Multi-Axis Turning Center

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Garey Gaines
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1 Multi-Axis Turning Center

Main Spindle Left & Right spindle have the same capacity TT1800SY 8 inch Chuck Bar working dia. 2.625" PUMA TT1800SY Max.

001 increments) Oil Cooling Unit for Spindles Each motor is surrounded by an oil jacket cooling system to minimize thermal displacement and ensure consistency through a wide range of cutting

2 Main Spindle Left & Right spindle have the same capacity TT1800SY 8 inch Chuck Bar working dia " PUMA TT1800SY Max. spindle speed 5,000 rpm Motor(30 min) 30 Hp Hydraulic C-axis Brake Hydraulic disc brake locks the C-axis in position for heavy machining. C1, C2-axis index 360 (in increments) Oil Cooling Unit for Spindles Each motor is surrounded by an oil jacket cooling system to minimize thermal displacement and ensure consistency through a wide range of cutting conditions. Left & Right Spindle power-torque diagram Both the left and right side spindles are integral type motors with identical horsepower and torque. This allows high power cutting or finishing operations to be performed at either the same or at different times. PUMA TT 1800SY Spindle motor power : 30 Hp (Built-in) Max. Spindle speed : 5,000 rpm OUTPUT(Hp) S2 30min S3 40% S1 Cont. 15Hp 152 ft-lbs ft-lbs ft-lbs 76.8 ft-lbs 64.2 ft-lbs S2 30min S1 Cont. 20Hp 30Hp 25Hp ,400 4, , ,000 2,000 5,000 SPINDLE SPEED (rpm) 2

Turret Synchronized upper & lower turret Both turrets are 12 stations, thus providing the ability to use up to 48 tools with the use of double tool holders and 15

5 Hp) Total of 24 tool stations on the on the upper and lower turret (BMT55P) make it possible to complete complicated parts requiring many tools in just one set-up.

of tool station (Upper+Lower turret) 24 stations(12+12) OUTPUT (Hp) 13.4 8.0 5.4 2.7 1.3 34.7 ft-lbs 10.3 ft-lbs SPINDLE SPEED (rpm) 7.4Hp S3 25% 1.

These high torque drive motors are connected to the ball screws without intermediate gears for quiet and responsive slide movement with virtually no backlash.

3 Turret Synchronized upper & lower turret Both turrets are 12 stations, thus providing the ability to use up to 48 tools with the use of double tool holders and 15 deg. tool indexing. No. of tool positions (Upper+Lower turret) Up to 48 tool(24+24) Rotary tool spindle power-torque diagram Max. speed : 5,000 rpm (7.5 Hp) Total of 24 tool stations on the on the upper and lower turret (BMT55P) make it possible to complete complicated parts requiring many tools in just one set-up. Reliable servo driven turrets reduce the total cycle time required to machine parts. Index time (1-station swivel) 0.15 sec. Rapid Traverse No. of tool station (Upper+Lower turret) 24 stations(12+12) OUTPUT (Hp) ft-lbs 10.3 ft-lbs SPINDLE SPEED (rpm) 7.4Hp S3 25% 1.5Hp S ,115 2,500 4, ,000 2,000 3,500 5,000 Each axis is powered by a maintenance free digital AC servo motor. These high torque drive motors are connected to the ball screws without intermediate gears for quiet and responsive slide movement with virtually no backlash. High precision linear guides (Z1, Z2 and A-axis) with comparable rigidity to box way guide systems are used to ensure smooth slide movement. Z1,2-axis 1,575 ipm A-axis 1,575 ipm Accurate & Reliable Box Guide Ways (X1, X2, Y-axis) X1,2-axis 787 ipm 3

Robust Design A robust design provides a stable base for multi-axis cutting.

design inhibits thermal deformation and twisting.

guideway. This ensures maximum rigidity and virtually no deformation under heavy loads. 0.

machining on a single spindle or both left and right spindles. Z1-Axis Roughness 0.

productivity and provide for just-in-time production by reducing lead time, set-up time, and changeover

4 Robust Design A robust design provides a stable base for multi-axis cutting. FEM (Finite Element Method) Torque tube of triangular frame The heavily ribbed triangular torque frame design inhibits thermal deformation and twisting. The bed guideways are on a 45 degree slant to maintain a minimal and constant distance from tool tip to guideway. This ensures maximum rigidity and virtually no deformation under heavy loads µm Roundness Machine Construction 8 Controllable axes provide multi-axis machining with simultaneous machining on a single spindle or both left and right spindles. Z1-Axis Roughness 0.16µm (Ra) Y-Axis C1-Axis X1-Axis C2-Axis A-Axis X2-Axis Z2-Axis Multi-tasking capabilities increase productivity and provide for just-in-time production by reducing lead time, set-up time, and changeover time. Machining capacity Accuracy Material : Brass Cutting Feed : ipr Workpiece dia. : 2.32" Spindle Speed : 5,000 rpm Tool : Diamond (Nose R0.024) Actual results may be slightly different due to material and cutting conditions 4

Y-axis Function The addition of a Y-axis to the upper turret allows parts requiring complex machining to be completed in just one set-up.

