New Generation
TURN-MILL

Complete Machining. Redefined.

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In an era of skil­led labor shorta­ges, rising qua­lity requi­re­ments, and incre­asing cost pres­sure, redu­cing inter­sec­tions has become a decisive com­pe­ti­tive fac­tor. The next gene­ra­tion of NILES‑SIMMONS TURN‑MILL was deve­lo­ped to manu­fac­ture com­plex work­pie­ces as com­ple­tely as pos­si­ble in a sin­gle machine, in one setup, and wit­hout manual inter­ven­tion. For maxi­mum pro­duc­ti­vity, pro­cess relia­bi­lity, and cost effi­ci­ency – Engi­nee­red for Your Peace of Mind.

The NSH Group and its NILES‑SIMMONS brand are taking com­plete machi­ning of com­plex work­pie­ces with hori­zon­tal, modu­lar turn‑mill machi­ning cen­ters to the next level and intro­du­cing num­e­rous new modu­les, opti­ons, and con­fi­gu­ra­tion pos­si­bi­li­ties with the next TURN‑MILL gene­ra­tion. The next gene­ra­tion of the NILES-SIMMONS TURN-MILL series com­pri­ses six machine sizes, ran­ging from sizes N20 MC to the N60 MC, and has been exten­si­vely enhan­ced in terms of available machi­ning lengths, work­piece capa­ci­ties, module con­fi­gu­ra­ti­ons, and soft­ware opti­ons. This enables the machine to be tail­o­red even more pre­cis­ely to spe­ci­fic work­piece geo­me­tries, mate­rial requi­re­ments, and indi­vi­dual manu­fac­tu­ring processes.

EXPERIENCE NILES-SIMMONS TURN-MILL LIVE @AMB

YOUR TURN-MILL BENEFITS AT A GLANCE

    • Maxi­mum modu­la­rity – pre­cis­ely con­fi­gu­red machine solu­ti­ons tail­o­red to every work­piece family and appli­ca­tion requirement.
    • Tech­no­logy tail­o­red to your needs – exactly the machi­ning modu­les and pro­ces­ses requi­red for each indi­vi­dual manu­fac­tu­ring challenge.
    • Com­plete machi­ning in a sin­gle setup – fewer inter­faces, redu­ced sources of error, hig­her pro­duc­ti­vity, and shorter cycle times.
    • Inte­gra­ted soft­ware and pro­cess solu­ti­ons – full trans­pa­rency, intel­li­gent moni­to­ring, and com­plete pro­cess con­trol for maxi­mum manu­fac­tu­ring reliability.
    • Pro­ven tech­no­logy and deca­des of exper­tise – engi­nee­ring excel­lence built on gene­ra­ti­ons of expe­ri­ence in hori­zon­tal tur­ning and mil­ling machine development.
    • Engi­nee­red for Your Peace of Mind – relia­ble pro­duc­tion results, out­stan­ding cost effi­ci­ency, and maxi­mum con­fi­dence throug­hout the entire manu­fac­tu­ring pro­cess, com­bi­ned with excel­lent ope­ra­tor usa­bi­lity and ser­vice-fri­endly machine design. 

SERIES UPGRADE | BIGGER. STRONGER. MORE PRECISE.

The NILES-SIMMONS TURN-MILL plat­form is engi­nee­red to machine work­pie­ces up to 9.5 m (31 ft) in length, with swing dia­me­ters up to 1.5 m (59 in.) and work­piece weights of up to 15 metric tons. A carefully matched port­fo­lio of direct-drive and geared-drive sys­tems, com­bi­ned with spindle con­fi­gu­ra­ti­ons ran­ging from A8 to A20, deli­vers excep­tio­nal ver­sa­ti­lity across a wide range of appli­ca­ti­ons. Whe­ther per­forming high-per­for­mance roug­hing with maxi­mum mate­rial rem­oval rates or ultra-pre­cise finis­hing ope­ra­ti­ons approa­ching grin­ding qua­lity, every con­fi­gu­ra­tion is desi­gned to maxi­mize performance.

