APPLICATION BULLETIN: AB008

Applicable Machines

• EM69ATC
• EM79
• F69A

Relevant Parts

5537A: Computer Controlled Automatic 4th Axis – Proprietary Rottler Design allowing for high accuracy machining of Engine Blocks (all models) and Cylinder Heads (EM69HP). Power Sliding Tail Stock on Linear Slideways provides for increased versatility and fast set up and change over. Requires mounting system adapter kits listed in the details. Maximum Engine Block Length 30″ (762mm) overall/outside length. Maximum Cylinder Head Length 37″ (940mm) overall/outside length

• 5537C – Universal Engine Block Mounting System
• 5537B – Universal Cylinder Head Mounting System
• 5537D – Universal 3 Jaw Scroll Chuck
• 5517F – T-slot Table For Mounting Manifolds, Heads, Raw Stock, or Vises in 5537A 4th Axis
• 11110 – Riser Kit for 4th Axis Compatibility on EM79

Overview

Rottler Manufacturing has improved upon its 4th axis offering for the CNC block machining centers, which include the F69A, EM69ATC, and EM79 series machines. Historically, these machines were offered with the 690-3-63 4th axis. The 690-3-63 4th axis was comprised of a worm drive gear box rotary axis for its head stock, and a pneumatically sliding tail stock.

Now, Rottler has introduced the 5537A Zero Back Lash Servo Driven 4th Axis System. The 5537A 4th axis retains the same working capacity as the 690-3-63 system with improvements being made to the rigidity, precision, and flexibility of the 4th axis system. The 5537A uses a servo driven headstock with a zero backlash direct drive planetary gearbox, and retains a pneumatically sliding tail stock design, with the difference being that the 5537A tail stock uses precision linear slideways which allowed improved range of motion from 6″ of travel to 7″.

The 5537A also includes a modular headstock and tail stock design, which allows fixture change overs between Block fixturing, Head fixturing, and Universal Part Fixturing. The attachments for change over include 5537C for Blocks, 5537B for Heads, 5537D for 3 Jaw Chuck, and 5517F – in conjunction with 5537B – for Universal T-Slot Table.

Figure 1: 5537A 4th Axis

Sections – Work Envelope and Use Cases

Block Work

The 5537A 4th Axis has the same capacity for block work as the old 690-3-63 4th Axis. Table to Centerline of the 5537A is 13.5″, this is the max swing radius allowed in the 4th axis for blocks. This accommodates all common domestic V8 engines, currently including large diesel V8 blocks such as 6.7L Powerstroke and 6.6L Duramax.

Block work can be performed using the 5537C Block Fixturing Kit and the common 650-x-xx 4th axis locator kits and individual main and expanding cam locators typically used with the previous 690-3-63 4th axis. These items can be found in the details section of the quoting system or from your local sales representative.

Figure 2: 5537C Block Fixturing System and 650-x-xx Locators

Head Work

The 5537A may be equipped with the optional 5537B Cylinder Head Mounting System. When equipped with the 5537B, the common PFIX-xx cylinder head porting plates can be used to mount cylinder heads in the 4th axis. This configuration allows for the capability of performing 4 axis machining operations on cylinder heads. Operations such as machining valve cover surfaces, manifold surfaces, seat pockets, guides, Oring interpolation, and engraving may be performed on various cylinder heads. The PFIX-xx plates can be found in the details section for the 5537B mounting system.

Figure 3: 5537B Cylinder Head Mounting System

Figure 4: PFIX-LS1 Cylinder Head Plate

Universal Parts Work

The 5537A may be equipped with the optional 5537D Universal 3 Jaw Chuck or the 5537B in conjunction with the 5517F T-Slot Mounting Table. These fixturing systems allow for work to be performed on either cylindrical raw stock with the 5537D 3 Jaw Chuck while the 5517F allows for the mounting of vises for positional 4 axis machining of billet parts.

Incorporating these fixturing systems allows for flexibility and opportunities for work to be performed on Rottler equipment outside of the standard engine block work. This greatly increases the value proposition of a Rottler CNC block machining center, seeing as it allows shops to perform work in-house that they may have previously had to outsource or refuse.

Figure 5: 5517F Universal T-Slot Table

Figure 6: 5537D Universal 3 Jaw Chuck

CONTACT

For additional information regarding Rottler Manufacturing’s new and improved 5537A 4th Axis, please contact Ryan Thompson or Nick Jenkins via the emails listed below.

• Ryan Thompson, Lead Applications Engineer, Tel: +1 (206) 707-2458
• Nick Jenkins, Applications Engineer, Tel: +1 (206) 406-1880