96") Y-axis rapid 295 ipm Y-axis Travels Spindle center 0.24 1.96 1.96 1.83 0.24 9.7 2.85 6.26 6.5 3.

Y-axis X-axis On-center face milling Y-axis X-axis Poly-side machining X-axis Y-axis Off-center side milling X1+Y-axis X and Y axis

05" B : Max. turning length 9.1" C : Max. bar working dia. 2.625" L : Distance spindle nose to spindle nose. 38.

5 Y-axis Function The addition of a Y-axis to the upper turret allows parts requiring complex machining to be completed in just one set-up. Synchronized interpolation of X1-axis and Ys-axis create the Y-axis movement. Multi-Axis Flexibility Y-axis travel 3.93" (±1.96") Y-axis rapid 295 ipm Y-axis Travels Spindle center Increased productivity and shorter cycle times can be achieved by balancing the machining work load between the upper and lower turrets. Y-axis X-axis On-center face milling Y-axis X-axis Poly-side machining X-axis Y-axis Off-center side milling X1+Y-axis X and Y axis circular interpolation Working Range L Systemized compact structure ø C ø A ø C Z1-Axis X1-Axis Y-Axis A-Axis B A : Max. turning dia. 9.05" B : Max. turning length 9.1" C : Max. bar working dia " L : Distance spindle nose to spindle nose. 38.5" B Height C1-Axis X2-Axis C2-Axis Z2-Axis X1axis (Upper turret) 6.5" X2-axis (Lower turret) 7.48" B-axis 30.31" Travel Z1axis (Upper turret) 27.5" Z2-axis (Lower turret) 28.34" Length Length Width Height 153.7" 81.5" 82" Width 5

Ergonomic Design Carefully engineered ergonomic operating environment.

double panel shock absorbing type glass. Designed and tested to resist high impacts for operator safety.

1" 0~90 Convenient maintainability Pressure control for spindle (Left & Right) Pressure control for Right spindle Operator

Removal of waste oil extends coolant life and keeps the inside of the machine cleaner.

Oil Skimmer A belt-driven type oil skimmer removes waste oil from the coolant tank and is easily drained.

$Main menu of Doosan Infracore tool monitoring system Tool load monitoring system This screen shows a tool and its number,$

6 Ergonomic Design Carefully engineered ergonomic operating environment. Resin Safety & Operability Front door safety window Viewing window is unobstructed by grating or bars and is constructed of a double panel shock absorbing type glass. Designed and tested to resist high impacts for operator safety. Polycarbonate(exterior) Tempered glass(interior Door interlock Swivel type operator panel Just 6.1" 0~90 Convenient maintainability Pressure control for spindle (Left & Right) Pressure control for Right spindle Operator oriented design with 90 swivel Separate coolant tank Lubrication tank Eco-friendly Design Collection of Waste Lubrication Oil Removal of waste oil extends coolant life and keeps the inside of the machine cleaner. It also provides a healthier work environment for the operator. Oil Skimmer A belt-driven type oil skimmer removes waste oil from the coolant tank and is easily drained. Turning Center Tool Monitoring System Tool Monitoring System protects the machine and tools from damage caused by tool wear or breakage. This system monitors the tool status during machining operations by dectecting the load of each axis and spindle. Main menu of Doosan Infracore tool monitoring system Tool load monitoring system This screen shows a tool and its number, load meter of each axis and spindle limit load Tool management function This function consists of tool pre-check function, substitutive tool selection with tool life management and different tool & tool number command function. 6