Out­stan­ding pro­duc­ti­vity, fle­xi­bi­lity, and long-term reliability—combined with appli­ca­tion-spe­ci­fic machine con­fi­gu­ra­ti­ons tail­o­red to each cus­to­mer’s manu­fac­tu­ring requirements—are the hall­marks of the NILES-SIMMONS TURN-MILL series. Built on uncom­pro­mi­sing machine tool engi­nee­ring, this new gene­ra­tion com­bi­nes a rigid machine plat­form with per­fectly inte­gra­ted machi­ning modu­les, advan­ced soft­ware solu­ti­ons, and intel­li­gent auto­ma­tion con­cepts to create a highly capa­ble and future-ready manu­fac­tu­ring system.

Bey­ond com­pre­hen­sive tur­ning and mil­ling capabilities—from TRA­ORI-sup­ported 5‑axis machi­ning to power skiving—the new gene­ra­tion also inte­gra­tes spe­cia­li­zed manu­fac­tu­ring tech­no­lo­gies directly into the machine. These include fir-tree slot machi­ning, heli­cal gear machi­ning, and advan­ced U‑axis or angle-head machi­ning for deman­ding inter­nal con­tours, slot mil­ling, and cross-hole dril­ling. Optio­nal rol­ler bur­nis­hing and grin­ding units deli­ver out­stan­ding sur­face finis­hes wit­hout requi­ring secon­dary ope­ra­ti­ons on sepa­rate machi­nes. Sen­sor-based pro­cess moni­to­ring, seam­lessly inte­gra­ted with NILES-SIMMONS」 pro­prie­tary soft­ware plat­form, pro­vi­des maxi­mum trans­pa­rency, enhan­ced pro­cess con­trol, and machi­ning relia­bi­lity. As a result, even the most com­plex work­piece geo­me­tries and con­tours can be pro­du­ced eco­no­mic­ally, con­sis­t­ently, and wit­hout manual inter­ven­tion. The result is excep­tio­nal manu­fac­tu­ring fle­xi­bi­lity, maxi­mum pro­cess relia­bi­lity, and signi­fi­cantly increased productivity.

A key advan­tage is the high degree of modu­la­rity enab­ling each machine to be con­fi­gu­red pre­cis­ely for the cus­to­mer’s appli­ca­tion and opti­mi­zed for a wide variety of work­piece types and geometries.

In addi­tion to the machi­ne’s core uni­ver­sal turn-mill unit, a second inde­pen­dent machi­ning slide, modu­lar tool maga­zi­nes, clam­ping and mea­su­ring sys­tems, and addi­tio­nal machi­ning units can be con­fi­gu­red to fit indi­vi­dual manu­fac­tu­ring requirements.

SIZES AND MODULAR DESIGN

Sizes
Modu­lar Design

MACHINING A WIDE VARIETY OF GEOMETRIES, FROM RAW PARTS TO FINISHED PARTS

Shaft Parts and Large Crankshafts

Heavy‑Duty Performance

A pri­mary appli­ca­tion area for hori­zon­tal NILES-SIMMONS TURN-MILL machi­ning cen­ters is the pro­duc­tion of shaft-type com­pon­ents, inclu­ding large cranks­hafts, cams­hafts, and simi­lar work­pie­ces used in the energy, auto­mo­tive, con­s­truc­tion equip­ment, and gene­ral machi­nery and mecha­ni­cal engi­nee­ring indus­tries. These com­pon­ents are found in appli­ca­ti­ons ran­ging from gene­ra­tors and large-scale indus­trial equip­ment to safety and coo­ling sys­tems, as well as marine pro­pul­sion and heavy-duty engine sys­tems. Manu­fac­tu­ring such cri­ti­cal com­pon­ents demands the hig­hest levels of pre­cis­ion, pro­duc­ti­vity, and pro­cess reliability.

