 
Machining time96 hours
Motorized spindle10,000 rpm
Power/torque66 kW/340 Nm
Cylinder block
Dimensions of raw material (mm)450x350x290
IndustryAutomotive
MaterialAluminium alloy
Motorized spindle10,000 rpm
Power/torque29 kW/35 Nm

Axis versions

Depending on customer requirement, the G800 large machining center is available as a 4-axis version or as a 5-axis version with recently developed swivel milling head.

4-axis version

In the 4-axis version, the three linear axes X', Z and Y and the rotary axis B' ensure efficient machining with symmetrical force distribution and optimum machine rigidity.

5-axis version

In the 5-axis version, the W feed axis integrated into the swivel milling head achieves a travel path of 300 mm for fast plunging into part contours and permits machining in various angular positions without interpolation of the main axes.

Rotary table versions

Various tilting rotary table versions are available for the G800, depending on the requirement. The powerful rotary tables are based on the latest torque motor technology and offer optimized dynamics.

Rotary table with T-slots arranged in parallel (standard)
Rotary table with T-slots arranged in parallel (standard)
Rotary table with grid hole pattern
Rotary table with grid hole pattern
Rotary table with pallet clamping system
Rotary table with pallet clamping system

Spindle versions

Besides the broad range of spindles, the motorized spindles designed and produced by GROB itself are the preferred choice for optimized process design. These are optimally matched to the G800 and have optimized quality features.

Motorized spindle versions
  • Getriebespindel 2,400 Nm, 6.000 rpm (4-axis version)
  • HSK.A63 206 Nm, 16,000 rpm (4-axis-/5-axis version)
  • HSK.A63 63 Nm, 30,000 rpm (4-axis version)
  • HSK.A100 340 Nm, 10,000 rpm(standard 4-axis version)
  • HSK.A100 582 Nm, 10,000 rpm (standard 5-axis version)
  • HSK.A100 340 Nm, 6,000 rpm (4-axis version)
  • HSK.A100 575 Nm, 9,000 rpm (4-axis version)
  • HSK.A100 1,666 Nm, 7,200 rpm (4-axis version)
  • HSK.A100 344 Nm, 6,000 rpm (4-axis version)
GROB Spindle Diagnostics (GSD)

GROB spindle diagnostics is a system that automatically monitors the condition of the motorized spindle. Benefits are a prolonged motorized spindle useful life, reduced tool wear and scheduled maintenance.

GROB Chip-in-Spindle Detection System (SiS)

This system is able to detect at an early stage tool clamping faults caused by chips between the plain surface and the spindle nose from 10 μm. So the machining process is optimized and rejects and damage are avoided.

Tool magazine

GROB tool magazine technology is set apart by fast chip-to-chip times, a smaller space requirement and optimized accessibility. Choose the right solution for you.

Additional tool magazine
Additional tool magazine
2-disk magazine (standard)
2-disk magazine (standard)
4-disk magazine (option)
4-disk magazine (option)

Control systems

Choose between the latest and most powerful CNC control systems from market leaders for the G800.

 

  • SIEMENS 840D sl (standard)

 

  • HEIDENHAIN TNC 640 (option)

Automation solutions

Draw on the experience we have garnered over several decades and benefit from our innovative automation technology. Improved productivity through retooling during part machining thanks to the 2-way pallet changer system.

2-way pallet changer system

Functional principle:

 

  • Pallets are interchanged by means of a rotating pallet changer
  • Optimally-matched pallet clamping system fixes pallets on the rotary table and setup station in the machine
  • An integrated seating check system and flushing of the zero point clamping system guarantee high process reliability during the pallet change operation.

Benefits:

 

  • Loading and unloading of the parts to the machine setup station during the machining operation
  • Double pallet changer system compactly integrated into the machine
  • Optimized access to the rotatable and lockable setup station
  • Fast exchange of pallets between work area and setup station
  • Integrated seating check system for the pallets
  • Wide-opening setup station doors with crane loading capability

Software options

Customize the G800 large machining center with additional software options to suit your requirements down to the finest detail.

CYCLE 996 (for SIEMENS control system) │ KinematicsOpt (for HEIDENHAIN control system)
CYCLE 996 (for SIEMENS control system) │ KinematicsOpt (for HEIDENHAIN control system)

Control-specific kinematic cycles for machine calibration. Highly precise determination, display and provisioning of measurement results.

GROB kinematic measurement inspection equipment set
GROB kinematic measurement inspection equipment set

In addition to the kinematic measuring cycles, all measuring instruments are supplied in an inspection equipment set.

Energy efficiency package
Energy efficiency package

For efficient use of energy by reducing the power consumption of the G800 (with SIEMENS control system).

GROB<sup>4</sup>Track
GROB4Track

GROB4Track monitors the state of the machine. Thanks to an automated analysis function, the machine state is known at all times and unscheduled downtimes can be avoided. This allows you to precisely plan preventive maintenance work and initiate spare part orders at the right time.

Accessories

Our extensive range of accessories makes the G800 more flexible, while increasing your own productivity and economy at the same time.

High-pressure cutting fluid system
High-pressure cutting fluid system

In addition to the 23 bar standard version, high-pressure pumps with 38 or 80 bar are also available for generating the cutting fluid high pressure.

Decentralized work area mist collecting system
Decentralized work area mist collecting system

Emulsion mist separator with various performance levels for keeping the work area clean.

Oil skimmer
Oil skimmer

The oil skimmer removes hydraulic and lubricating oil from the cutting fluid surface to keep the cutting fluid as clean as possible.

Tool cleaning device
Tool cleaning device

Combined, GROB-patented brushing/blow-off device for cleaning the tapered/contact surface of the tool interface.

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Tool coding
Tool coding

Write-read unit for tools with coding for reducing setup times and preventing errors during data input.

Laser measurement system for milling tools
Laser measurement system for milling tools

Contactless, optical tool monitoring/measurement of rotating tools, such as milling cutters and drills.

Electromechanical tool breakage detection device
Electromechanical tool breakage detection device

Tool breakage detection via a tactile tool breakage detection device for monitoring process during machining.

Hand-held controllers
Hand-held controllers

Hand-held controllers with keys for selecting the axis directions, feed, rapid travel, emergency stop and for acknowledging axis movements.

Machine status lamp
Machine status lamp

A three-color status lamp is used to visually indicate the machine status. A distinction is drawn between automatic mode (green), warning (yellow) and malfunction (red).

Touch probe
Touch probe

Touch probe for aligning and measuring parts and clamping fixtures, as well as setting zero and reference points for downstream machining.

Machine platform
Machine platform

Platform for the machine version with or without pallet changer and free setup anywhere in the production hall.

Continuous cooler
Continuous cooler

An external continuous cooler for cooling the cutting fluid is available for all high-pressure cutting fluid pumps.

GROB Service
Customer service

GROB Group
Phone:  +49 (8261) 996-777
E-mail:   info.service@grob.de