Micro Milling Machine – μltraMill available with 3, 4 or 5 axes

μltraMill is a bench top micro milling machine capable of milling, drilling and grinding of a wide range of miniature components as well as machining micron sized surface features on components of up to 150 x 150 x 120 mm in size. Its unique construction, using air bearings and direct drives on all axes means that it can achieve outstanding dimensional precision, surface geometry and surface finish making it suitable for manufacturing small components and moulds used in the optical, medical and electronics industries.

Machine Features:

  • Aerostatic bearings used in conjunction with direct drives completely eliminates the noise and vibration produced by conventional drive elements such as gears, lead screws and couplings enabling exceptionally smooth axis motion and positioning accuracy.
  • 150 000 rpm aerostatic spindle with a high efficiency synchronous DC Brushless motor provides smooth running with low thermal growth over a wide speed range.
  • Vibration isolated natural granite base provides excellent thermal stability and damping capacity.
  • PC based CNC control system with Windows platform and customisable HMI.
  • Modular construction enables easy upgrade from 3 to 4 to 5 axes.
  • Available in standard or customised designs.

Capabilities:

  • Complex miniature 3D components finish machined in one set up.
  • Surface features as small as 20 x 20 x 1 μm deep.
  • Surface finishes as low as 10 nm Ra on soft metal substrates.
  • Tools with cutting tip diameters as low as 50 μm can be used with good machining rates and low risk of damage.
  • Suitable for use with tungsten carbide, CBN, PCD and single crystal diamond tools.
  • Suitable for machining soft materials such as aluminium, copper and plastic and hard or brittle materials such as glass, nickel and steel.
  • Applications include high precision mould tools, small optical components, medical devices, transducers, watch components, micro printed circuit boards, electronic components and tribological components.

Acknowledgements:

UPM gratefully acknowledges the European Commission for funding the development of Ultramill as part of the FP6 MASMICRO project, Brunel University and ITP Group UK for collaboration with the machine development.

OUTLINE SPECIFICATION:

Linear Axes
Type X Y Z
  Modular construction with integral micro recessed air bearings, linear motor and encoder
Stroke (mm) 220     200     150
Feed rate (mm/min) 0 - 3000 0 - 3000 0 - 3000
Drive System DC brushless linear motor
Encoder Resolution (nm) 5 5 5
Position Accuracy (μm) < 1.0 < 1.0 < 1.0
Motion Error (μm) <0.2 <0.2 <0.2
Peak Drive Force (N) 240 240 240

 

 

 

 

 

 

 

 

 

Machine Configuration and Requirements
System Feature Description
Machine Frame Gantry configuration 0.8 x 0.7 x 0.9 m high manufactured in natural granite
Machining Envelope 150 x 150 x 120 mm high
Overall Machine Size 1.1 m wide x 0.8 m deep x 2.1 m high
Control System Delta Tau PC based multi axis motion controller (PMAC) in a Windows environment. Located in a sliding drawer beneath the machine frame for easy access and compact machine size
CNC User Interface Delta Tau Advantage 900 system; 15 in. flat panel display; Customised CNC software suitable for 3, 4 or 5 axes; wireless or cable pendant
Air consumption (l/min) 200
Electricity Supply 440V, 3 phase, AC
Cooling Water (l/min) 2
Local Environment For high accuracy machining the environment temperature should be controlled to within +/- 0.5 ˚C

 

Rotary Table - C Axis
C Axis Feature Specification
Type Air Bearing
Load Capacity (N) 150 – Radial; 300 - Axial
Static Stiffness (N/μm) 50 – Radial; 400 - Axial
Maximum Speed (rpm) 300
Drive System DC Brushless Torque Motor
Position Resolution (arcsec) 0.08
Motion Error (μm) <0.25 axial and radial
Peak Torque (Nm) 2.0

 

 

 

 

 

 

 

 

Swivelling Spindle – B Axis
B Axis Feature Specification
Type Precision Ball Bearing
Rotation +/- 90˚
Load Capacity (kN) >1
Static Stiffness (N/μm) >200
Speed Range (rpm) 0 - 30
Drive System DC Brushless Motor
Position Resolution (arcsec) 0.03
Motion Error (μm) < 1 – axial, <2 - radial
Peak Torque (Nm) 9.1

 

 

 

 

 

 

 

 

 

Milling Spindle
Feature Specification
Type Water Cooled Micro Recessed Air Bearing
Load Capacity (N) Axial – 45; Radial (at nose) - 55
Static Stiffness (N/μm) Axial – 3; Radial (at nose) - 4
Maximum Speed (rpm) 150 000
Drive System DC Brushless Motor
Power (Watts) 300
Motion Error (μm) <1 axial TIR and <2 radial TIR
Tool Holding Manual Collet, 3mm Tool Diameter

 


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