To meet these requi­re­ments, NILES-SIMMONS TURN-MILL machi­nes can be con­fi­gu­red in the MCM ver­sion for shaft machi­ning. In addi­tion to the uni­ver­sal turn-mill unit, this con­fi­gu­ra­tion fea­tures a high-per­for­mance exter­nal mil­ling unit moun­ted on a second inde­pen­dent machi­ning slide. Deli­ve­ring up to 10,000 Nm of tor­que, it enables excep­tio­nal cut­ting rates for deman­ding heavy-duty roug­hing appli­ca­ti­ons. The com­bi­na­tion of the uni­ver­sal turn-mill unit with the powerful mil­ling wheel sets new bench­marks in effi­ci­ency, pro­duc­ti­vity, and machi­ning fle­xi­bi­lity. It deli­vers out­stan­ding mate­rial rem­oval per­for­mance during rough machi­ning and has pro­ven its­elf in num­e­rous indus­trial appli­ca­ti­ons as a robust and highly pro­duc­tive solution.

Alter­na­tively, the MCT con­fi­gu­ra­tion adds an upper or lower tool tur­ret equip­ped with up to 12 tool sta­ti­ons for both sta­tic and live too­ling. This pro­vi­des an effi­ci­ent solu­tion for end-face machi­ning, dril­ling, tap­ping, and simi­lar secon­dary ope­ra­ti­ons. The tur­ret con­fi­gu­ra­tion redu­ces tool change times while allo­wing for a more com­pact machine foot­print in appli­ca­ti­ons that require a smal­ler tool inven­tory wit­hout the need for a second tool magazine.

To fur­ther opti­mize the machi­ning pro­cess, the machine can be equip­ped with a pro­gramma­ble tail­stock, a wide range of clam­ping solu­ti­ons, and up to four ste­ady-rest slides, each capa­ble of car­ry­ing two ste­ady rests. An optio­nal hydro­sta­tic work­piece sup­port sys­tem pro­vi­des com­ple­tely cont­act-free sup­port, eli­mi­na­ting fric­tion and vibra­tion while pre­ven­ting scrat­ches or machi­ning marks. Tog­e­ther, these fea­tures enable highly fle­xi­ble pro­cess design and con­sis­t­ently supe­rior sur­face finis­hes, even on long, heavy, and deman­ding shaft-type workpieces.

Tube‑ and Housing‑Type Components

High-strength transparency

Tubu­lar and housing-type com­pon­ents repre­sent ano­ther key appli­ca­tion for hori­zon­tal NILES-SIMMONS TURN-MILL machi­ning cen­ters. These work­pie­ces are com­monly found in the aero­space, heavy equip­ment, energy, and con­s­truc­tion machi­nery indus­tries, where com­plex inter­nal fea­tures and deman­ding mate­rial pro­per­ties require excep­tio­nal machi­ning capability.

For these appli­ca­ti­ons, NILES-SIMMONS TURN-MILL machi­nes can be equip­ped not only with the uni­ver­sal turn-mill unit moun­ted on the main spindle side, but also with a dedi­ca­ted bor­ing-bar machi­ning slide posi­tio­ned on the tail­stock or coun­ter-spindle side for com­plete inter­nal machining.

Depen­ding on the spe­ci­fic machi­ning requi­re­ments, the sys­tem accom­mo­da­tes bor­ing bars up to 2.4 m (7.9 ft) in length, inclu­ding dri­ven bor­ing bars, sta­tic bor­ing bars with or wit­hout pro­gramma­ble cut­ting-edge adjus­t­ment, mea­su­ring pro­bes, sen­sor-equip­ped vibra­tion-dam­ped bor­ing bars, and cas­sette sys­tems with inte­gra­ted drive and chuck func­tions. All tools are auto­ma­ti­cally exch­an­ged into the machi­ning area via an inte­gra­ted bor­ing-bar chan­ger. For spe­cia­li­zed appli­ca­ti­ons, tool lengths of up to 3 m (9.8 ft) are also available.

