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5-axis machining centre for high accuracy contouring

5-axis machining centre for high accuracy contouring

Added to MTDCNC by MTDCNC on 02 August 2012

A new, 5-axis, vertical-spindle machining centre has been introduced by Japanese manufacturer, Makino, designed specifically for 3D profiling of small, complex components. Rotary indexing accuracy of better than 3 arc-seconds and Ra 0.2 &mum surface quality on machined components are claimed.

Designated D300 and available in the UK through sole agent, NCMT, the compact machine is aimed at a wide range of applications, notably the manufacture of impellers, blisks and turbine blades for the aerospace industry, production of high precision automotive and motorsport parts, precision jobs in the semiconductor, medical and optics sectors, mould and die manufacture, and high-end job shop work.

Similar to the larger D500 announced in 2010, the D300 enables companies to shorten set-ups, reduce cycle times and improve accuracy for tough, precision machining processes, whether roughing or finishing. The rigidity and thermal stability of the direct-drive rotary table ensures sustained dynamic accuracy, while its speed provides rapid positioning and feed rates to reduce manufacturing lead-times.

The 360-degree C-axis table, which has ± 120 degrees of A-axis trunnion movement, offers a work area of 300 mm diameter, accommodating workpiece sizes up to 450 mm by 270 mm and weighing 120kg. Makino uses direct-drive motor technology in the A-axis as well as the C-axis for high positioning accuracy and repeatability. The ultra-high-torque motors provide superior acceleration and rotary speed characteristics, reducing cycle times for complex, 5-axis simultaneous machining applications by up to 60 per cent.

The D300 provides X-, Y- and Z-axis travels of 300, 500 and 350 mm respectively at feed rates up to 60 m/min. Linear roller guides in all linear axes impart superior rigidity and stiffness.

The machine comes equipped as standard with a 15,000 rpm, HSK-A63 spindle with 120 Nm of torque (42 Nm continuous) for flexible, high speed machining of various workpiece materials from aluminium through steel to titanium. Optional spindle configurations include a 20,000 rpm, HSK-A63 spindle and 30,000 rpm, HSK-F63 spindle. Tool-to-tool time is particularly rapid at 0.7 sec.

The Makino Professional 5 control provides a Windows CE graphical user interface with touch-screen access and the networking and storage capabilities of a data centre, which features flexible, user-friendly program and data management for quick, seamless changeovers from one setup the next. Built-in Ethernet networking offers ready integration to off-machine program storage.

Featured also is Makino&rsquos proprietary, next-generation Super Geometric Intelligence (SGI.4) software developed specifically for high feedrate, tight tolerance machining of complex, 3D contours involving continuous tiny blocks of NC data. The software helps reduce cycle times and costs by reducing machining cycle times on dies, complex cavities, cores and medical parts by as much as 40 per cent when compared to most other control technologies.

The D300 incorporates CNC enhancements to improve 5-axis machining performance and operability. The tool centre point (TCP) control allows programming based on the tool tip so that tool compensation features can be applied. Further TCP developments improve the cutter path to achieve higher surface quality. Dedicated, user-friendly screens simplify the application of 5-axis machining and easy-to-apply functions prevent interference between the spindle and trunnion during automatic operation to ensure risk-free production.

Upgrade for automation is possible at any time by the addition of an automatic pallet changer with 15-second APC time and the machine can also be retrofitted with Makino's MMC2 automated material handling system.
 


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