7 Working Range unit : inch Single OD Tool holder (Distance between spindle nose) (Z1-axis stroke) (A-axis stroke) Double OD Tool holder (Distance between spindle nose) (Z1-axis stroke) ID Tool holder Angular milling head (Distance between spindle nose) (Z1-axis stroke) (X1-axis stroke) ø (X2-axis stroke) 6.50 (X1-axis stroke) ø (X2-axis stroke) (Z2-axis stroke) (Distance between spindle nose) (Z1-axis stroke) (X1-axis stroke) ø (X2-axis stroke) 6.50 (X1-axis stroke) ø (X2-axis stroke) (Z2-axis stroke) max.4.72 max.3.54 max (Z2-axis stroke) (Z2-axis stroke) 2.36 Straight milling head (Distance between spindle nose) (Z1-axis stroke) 5.51 Y-axis travels Straight milling head Angular milling head Spindle center 9.91 Spindle center 6.50 (X1-axis stroke) 0.87 ø max.2.64 max.ø (X2-axis stroke) (Z2-axis stroke)

8 Tooling System (Upper & Lower turret) unit : inch Note) Above tooling system is our recommendation. Depending on export condition, the standard tooling packed with the machine can be different. 8

9 Tool Interference Diagram unit : inch External Dimensions Top View unit : inch REAR CHIP CONVEYOR (OPTION) SIDE CHIP CONVEYOR(OPTION) Front View Side View SPINDLE CENTER (128.15) (153.74) (180.91)

10 Machine Specifications Description Unit PUMA TT1800SY Max. distance between spindle noses inch 38.5 Swing over saddle inch 9.1 Recom. Turning diameter inch 9.05 Capacity Max. Turning diameter inch Upper Turret : 9.05 / Lower Turret : Max. Turning length inch Bar working diameter inch Spindle speed rpm 5,000 Spindle nose ASA A2#6 Spindle bearing diameter (Front) inch 4.3 Left Spindle Spindle bore diameter inch 2.99 Cs Spindle Index angle deg 360 (in deg. increment) Cs Spindle Index Speed rpm 600 Spindle speed rpm 5,000 Spindle nose ASA A2#6 Spindle bearing diameter (Front) inch 4.3 Right Spindle Spindle bore diameter inch 2.99 Cs Spindle Index angle deg 360(in deg. increment) Cs Spindle Index Speed rpm 600 Travel distance X1/2-axis inch X1: 6.5 / X2: 7.48 Z1/2-axis inch Z1: 27.5 / Z2: A-axis inch Y-axis inch 3.93 <±1.96> Carriage Rapid traverse X1/2-axis ipm 787 Z1/2-axis ipm 1,575 A-axis ipm 1,575 Y-axis ipm No. of tool stations (Upper+Lower) st (24+24) OD tool shank size inch 0.75 Turret Boring bar diameter inch 1.25 (Upper+Lower) Indexing time sec 0.15 Rotary tool spindle speed rpm 5,000 Left & Right spindle motor (Int./Cont) Hp 30 / 25 Rotary tool spindlemotor Hp 7.4 Servo motor X1-axis Hp 4.0 X2-axis Hp 2.1 Motor Z1-axis Hp 3.6 Z2-axis Hp 3.6 A-axis Hp 3.6 Y-axis Hp 2.1 Coolant pump Hp 1.2 x 2 Electric power supply (Rated capacity) kva 76 Machine height inch 82.0 Other Machine dimensions length inch width inch 81.5 Machine weight lb 19,400 Standard Features Absolute positioning encoder Air blast for chuck jaw cleaning Bar feeder interface Coolant supply equipment Foot switch Front guard door interlock Full enclosure chip and coolant shield Hand tool kit (including small tool for operations) Hyd. actuating cylinder Hydraulic power unit Leveling jack screw & plates Lubrication equipment Manuals Move to Optional Features Oil skimmer Proximity switches for chuck clamp detection Parts unloader and conveyor Signal tower (yellow, red, green) Safety precaution name plates Spindle oil cooling unit Standard tool kit (tool holder & boring sleeve ) Tool monitoring system Tool pre-setter (hydraulic type) Work light Optional Features Air gun Automatic door Automatic power off Automatic measuring system* (in process touch probe) Chip conveyor Collet chucks* Coolant blower Dual chucking pressure Hardened & ground jaws High pressure coolant pump Minimum Quantity Lubrication (MQL)system Note) * : It should be reviewed in detail before contract. 10

