Connecting the Dots: Machining from Every Angle

The standard 1 deg indexing table is locked into place by a hydraulic actuated curvic coupling for maximum strength. The optional, 360,000 position, B-axis table is locked into place by a hydraulic actuated brake. The pallet that is not engaged in the machining area is able to be manually rotated and locked down every 90 deg to aid in part or fixture setup while the machine is in operation. This feature aids in achieving maximum machine uptime, with little to no time lost during changeover. Pallet change time including lock, unlock and rotation is 8 seconds.

All axes are of a Roller Linear Motion Guide type for higher stiffness, accuracy, and surface finish than more common Ball Bearing Guide types. They are heavy duty (X –  45 mm / 1.772 in, Y – 45 mm / 1.772 in, Z – 45 mm /  1.772 in) and widely spaced (X – 550 mm / 21.6535 in, Y – 570 mm / 22.441 in, Z – 400 mm / 15.748 in). Roller guide ways are three times more rigid, with two times more life than ball bearing guide ways and provide for optimal weight and force distribution. Each axis is driven by a high precision double nut ball screw that is supported on both ends by angular contact thrust bearings. This double pretension design provides outstanding positioning repeatability with virtually no thermal growth.

These large diameter  ball screws (X – 40 mm \ 1.57 in, Y – 40 mm \ 1.57 in, Z – 40 mm \ 1.57 in) are directly connected  to oversize A.C. servo drive motors without gears or belts in order to help eliminate backlash. The high speed, direct drive spindle system is a true cartridge type unit supported by high precision ceramic ball bearings that offers minimized vibration and thermal growth. The bearings are precision class P4 (AFBMA-B7) and are permanently grease lubricated. The versatile 12,000 rpm, 11 / 18.5 kW (15 / 25 hp) motor has 117 nm (86 ft-lb) of torque.

The CAT 40 Big Plus spindle also features rigid tapping, further increasing productivity. The Big Plus spindle system and tooling surpasses all other spindle concepts due to simultaneous taper and flange contact between the machine spindle and tool holder as well as complete interchangeability with existing machines and tools. Upon mounting the tool holder into the machine spindle, contact occurs prior to clamping. Due to the retention force, the taper of the tool holder expands the machine spindle in its elastic range. The tool is pulled further in until the tool flange touches the spindle face for maximum rigidity.

Air is supplied to the back of the pull stud and then forced through the tool using the same technique as through spindle coolant by use of M-code. The spindle air blow is commonly used on pre-hardened steel, die and mold cutting, cutting of plastics and anytime coolant would contaminate the work piece such as during the machining of certain medical components. Machine accuracy is maintained by using a refrigeration system that circulates cooled oil around the spindle thereby reducing the thermal effects of any heat generated by the machining processes.

The 60 tool Double Arm ATC provides reliable exchange of tools with a tool-to-tool time of 1.5 seconds. The tool changer design utilizes random access in order to deliver instant tool availability, even during short cutting cycles. All tools are returned to the pots from which they were originally taken so that collision problems involving large-sized tools need to be considered only once when they are first mounted. A dedicated positive displacement pump delivers the coolant directly to the tool tip. The immediate benefit is more aggressive feeds and speeds can be maintained throughout the cutting process. There is no need to stop and adjust coolant nozzles which increases both in cut time and operator safety.

Protecting the spindle and the vital rotary union from contamination is cyclonic filter which does not require the use of bags, reducing maintenance time. The 550 L (145 gal) tank stores an ample supply of coolant and is isolated from the machine bed to help prevent heat transfer. The bed guide ways are protected by a heavy gauge telescopic cover that is inclined at a 30 deg angle to help direct chips down into the trough. Dual, screw-type augers then move the chips to the rear of the machine where they can be easily removed or taken away by an optional chip conveyor. A separate pump provides flood coolant at spindle face through adjustable spindle mounted nozzles.

The newly designed Automatic Pallet Changer (5 APC) system is an easy to retrofit and very compact way to boost the productivity of the HC 400 II horizontal machining center. Featuring operator access doors at three stations, parts can be loaded and unloaded with no loss of time between machining cycles. With the ability to run either separate part programs per pallet or the same part number on all of the pallets, the 5 APC can be configured the way you need it, maximizing the machine’s uptime and getting you the most out of your investment.

