Machine Tool Case Studies

27/07/2010

Open Mind CAM Software - JK Engineering

When John Kenny left his job to start JK Engineering Ltd in 2001, the philosophy was to acquire the
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26/07/2010

Mikron 5 axis Machining Centre - Midland Precision Engineering

The catalyst behind MPE’s investment in the HSM 600U ProdMod machine was the Company’s successful
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20/07/2010

Mazak Quick Turn Nexus CNC Lathes - Williams & Co Ltd

“We have invested heavily in manufacturing systems and machine tool capacity to bring the business..
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19/07/2010

Wire and Spark erosion Machine Tools from Agie - Camcraft Ltd

The 3 machine tools replace older, less sophisticated EDM technology that Camcraft had at its
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High Speed CNC Machining on Aluminium and Titanium Components

Story added 28 February 2010.

MAG's MEGA 5 five-axis horizontal machining center is built for power and speed, with two spindle options providing high-torque machining of tough materials such as titanium or high-speed processing of aluminum, for large-part applications. The MEGA 5 combines twin ballscrew-driven axes in X-Y-Z, an infinite contouring B-axis table, and a compact u-frame, A-axis tilt spindle with 180? sweep for full five-axis contouring of highly complex parts. With its combined features, the MEGA 5 delivers five-sided machining capability, eliminating re-fixturing to reach odd angles and surfaces, for improved part accuracy and the lowest cost-per-part manufacturing.

The XT spindle configuration is designed for machining hard metals such as compacted titanium, graphite iron, steel and Inconel, and is offered in HSK100A and ANSI 50 versions. A dual-speed gearbox with rugged spindle headstock provides speeds up to 6000 rpm, with constant power availability at 375 rpm for machining a variety of metals. The high-performance 45 kW (60 hp) AC drive motor and 1146 Nm (845 ft lb) of torque for hard metal machining give the XT spindle an S6-60 duty rating. The AP spindle package, specially-designed for machining aluminum, features a choice of two high-speed spindles – one rated for continuous operation at 50 kW (67 hp) and the other rated at 30 kW (40 hp). Both have HSK63A tooling interface, 61 Nm (45 ft lb) of torque and are capable of 24,000 rpm.

The MEGA 5 is built on one-piece nodular cast iron bed using a symmetrical design for high thermal and geometric stability. The machine's T-layout moves the part to and from the spindle in a straight line for optimum boring position. Digital scales provide linear accuracy of 9 µm (0.00035in) and repeatability of 6 µm (0.00024in), A and B rotary axes are accurate to 8 arc seconds and repeatable to 6 arc seconds.

The MEGA 5 features high dynamic stiffness for hard-metal processing, as well as a high feed rate of 60 m/min (2362 ipm) and 0.8G (7.8 m/s2) (310 in/s2) acceleration rate for high-speed processing. With 1425 mm (56.1 in) of X-axis travel, 1350 mm (53.1 in) of Y-axis travel and 1265 mm (49.8 in) of Z-axis travel, the MEGA 5 can handle parts up to 1300 mm (51.2 in) diameter and 2000 mm (78.7 in) high. A robust two-pallet automatic workchanger accommodates loads weighing up to 2200 kg (4840 lbs), and can swap square 800 mm x 800 mm (31.5 in x 31.5 in) or rectangle 800 mm x 1000 mm (31.5 in x 39.4 in) pallets in a best-in-class14.5 seconds, unclamp-to-clamp. A rotary table with pallet registration system ensures alignment each time a new pallet is shuttled into the machining zone.

An automatic tool changer handles 40-, 80- or 120-tool chains and can accommodate tools up to 540 mm (21.3 in) long, weighing up to 30 kg (60 lbs), and tool diameters up to 125 mm (4.9 in) with all pockets loaded – 335 mm (13.2 in) with adjacent pockets empty. The servo-driven, continuous motion tool changer features a tool-to-tool interchange time of just 2.4 seconds, utilizing tool queuing to minimize next-tool wait time. Metal-to-metal interchange time is 5.7 seconds to mid-travel.

The MEGA 5 features extra-large coolant capacity for thermal stability and improved part accuracy. High-pressure, 15 bar (220 psi) thru-spindle coolant is standard, with an option for 55 bar (800 psi) or 103 bar (1500 psi) for the HSK100A spindle. High-volume chip evacuation is handled via an extra-large center trough in the machine base.

 



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