11 NC Unit Specifications (Fanuc 31i-A) AXES CONTROL - Controlled path 2 path - Controlled axes X1, Z1, C1, Y X2, Z2, C2, A - Simultaneous controlled axes 4 axes - Angular axis control - Axis control by PMC - Backlash compensation 0 ~ ±9999 pulses - Backlash compensation for each rapid traverse and cutting feed - Chamfering on / off - Cs contouring control - Synchronous / Composite control - Emergency stop - Follow-up - HRV2 control - Inch / Metric conversion - Interlock All axes / each axis - Least input command / mm/inch - Machine lock All axes / each axis - Mirror image - Overtravel - Position switch - Servo off - Stored pitch error compensation - Stored stroke check 1 - Torque control - Interference chek for rotary area - Unexpected disturbance torque detection function OPERATION - Automatic operation (memory) - MDI operation - DNC Operation with Memory card - Buffer register - Dry run - Handle incremental feed X1, X10, X100 - Program restart - Wrong operation prevention - JOG feed - Manual handle feed 1 unit - Manual intervention and return - Manual pulse generator 1 ea - Manual reference position return - Program number search - Refernce position setting without dog - Sequence number search - Single block INTERPOLATION FUNCTIONS - Nano interpolation - Positioning G00-1st. Reference position return Manual, G28-2nd. reference position return G30-3rd/4th reference position return - Balance cutting - Circular interpolation G02 - Continuous threading - Cylindrical interpolation - Dwell (per sec) G04 - Helical interpolation - Linear interpolation G01 - Multiple threading - Polar coordinate interpolation - Reference position return check G27 - Skip G31 - Thread cutting / Synchronous cutting - Thread cutting retract - Torque limit skip FEED FUNCTION - Automatic acceleration / deceleration - Cutting feedrate clamp - Feed per minute - Feed per revolution - Feedrate override (10% unit) % - Jog feed override (10% unit) mm/min - Manual per revolution feed - Override cancel - Rapid traverse override F0, 25, 100 % - Tangential speed constant control - AI Contour control I (Look-ahead block no. is Max.30) G5.1 Q1 AUXILIARY / SPINDLE SPEED FUNCTION - Spindle orientation - Auxiliary function lock - Constant surface speed control - High speed M/S/T interface - M - code function M3 digits - Multi spindle control - Rigid tapping - S - code function S4 / S5 digits - Spindle serial output S4 / S5 digits - Spindle speed override % - Spindle synchronous control - Spindle Output switching - Actual spindle speed output - Waiting function PROGRAM INPUT - Addition of custom macro common variables #100~#199, #500~#999 - Automatic coordinate system setting - Canned cycle for drilling / Turning - Canned cycle - Circular interpolation by R programming - Control in / out - Coordinate system setting G50 - Coordinate system shift - Custom macro - Decimal point programming - Pocket calculator type decimal point programming - Diameter / radius programming (X axis) - Direct drawing dimension programming - Direct input of coordinate system shift - G code system A - G code system B/C - Input unit 10 time multiply - Label skip - Macro executor - Manual absolute on and off - Maximum program dimension ± 9 digit - Multiple repetitive canned cycle G70 - G76 - Multiple repetitive canned cycle II - Optional block skip 9 pieces - Parity check - Plane selection G17,G18,G19 - Program file name 32 characters - Program stop / end (M00, M01 / M02, M30) - Programmable data input G10 - Sequence number N8 digit - SUB program call 10 folds nested - Tape code : ISO / EIA auto recognition EIA RS422/ISO840 - Tape format for FANUC Series15 - Work coordinate system G52 - G59 TOOL FUNCTION / TOOL COMPENSATION - Automatic tool offset - Direct input of offset value measured - Direct input of offset value measured B - T - code function T2 +2 digits - Tool geometry / wear compensation - Tool life management - Tool nose radius compensation - Tool offset G43, G44, G49 - Tool offset pairs 99 (Upper=50 / Lower=49) pairs - Tool offset value counter input - Y-axis offset EDITING OPERATION - Back ground editting - Extended part program editing - Memory card edit & operation - Number of registered programs 1000 ea - Part program editing - Part program storage size Upper=640m / Lower=640m(512 kb) - Program protect SETTING AND DISPLAY - Actual cutting feedrate display - Alarm display - Alarm history display - Current position display - Periodic maintenance screen - Display of spindle speed and T code at all screens - Help function - Optional path name display (Only for 2path) - Multi-language display - Operation history display - Parameter setting and display - Program comment display 31 characters - Run hours / part count display - Self-diagnosis function - Servo setting screen - Spindle setting screen - Status display - Operating monitor screen - Servo waveform display DATA INPUT / OUTPUT - External key input - External data input - External work number search 15 points - Memory card input/output - Reader / puncher interface CH1.interface - RS232C interface - Automatic data backup - Screen hard copy OTHERS - Cycle start and lamp - Display unit 10.4" Color TFT LCD - Feed hold and lamp - NC and servo ready - PMC system 31iA-PMC - Reset / rewind OPERATION GUIDANCE FUNCTION - EZ Guide i (Conversational Programming Solution) INTERFACE FUNCTION - Ethernet function Embedded ethernet OPTIONAL SPECIFICATIONS AXIS CONTROL - Chuck and tail stock barrier - Stored stroke 2 and 3 - Stroke limit check before move OPERATION - DNC operation (Reader/puncher interface is required) - Manual handle feed 2 units - Manual handle interruption - Reference position shift - Tool retract and recover INTERPOLATION FUNCTIONS - 3rd / 4th reference point reurn - Circular threading - Multi step skip - Polygon machining with two spindle - Variable lead threading FEED FUNCTION - AI Contour Control II 200 blocks - External deceleration - Feed stop PROGRAM INPUT - Addition of workpiece coordinate system pair 48 pairs - Automatic corner override - Interruption type custom macro - Pattern data input - Work coordinate system preset - Optional block skip (Soft operator's panel) 9 pieces TOOL FUNCTION / TOOL COMPENSATION - Tool Load Monitoring system - Tool offset pairs 200 / 400 / 999 pairs EDITING OPERATION - Number of registered programs 2000 / 4000 ea - Part program storage length 2560 / 5120 m - Play back SETTING AND DISPLAY - Directory display of floppy cassette DATA INPUT / OUTPUT - Data server Only for 1 path - Fast Ethernet function - Remote buffer Only for 1 path ROBOT INTERFACE - Robot interface with PMC I/O module (Hardware between PMC I/O mudules) - Robot interface with PROFIBUS-DP 11