To maxi­mize pro­duc­ti­vity during exten­ded machi­ning cycles, the machine can be con­fi­gu­red with a bor­ing-bar maga­zine pro­vi­ding sto­rage for up to 16 bor­ing-bar cas­set­tes. These long tools—with length-to-dia­me­ter ratios of up to 14:1 and weights of up to 150 kg (330 lb)—can be ope­ra­ted with high-pres­sure coo­lant sys­tems deli­ve­ring pres­su­res up to 300 bar (4,350 psi) and flow rates of up to 250 L/min (66 gal/min). The tem­pe­ra­ture-con­trol­led coo­lant sup­ply can be regu­la­ted by eit­her pres­sure or flow rate, ensu­ring opti­mum cut­ting con­di­ti­ons throug­hout the machi­ning pro­cess. This con­fi­gu­ra­tion is par­ti­cu­larly well sui­ted for deep-hole dril­ling and the relia­ble machi­ning of high-strength mate­ri­als. Com­bi­ned with the excep­tio­nal struc­tu­ral rigi­dity of the TURN-MILL plat­form and its pro­ven vibra­tion-dam­ping sys­tem, sta­ble, low-vibra­tion machi­ning is main­tai­ned even with extreme tool overhangs.

Ano­ther key fea­ture is the optio­nal Auto­ma­tic Tool Change (ATC) sys­tem for bor­ing-bar appli­ca­ti­ons. Using the machi­ne’s stan­dard tool chan­ger, addi­tio­nal Capto® or HSK inter­face tools can be auto­ma­ti­cally trans­fer­red from two left-side chain maga­zi­nes, each accom­mo­da­ting up to 96 tools, into the bor­ing bar posi­tio­ned on the right side of the machine. This ensu­res that the appro­priate cut­ting tool is always available auto­ma­ti­cally for each machi­ning ope­ra­tion while also enab­ling fully auto­ma­tic in-machine tool measurement.

For the inter­nal machi­ning of high-value, tight-tole­rance com­pon­ents manu­fac­tu­red from deman­ding mate­ri­als such as tita­nium, Inco­nel®, and other high-strength alloys, where heat gene­ra­tion, tool wear, and vibra­tion pre­sent signi­fi­cant machi­ning chal­lenges, NILES-SIMMONS offers the option of inte­gra­ting Sand­vik Silent Tools™ Plus with the latest-gene­ra­tion embedded elec­tro­nics tog­e­ther with Coro­Plus® Con­nec­ted pro­cess moni­to­ring soft­ware. Through a pro­prie­tary PLC inter­face deve­lo­ped exclu­si­vely by NILES-SIMMONS, these intel­li­gent too­ling sys­tems are fully inte­gra­ted into the machine con­trol plat­form. This uni­que level of inte­gra­tion pro­vi­des com­plete pro­cess trans­pa­rency, maxi­mum ope­ra­tio­nal relia­bi­lity, and com­pre­hen­sive con­trol throug­hout the entire machi­ning cycle.

For more infor­ma­tion, please see our white paper, which is available here: Down­load

Ring‑ and Disc‑Type Components

Simultaneous Process Reliability

In addi­tion to shaft- and tube-shaped com­pon­ents, hori­zon­tal TURN-MILL machi­ning cen­ters are equally desi­gned to pro­duce ring- and disc-shaped work­pie­ces. For these appli­ca­ti­ons, the mul­ti­tas­king machi­nes are equip­ped as stan­dard with two iden­ti­cal turn-mill units com­bi­ned with full main and coun­ter spind­les, enab­ling simul­ta­neous machi­ning, inte­gra­ted work­piece trans­fer, and com­plete machi­ning in one setup. The con­fi­gu­ra­tion pro­vi­des iden­ti­cal machi­ning capa­bi­li­ties on both sides of the machine, inclu­ding inde­pen­dent Y- and B‑axis functionality.

