Metalex invests in a fourth Starrag machine

Cincinnati-based Metalex Manufacturing, already owns three Starrag machine tools, but after extensive benchmarking, has chosen to invest in a Droop+Rein T portal machining centre from Starrag — its largest investment to date.

The contract machining company, a specialist in producing sophisticated and high-quality workpieces, was looking for a machine that could machine a wide range of materials with flexibility, efficiency and precision — all in a single clamping operation.

Metalex decided on the Droop+Rein T series — a powerful milling/turning centre offering high levels of accuracy thanks to its perfectly rigid design and hydrostatic guide concept. The machine’s dimensions comprise table length: 18,000mm; horizontal pass: 9,000mm; vertical pass: 7,000mm and a huge working area of X:19,000mm; Y:9,000mm; Z:3,000mm.

The huge amount of space offered by this new model means that processing large workpieces in a single clamping operation is easy. There is also an option for highly flexible 5-axis processing, thanks to the integrated C-axis with stepless rotation and the universal fork-type milling head, featuring a B-axis that swivels ±95°. The sixth-axis (W) – a 5,500mm continuously movable crossbeam – complemented the universal approach that the contract machining company required.

The processing centre uses a 100kW main spindle with a maximum torque of 7,500Nm, transmitted via vertical and horizontal milling heads; two fork-type milling heads designed for 5-axis operation as well as a slim outboard bearing for drilling through. If entirely new orders come in, there is an option to use additional heads for milling, turning, grinding and turning out. The versatile robot magazine, which has space for up to 400 tools, supplies the milling and turning heads with three different tool systems. Integration into Metalex’s production and tool management systems is undertaken by the Integrated Production System (IPS), Starrag’s ‘building block’ for Industry 4.0 solutions.

The table construction with two large tables (6,000 x 8,000mm) ensures very efficient machining. This construction means that one table can be used under the spindle while the other is loaded and unloaded outside the work area. Extra-long workpieces are machined in coupled tandem operation, for which tables are extended to 18,000mm. Each table also features an integrated rotary table from the Dörries series (diameter: 6,000mm). Thanks to the two 111kW main drives, the turning of components weighing up to 200 tonnes is also possible. The rotary table can also be used as a C-axis for precise positioning when milling and drilling.