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12 Sales & Support Network ARGENTINA/Rosario AUSTRALIA/Melbourne/Sydney AUSTRIA/Vienna BELGIUM/Gullegem BRAZIL/Sao paulo BULGARIA/Sofia CANADA/Edmonton/Montreal/Toronto/Vancouver CHILE/Santiago CHINA/Beijing/Chongqing/Guangzhou/Shanghai/Shenyang COLOMBIA/Bogota CZECH/Brno DENMARK/Randers EGYPT/Cairo FINLAND/Tampere FRANCE/Annecy GERMANY/Dusseldorf GREECE/Athens HONG KONG/Kowloon HUNGARY/Budapest INDIA/Bangalore/Pune INDONESIA/Jakarta IRAN/Tehran ISRAEL/Herzlia ITALY/Parma MALAYSIA/Kuala Lumpur/Penang/Johor Bahru MEXICO/Guadalajara /Mexico City /Monterrey /Vera Cruz NETHERLANDS/Goorn NEW ZEALAND/Auckland NORWAY/Oslo PAKISTAN /Islamabad/Karachi/Lahore PHILIPPINES/Manila POLAND/Krakow PORTUGAL/Lisbon ROMANIA/Bucharest RUSSIA/Moscow SAUDI ARABIA/Riyadh SINGAPORE/Singapore SLOVENIA/Ljubljana SOUTH AFRICA/Kempton Park SPAIN/Barcelona SWEDEN/Stockholm SWITZERLAND/Zurich TURKEY/Istanbul THAILAND/Bangkok U.A.E/Sharjah U. K./Leamington U.S.A./Atlanta/Birmingham/Charlotte/Chicago/Cincinnati/Cleveland/Dallas/Denver/Detroit/Houston/Indianapolis/Kansas City/Little Rock/Los Angeles/Milwaukee/Minneapolis /New Orleans/Norfolk/Philadelphia/Phoenix/Pittsburgh/Portland/Rochester/Salt Lake City/San Diego/San Francisco/Seattle/Springfield/St. Louis/Tampa/Trenton/Tulsa VENEZUELA/Valencia VIETNAM/Hanoi/Ho Chi Minh City Corporate Office & Engineering Center : 19 Chapin Rd. Pine Brook, NJ 07058, U.S.A. Tel : Fax : Midwestern Technical Center : 1701 F Howard Street, Elk Grove Village, IL Tel : Fax : Southern Technical Center : Houston Oaks Drive, Houston, TX Tel : Fax : Western Technical Center : 488 W. Meats Avenue, Orange, CA Tel : Fax : Design and specifications are subject to change without prior notice. i-ser DIA1102SP

High Productivity Turning Center

High Productivity Turning Center High Performance and Heavy Duty Turning Center Combining rigid slant bed construction with advanced technology for superior machining of mid to large sized workpieces.