Freeform® L

Freeform L/GL/TL diamond machining center
  • Overview +


    Whether you need to manufacture a freeform part today or want the flexibility for future market requirements, the Freeform L is precisely the machine you need.

    Precitech has added an innovative vertical axis to our field proven large frame platform, increasing flexibility and precision. With the Freeform L, customers can diamond turn, micro-mill, micro-grind, and groove non-rotationally symmetric surfaces. Adding this third linear axis gives users the flexibility to produce freeform surfaces which may not be achievable using 2 linear axis machining

    • Industry leading swing and load capacity
    • Flexibility to produce freeform geometries with 3 linear and up to 2 rotary CNC axes
    • 5 Axis freedom with 3 axis performance Y axis and spindle designed for maximum thermal stability
    • Thermally controlled enclosure options insure accuracy during long cutting-time parts
    • Reduced sensitivity to vibration enabled by its integral TMC MaxDamp® isolation system
    • Capability to produce large and small parts auxiliary spindle mount to the X axis


    Turning Configuration (T)
    Milling Configuration (M)
  • Key Specs +


    Turning performance: Surface roughness < 1.5 nm Ra Form accuracy < 0.125 micron P-V

    Milling performance:
    Surface roughness < 10 nm Ra (< 3 nm is achievable with optimum material and cutting conditions)

    Form accuracy:
    < 0.2 micron P-V

    Ultimate load capacity:
    91 kg (200 lbs) @ 100 psi supply pressure

    Standard swing capacity:
    650 mm diameter over the B axis – can be expanded to 700 mm when equipped with temperature controlled room

  • Common Applications +


     

    Y Z turning test resulting in a 0.83 nm Ra surface finish

  • Technical Specifications +


    Machine Base and Control Description
    Machine base Sealed natural granite base provides exceptional long term machine tool stability
    Machine type Ultra precision five axis (Freeform TL) or four axis (Freeform ML) CNC contouring machine
    Vibration Isolation Self leveling dual chamber pneumatic isolation system (Optional PEPS® II-VX active vibration cancellation available)
    Control system UPx™ machine tool control operating system with UPx Data Store and Windows 7
    sub systems
    Operating system QNx real time operating system with 64 bit floating point decimal precision
    Programming resolution 0.01 nm linear / 0.0000001˚ rotary
    File transfers USB, CD-ROM, Ethernet
    Turning performance Surface finish < 1.5 nm Ra
    Form accuracy < 0.125 µm P-V
    Milling performance Surface roughness < 10 nm Ra (< 3 nm is achievable with optimum material and cutting conditions)
    Milling form accuracy < 0.2 µm P-V


    Linear Oil Hydrostatic Slideways Description
    Type Hydrostatic bearing slideways with symmetrical linear motor placement and liquid cooling
    Travel X axis: 350 mm (13.8 in.) Vertical Y axis: 150 mm (5.9 in.) Z axis: 300 mm (11.8 in.)
    Maximum feedrate 3000 mm/min. (118 in./min.)
    Drive system Linear Motors used in all three linear axes
    Position feedback resolution 8 pm (0.008 nm) for all three linear axes
    Straightness horizontal / vertical X axis: 0.3 µm (12 µin.) /0.75 µm (30 µin.) over full travel
    Y axis: 0.5 µm (20 µin.) over full travel both directions; 0.3 µm over the central 100 mm
    Z axis: 0.3 µm (12 µin.) / 0.75 µm (30 µ/in.) over full travel
    X, Z pitch / roll motion 2.0 arc-sec
    Y pitch / yaw motion 2.0 arc-sec
    X, Z vertical/horizontal stiffness 438 N/µm (2,500,000 lbs/in.) in both directions
    Y axis in the X and Z direction 263 N/µm (1,500,000 lbs/in.) in both directions
    Y axis working load capacity 91 kg (200 lbs)
    Hydrostatic oil supply system Hydro-7 Smart Servo Control, low pulsation pump, optional thermal control


    Workholding air bearing spindle High Performance HS150 Spindle
    Spindle air bearing type Slot type thrust bearing
    Materials Steel shaft / Bronze journal
    Standard swing capacity 650 mm max | 415 mm dia. over the B axis | 700 mm when equipped with temperature controlled room
    Ultimate load capacity
    @ spindle nose with Y axis locked down
    136 kg (300 lbs) @100 PSI / 204 kg (450 lbs) @150 PSI
    Axial stiffness 230 N/µm (1,314,000 lbs/in.)
    Radial stiffness 130 N/µm (743,600 lbs./in.)
    Motion accuracy Axial/Radial ≤ 15 nm (0.6 µin.)
    Thermal control Liquid cooled chiller +/- 0.1° C accuracy
    C-axis feedback resolution 0.010 arc-sec 16,200 line encoder (0.018 arc-sec 9,000 line encoder available)
    C-axis positioning accuracy +/- 1 arc-sec
    C-axis max speed 2,000 RPM (4,000 RPM with 9,000 line encoder)
    Workholding spindle max speed 10,000 RPM