The LPS II Compact Pallet System is an easily retrofitted linear pallet system, designed for shops who want the utmost in flexibility and productivity from their HC 400 II HMC. With 12 pallets available on demand, the LPS II compact enables users to queue up multiple jobs and call them up as needed, increasing throughput and maximizing work flow. Ideally suited to manufacturers who produce a family of parts with rapidly changing production schedules, the LPS II compact represents the pinnacle of efficiency for the most demanding of time critical machining challenges.

A TRUE 5-AXIS UNIVERSAL MACHINING CENTER
The FM 200/5AX Linear machining center is a high-speed, high precision full 5-axis machining center. Utilizing the latest in linear motor and direct drive technology, the FM 200/5AX Linear delivers the ultimate platform for simultaneous 5-axis contouring. Ideal applications include medical devices, automotive turbo chargers and other precision mold and die parts.

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The FM200/5AX Linear is built upon a rigid bridge-type base composed of a highly stable mineral composite material that provides superior surface finishes. Additional benefits of a mineral composite bed structure are excellent vibration isolation and thermal stability. Mineral castings absorb vibration at ten times the rate of iron castings, resulting in greatly increased tool life.

The XYZ linear axes on the FM200/5AX Linear are driven by high-precision linear motors to provide extra high accel/decel and feed rates and practically no backlash. The 4th and 5th axes rotary tables are equipped with direct drive motors to deliver matching high speed and rapid accel/decel. The platter size is 7.9 in in diameter with a capacity load of 33.1 lb. Travels on the FM 200/5AX Linear are X-axis, 7.9 in, Y-axis, 13.4 in and Z-axis, 11.8 in. Rapid travers rates on all axes are 1968.5 ipm, with a cutting federate of 787 ipm.

Spindle speed of 45,000 rpm is the highest in its class. Spindle vibration has been minimized to maximize stability. Spindle taper, HSK E40. Spindle motor power is 19 hp. The 24 tool stations (standard) increase productivity while the direct drive, servo-driven ATC achieves optimum reliability. Type of tool shank: HSK E40. Maximum tool diameter: 2 in. Maximum tool length and weight: 7.1 in and 2.2 lb.

COMMITMENT CLOSES THE LOOP
Integrating highly advanced machine tools such as these through MTConnect would not be complete without service and support, and Doosan now offers new complimentary customer service products on its full line of machine tools. They pertain to enhanced factory quality control, an extended warranty, and round-the-clock technical support availability all under the single brand theCommitment.

“It’s important to note,” said HJ Henry Kim, the chief executive officer of the company, “that these three service pillars are now part of our permanent, on-going commitment to our customers. They don’t have an expiration date like some temporary promotions do, and they don’t apply to just certain models or segments of our product line. They extend across the full enterprise of our comprehensive line.”

The first new service initiative included in theCommitment surrounds enhanced quality control before shipment, which features a new double inspection process at the factory. Service technicians will conduct an additional, lengthy quality checklist after assembly and rigorous testing, prior to shipment from the factory.

The second, and perhaps most compelling, pillar of theCommitment is what Mr. Kim refers to as a “best-in-class” three-year limited warranty offering three years of machine parts, two years of parts and labor on the Fanuc control, and one year of labor costs. The third pillar of service relates to customer support. The company has extended its availability to provide technical phone support for a full 24 hours each weekday.

Mr. Kim added, “Taken as a whole, we believe theCommitment is the most generous and wide-ranging of any machine tool builder and underscores the confidence Doosan has in its products and organization. In fact, we could not offer such support if we didn’t feel confident that our product quality was second to none.”

Doosan Infracore Machine Tools designs, engineers and manufactures the industry’s widest breadth of CNC machine tools. The company, which is part of the larger Doosan Group, continues to increase its competitiveness in global machine tools while establishing a firm foundation to become a global leader in the machine tools industry, assisting its customers in performance under pressure.

Doosan Infracore Machine Tools, 19A Chapin Road, Pine Brook, NJ 07058, 973-618-2500, Fax: 973-618-2501, www.doosanmachinetoolsusa.com.