When requi­red, part-off ope­ra­ti­ons can also be fully inte­gra­ted into the machi­ning pro­cess. Typi­cal appli­ca­ti­ons include tur­bine disks, engine rings, discs, and blisks. Manu­fac­tu­r­ers can signi­fi­cantly reduce non-pro­duc­tive times, increase pro­duc­ti­vity, and achieve the hig­hest levels of pre­cis­ion and pro­cess reliability.

ENGINEERED FOR YOUR PEACE OF MIND

His­to­ri­cally, NILES‑SIMMONS stands for a long tra­di­tion of pre­mium hori­zon­tal tur­ning machi­nes with pre­cis­ion “Made in Ger­many.” Buil­ding on this heri­tage, NILES-SIMMONS was among the first in the mar­ket to deve­lop mul­ti­func­tional hori­zon­tal turn‑mill machi­ning cen­ters distin­gu­is­hed by modu­lar archi­tec­ture and inte­gra­tion of mul­ti­ple tech­no­lo­gies into one machine. Through deca­des of engi­nee­ring, tech­no­logy, soft­ware deve­lo­p­ment, and prac­ti­cal expe­ri­ence, the “Clo­sed Door Machi­ning” con­cept has been con­ti­nuously refi­ned: com­plete machi­ning of a work­piece in a sin­gle setup wit­hout manual intervention.

By inte­gra­ting tur­ning, mil­ling, dril­ling, deep‑hole dril­ling, tap­ping, gear mil­ling, and grin­ding into one machine, the need for mul­ti­ple dedi­ca­ted machi­nes is eli­mi­na­ted. This redu­ces pro­cess time, sim­pli­fies pro­duc­tion work­flows, and sus­tain­ably impro­ves effi­ci­ency. The pro­ven mul­ti­func­tional machi­ning cen­ters have now been advan­ced to the next stage of development.

The next gene­ra­tion NILES-SIMMONS TURN‑MILL deli­vers the right con­fi­gu­ra­tion for every work­piece family, the ideal tech­no­logy for every pro­cess, and maxi­mum pro­cess reliability.

The high degree of modu­la­rity within the TURN-MILL series enables each machine to be pre­cis­ely con­fi­gu­red for a wide range of work­piece geometries—from shafts, large cranks­hafts, and cams­hafts to tubu­lar and housing com­pon­ents, as well as rings, discs, and blisks. A com­pre­hen­sive sel­ec­tion of machi­ning units, too­ling sys­tems, bor­ing-bar solu­ti­ons, tur­ret con­fi­gu­ra­ti­ons, mil­ling units, clam­ping sys­tems, and auto­ma­tion com­pon­ents can be indi­vi­du­ally tail­o­red to meet spe­ci­fic pro­duc­tion requirements.

The key bene­fit for manu­fac­tu­r­ers is uncom­pro­mi­sing com­plete machi­ning from a sin­gle source. Tur­ning, mil­ling, dril­ling, deep-hole dril­ling, thread cut­ting, gear machi­ning, grin­ding, rol­ler bur­nis­hing, mea­su­re­ment, and num­e­rous spe­cia­li­zed pro­ces­ses are inte­gra­ted into one machine and per­for­med when­ever pos­si­ble in a sin­gle setup. This signi­fi­cantly redu­ces setup effort, non-cut­ting time, and poten­tial sources of error while set­ting up the foun­da­tion for eco­no­mical, repeata­ble, and highly pro­duc­tive manufacturing.

The modu­lar machine plat­form is com­ple­men­ted by powerful soft­ware and auto­ma­tion solu­ti­ons. Intel­li­gent pro­cess moni­to­ring, sen­sor-based tech­no­lo­gies, adap­tive machi­ning stra­te­gies, and seam­less inte­gra­tion of too­ling, mea­su­re­ment, and moni­to­ring sys­tems pro­vide maxi­mum trans­pa­rency throug­hout the entire machi­ning process.

Ope­ra­tors gain com­plete con­fi­dence that the machine, too­ling, and manu­fac­tu­ring pro­cess are working tog­e­ther at peak performance—Engineered for Your Peace of Mind.

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