    Rotary Oil hydrostatic B-axis HydroRound II Rotary B-axis with Hydrolock
    Type Patented self compensated oil hydrostatic bearing, Bi-conic, integral brushless DC motor
    Load capacity 454 kg (1,000 lbs)
    Tabletop size 381 mm (15 in.) diameter
    Maximum speed 3,600˚/min.
    Feedback resolution 0.003 arc-sec
    Positioning accuracy +/- 0.1 arc-sec
    Radial error motion 0.10 µm (4 µin.) @ tool height (6.9 in. above table top), can be improved with optional error mapping
    Axial error motion 0.10 µ (4 µin.)
    Coning error 1.0 nm/mm (1.0 µ/in.)
    Radial stiffness 525 N/µm (3,000,000 lbs/in.)
    Axial stiffness 875 N/µm (5,000,000 lbs/in.)
    Moment stiffness 17 N-m/µrad (150 inch-lbs/µrad)
    Hydrolock holding torque > 108 N-m / 80 ft-lb


    Optional Milling / Grinding Spindles SP75FF Spindle Levicron High Speed Milling Spindle
    Air supply pressure 690 kPA (100 PSI) 610 kPA (88 PSI)
    Air consumption 50 l/m (1.7 SCFM) 70 l/m (2.5 SCFM)
    Radial load capacity 32 kg (70 lbs) ultimate load capacity 29 kg (65 lbs) ultimate load capacity
    Axial stiffness 70 N/µm (400,000 lbs/in.) 50 N/μm (285,000 lbs/in.)
    Radial stiffness 22 N/µm (125,000 lbs/in.) 35 N/μm (200,000 lbs/in.)
    Axial error motion Under 0.05 µm (2 µin.) < 30 nm asynchronous
    Radial error motion Under 0.05 µm (2 µin.) < 30 nm asynchronous
    Maximum speed 15,000 RPM 80,000 RPM (stiffness increases 50% with 60k RPM model)


    Facility Requirements  
    Power 208 or 230 VAC - 1 phase - 50/60 Hz - 4.5 KVA
    Compressed air supply Typical: 14 SCFM at 100 psig, filtered to 50 µm and dry to 10° C dew point
    Machine size and weight 216 cm x 140 cm x 203 cm (85 in. x 55.5 in. x 80 in.) 3400 kg/7500 lbs (Not including control pendant or auxiliary equipment)
  • Application Notes +


    High speed lens array for automotive headlamp mold
    Demonstrate high speed machining of a lens array on nickel plated steel.

    Zinc Sulfide (ZnS) with laser assisted machining
    Utilizing laser assisted machining, demonstrate improved surface finish and cosmetic appearance by reducing visual haze and pullouts on ZnS.

    Micromilling of crystalline material (CaF2)
    Demonstrate the surface finish and flatness results achievable on calcium fluoride using a Freeform® TL machine and a Levicron milling spindle.

    3 Axis (XYX) ruling using PEPS® II-VX
    Demonstrate part cutting time, surface finish, and form accuracy achievable by 3 axis ruling on a Freeform® L equipped with PEPS II-VX, an active on machine vibration cancellation and precision leveling system.

    Aspheric Toric using Adaptive Control Technology (ACT)
    Demonstrate freeform surface finish and form accuracy by diamond turning an aspheric toric on the Freeform® L Ultra Precision Machine platform using Adaptive Control Technology (ACT).

    XZ vertical grinding
    Demonstrate surface finish by vertical grinding on the Freeform® L Ultra Precision Machine platform.

    Freeform® 700 micro lens array milling
    Milling a lens array in Electroless Ni mold insert.

    Freeform® 700 spiral milling 
    Spiral milling of a 3 dimensional continuous surface.

    Freeform® Head-up Display (HUD) Mold using Adaptive Control Technology (ACT)
    Demonstrate the surface finish and form accuracy achievable when machining a Head-Up Display (HUD) mold on either the Nanoform® 700 ultra or the Nanoform® L 1000 machine platform using Adaptive Control Technology (ACT) and an HD160 high capacity work holding spindle.

    Freeform augmented reality (AR) lens mold
    Demonstrate the surface finish achievable when manufacturing a Freeform Augmented Reality Lens Mold by Slow Tool Servo (STS) on a Freeform® L.

    Freeform micro-grooving by fly-cutting
    Demonstrate the surface finish and form accuracy achievable when grinding glass with a Levicron® ultra precision spindle

  • Brochures +