Things are currently happening in rapid succession at the Nürtinger Maschinenfabrik HELLER: in the fall of 2023, the Swabians presented the F 6000, the first 5-axis machining center of the new generation of their F series. Just six months later, another model, the F 5000, was launched on the market. And the larger F 8000 has recently become available. Like its siblings, it is suitable for use in a range of applications from single-part to flexible 24/7 series production for users in numerous industries – from mechanical engineering to energy technology and aerospace.

Improvements in many areas

The F 8000 is based on the successful 5-axis F product line, which has been on the market for more than a decade. However, it outperforms its predecessors in many areas. For example, at 4.2 meters wide, its footprint is significantly slimmer and the basic version requires around 25 percent less space. In addition, the optional PRO version boasts excellent technical data. The axis acceleration in X/Y/Z has been increased by 50 percent to six seconds squared. The chip-to-chip time has been reduced by around 30 percent. The F 8000 with PRO package also improves in terms of accuracy. The position tolerances in X/Y/Z are six micrometers and thus 25 percent better than for the predecessor model.

More flexibility in machining

Another advantage of the new F 8000 is its large working range (X/Y/Z: 1,400/1,200/1,400 millimeters), which allows for larger workpieces and, above all, provides even more flexibility during machining thanks to the 150-millimeter increase in the X-axis stroke. In addition to the 800 x 800 millimetre pallets, larger 1,000 x 1,000 millimetre pallets can also be used. Dr.-Ing. Manuel Gerst explains: “The maximum payload is 2,000 kilograms. From the end of 2024, we will be offering an optional payload of up to 3,000 kilograms.”

Full compatibility with the previous generation

To make it as easy as possible for users to switch to the new generation of the F series, HELLER has ensured maximum consistency. This means, for example, that the pallets and tools are fully compatible with the old 5-axis series. With SINUMERIK ONE, the new machine uses the current control generation from Siemens. Nevertheless, the user can easily adopt all NC programs that have already been used in the predecessor machines with the Siemens predecessor control SINUMERIK 840D sl. Thanks to the main operating unit in a console design with a 24-inch touch screen and numerous other features, working with the new control is said to be even more pleasant.

Extensive compatibility with the new 4-axis H-series machining centers

HELLER not only ensures full continuity with previous generations in the new F-series. At the same time, the developers have ensured extensive compatibility with the new 4-axis machining centres of the H series. Pallets and tools can be exchanged as required, and the standardization with regard to structural components such as beds and stands enables the same strokes, loads and workpiece dimensions.

Lean footprint provides more space for automated machining

The standardization of the 5-axis machine within the series goes even further. In terms of key components such as heads, spindles and tool magazines, the F 8000 uses the same modules as the entire F series. The machine structure is also uniform across the entire F series, which, among other things, results in the already mentioned narrow footprint. Equally important for the slim appearance of the new F 8000 are the new tool rack systems from HELLER. They are all almost two meters narrower than the previously available versions. This is an advantage that comes into its own when several machining centers are automated. Where there used to be space for three machines, four machines can be placed in a row in the future.

Machining units with swivel and tilt kinematics

The highlight of the F 8000 – and the entire new F series – is the fundamentally redesigned swivel heads, which ensure maximum performance in machining. The motorized spindles integrated into these units were developed and are produced by HELLER itself. Equipped with an HSK-A-100 interface as standard, the Dynamic Cutting Universal (DCU) unit achieves torques of 400 Nm and speeds of 12,000 rpm. The Speed Cutting Unit (SCU) offers 15,000 rpm in conjunction with HSK-A 100. In addition, HELLER offers further spindles that achieve speeds of up to 18,000 rpm in conjunction with the optional HSK-A-63 tool holder. The Power Cutting Universal (PCU) unit with geared spindle is still available for heavy-duty machining – it delivers a torque of 1,146 Nm and speeds of 8,000 rpm. In addition to the swivel heads, HELLER also provides a fork head variant for the F 8000. This is characterized by particularly high flexibility in five-axis machining. The tilt kinematics allow undercuts and undercuts to be executed, which are required, for example, for the production of integral components in the aerospace industry.

Ready for any type of automation

Whether producing single parts or flexible series, the F 8000 5-axis machining centre is always the right choice for users, according to HELLER. For those who are not yet sure whether they want to equip the machine with an automated pallet system, HELLER offers the “Automation-READY” option for maximum flexibility. This is because it allows the available standardized automation systems to be quickly and easily integrated, even at a later date. The F 8000 is equipped with an automatic pallet changer as standard. In addition to this, advanced automation with linear storage, rotary storage or robots can be ordered.

Mill-Turn function for combined milling and turning tasks

In addition to automation, complete machining is playing an increasingly important role for many manufacturing companies. HELLER follows this all-in-one concept and offers an optional mill-turn function for combined milling and turning tasks for the entire F series. The centerpiece here is the high-torque DDT (Direct Drive Turning) rotary table. In addition to milling and drilling operations, it can also be used to turn external and internal contours lengthwise or crosswise in a single clamping, as well as to realize a wide variety of recesses and cutouts. It can even create external and internal threads. This eliminates the need for re-clamping on separate turning machines, which increases the accuracy of the workpiece and reduces throughput times.

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