MECAL KOSMOS

General

The Mecal Kosmos redefines the capabilities of 4-axis compact CNC profile machining centres, offering multiple options for demanding applications. Engineered for maximum versatility, the Kosmos efficiently processes aluminium extrusions, vinyl profiles, light alloys, and even light steel profiles. It comes standard with a robust 6 kW, 18,000 rpm electro-spindle, with an optional 8.5 kW upgrade for heavier-duty applications. A 10-tool magazine ensures uninterrupted operations, expandable to a 16-tool capacity for increased productivity.

Mecal’s iconic A-axis rotating beam, featuring a sophisticated clamping system for secure material holding, provides a wide working range of ±125° around the X-axis. This allows for high-precision drilling, milling, and tapping at virtually any angle within this range. The Y and Z axes are ball-screw driven, while the X-axis uses a high-precision rack and pinion system—delivering smooth and accurate linear and circular interpolation across three axes.

The Kosmos also supports end-notching operations using a milling cutter and accommodates various aggregates for advanced end-work. Two pneumatically operated reference stops, positioned at each end of the rotating beam, streamline workflow by enabling dual-piece processing in a single cycle and accommodating profiles longer than the machine’s nominal capacity.

Clamping

The Kosmos raises the bar in material handling with a rigid clamping structure featuring precision linear-guided, quick-adjust movable jaws. Clamp positioning is available via two systems: the head-driven DPM system or the highly advanced MMI self-motorized clamps. Unique to the MMI system, the clamps can move simultaneously, independently, and rapidly to calculated positions—offering unmatched flexibility and efficiency in setup.

Programming

Programming the Mecal Kosmos is both intuitive and powerful. It utilizes Mecal CAD/CAM3D software for ease of use, while also supporting standard Mecal ISO programming for advanced operators. For enhanced integration with third-party design tools, the optional STEP/IGES driver CADLink allows seamless import of 3D design files, streamlining the engineering workflow.

Features

• 4 servo axis with absolute encoders, no axis referencing necessary
• Servo-driven rotating beam (A-axis) with integrated clamps for multi-angle machining.
• Workpiece clamps are mounted on precision linear guide rails for accurate positioning and secure material holding.
• Automatic self-motorized clamp positioning system
• The working area supports dual-zone setup, allowing two workpieces to be machined in a single cycle, resulting in more efficient processing
• Supports end-notching operations on either end of the profile with a dedicated disc cutter.
• Pneumatically operated flipping stops provide consistent workpiece positioning and efficient setup.
• The standard tool changer is located in a central embedded compartment. It accommodates up to 10 tools.  Additional tool holders are available as options.
• Delivers efficient tool cooling with minimal fluid usage, supporting cleaner operations and longer tool life.
• All linear guideways and ball screws are automatically lubricated through a central system, reducing maintenance needs.
• A large front safety door offers increased visibility into the machining area while providing full operator protection.
• The machine is pre-configured for optional chip collector trays or chip conveyor to facilitate easy cleanup and efficient chip handling

Technical Data

• Maximum Working Length: 4,013 mm (13 ft), including end milling
• Extended Machining Capability: Up to 8,026 mm (26 ft) using oversized part processing
• Spindle Power: 6 kW / 8.5kW
• Spindle Speed: 18,000 rpm / 24000 rpm
• Tool Holding System: ISO 30 / HSK 63F
• Tool Magazine Capacity: 10 tool
• Standard Clamp Width: 250 mm (10")
• Optional Clamp Width: 300 mm (12")
• Standard Number of Clamps: 4
• A-Axis (Beam Rotation): ±125° rotation around the X-axis
• Control Interface: Windows 10 based PC with 18.5” touch screen

Standard Equipment

• Electrospindle: air cooled, ISO30, 18000 rpm, 6 kW
• Magazine with 10 tools capacity
• 4 x Pneumatic clamps
• 2 x Reference stops
• Windows 10 based PC
• CAD/CAM 3D Graphic software with office licence

Optionals

• Configuration with MMI self-motorized clamps
• Upgrade to 8.5kW spindle
• Upgrade to 8.5kW spindle with encoder for rigid tapping
• Additional DPM clamps, max 6
• Additional MMI clamps, max 6
• Additional tool magazine, 3 seats on the RH
• Additional tool magazine, 3 seats on the LH
• Tool length measuring probe
• Work-piece touch probe
• Clamp capacity expansion kit
• Chip conveyor
• Inclined chip conveyor
• Chip bins
• Steel processing kit
• Roof kit for closed top and internal lighting
• Sound insulation kit
• Bar code reader
• Integration with third party software
• CADLink 3D file convertor
• Various aggregates for milling, cutting or tapping
• Tailor-made tool kit