High Speed Double Column Machining Center

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1 High Speed Double Column Machining Center

High speed double column machining center for large-sized workpieces In accordance with enhanced acceleration/deceleration characteristics due to a rigid machine structure, and high speed machining

2 High speed double column machining center for large-sized workpieces In accordance with enhanced acceleration/deceleration characteristics due to a rigid machine structure, and high speed machining capabilities, the BM2740P provides unrivalled productivity for the production of LCD/LED components and parts made from flat aluminium sheet. 02 High speed double column machining center for large-sized workpieces

3 High speed double column machining center for large-sized workpieces 03

Specification and Performance Optimized for LCD/LED Consumer Market BM 2740P This product has been exclusively designed for the production of LCD/LED components and parts made from flat Aluminium

Passage Height The distance from the table surface to the spindle nose has been minimised to allow for shortest possible tools and provide optimum rigidity. 580 mm (22.8 inch) 80 mm (3.

4 Specification and Performance Optimized for LCD/LED Consumer Market BM 2740P This product has been exclusively designed for the production of LCD/LED components and parts made from flat Aluminium sheet, such as Aerospace components. The investment cost has been reduced by using energy-saving and environmental-friendly elements during the product s development. Passage Height The distance from the table surface to the spindle nose has been minimised to allow for shortest possible tools and provide optimum rigidity. 580 mm (22.8 inch) 80 mm (3.1 inch) Selection of High Column (Raising Block) specification Optional high column specification (using raising blocks) can accommodate increased workpiece height. The widest passage width in its class The widest passage width Table size Loading capacity 2740 mm (107.9 inch) 4000 x 2500 mm (157.5 x 98.4 inch) 3000 kg ( lb) 2740 (107.9) 80 (3.1) 580 (22.8) 2740 (107.9) 230 / 380 (9.1 / 15.0) 730 / 880 (28.7 / 31.6) Standard Optional [150 / 300 mm (5.9 / 11.8 inch) Raising] 04 High speed double column machining center for large-sized workpieces

Special Features of the Machine Structure BM 2740P Based on a very strong structure, it is possible for high

Finite Element Method (FEM), from single elements such as bed, column etc through to the complete assembled

The crossrail is designed with an arch-type structure to reduce geometric errors caused by bend and twist of the

Bed and table structure The table traverses along three roller guideways and minimises table overhang at both

Saddle and spindle structure 01 High strength Z-axis propping structure 02 270 mm (10.

maximise rigidity, the Z axis assembly is supported by a 3 lane LM guide block structure.

reduce column bending during long periods of running.

5 Special Features of the Machine Structure BM 2740P Based on a very strong structure, it is possible for high speed processing for a long period and actualization of processing precision degree without change in the heavy cutting. Major features of machine structure Crossrail structure The BM2740P has been designed from the beginning using Finite Element Method (FEM), from single elements such as bed, column etc through to the complete assembled structure. This ensures minimum vibration levels during machining the workpiece. The crossrail is designed with an arch-type structure to reduce geometric errors caused by bend and twist of the cross beam. High accuracy of machining is achieved over long periods. Bed and table structure The table traverses along three roller guideways and minimises table overhang at both ends. This guarantees the same accuracy and performance across the entire table surface area. Saddle and spindle structure 01 High strength Z-axis propping structure mm (10.6 inch) Column structure Column bed connection structure In order to minimise displacement of the spindle and to maximise rigidity, the Z axis assembly is supported by a 3 lane LM guide block structure. The column has been designed using structural analysis and has an extra-wide base to optimise stability and reduce column bending during long periods of running. The column and bed are connected in two planesside and upper face - to provide high level rigidity and accuracy. Connection structure of column and bed rear face 02 Low spindle overhang distance The rigidity of the Z axis is optimised by reducing the distance from the Z axis to the spindle centre of gravity. This allows high acceleration / deceleration rates to be used when drilling and tapping small diameter holes

High Performance Spindle BM 2740P A high power / high torque 12000 r/min built in spindle is used to provide high performance machining capability and rapid acceleration / deceleration of the spindle.

Built-in main shaft A Belt or gear excluded built-in motor is equipped for the main shaft, which minimizes vibration and noise during high speed rotation.

precision for the main axis of which the vibration source is removed.

high productivity. Max. spindle speed Spindle motor 12000 r/min 18.5 / 22 kw (24.8 / 29.5 Hp) Spindle power- torque diagram Torque : N.m (ft.lb) S3 25% 204 (150.6) S2 15min S3 25% 147 (108.5) S1 Cont.

6 High Performance Spindle BM 2740P A high power / high torque r/min built in spindle is used to provide high performance machining capability and rapid acceleration / deceleration of the spindle. The heavy duty spindle assembly and face/taper contact spindle nose reduces vibration and improves workpiece surface finish during high speed machining. Built-in main shaft A Belt or gear excluded built-in motor is equipped for the main shaft, which minimizes vibration and noise during high speed rotation. Moreover, with an optimum combination of precision bearings effective for heat generation control at high speeds with 4-lane, it carries out high quality processing while maintaining a balance of precision for the main axis of which the vibration source is removed. In accordance with maintaining the strength of main shaft with minimizing rotating inertia, it allows great reduction of the time for reaching to the maximum speed of the main shaft, which leads to high productivity. Max. spindle speed Spindle motor r/min 18.5 / 22 kw (24.8 / 29.5 Hp) Spindle power- torque diagram Torque : N.m (ft.lb) S3 25% 204 (150.6) S2 15min S3 25% 147 (108.5) S1 Cont. 119 (87.8) S2 15min Power : kw (Hp) 22 (29.5) 18.5 (24.8) 15 (20.1) Selection of dual contact connecting spindle The spindle taper and nose are finish-ground together to allow simultaneous face and taper location of tooling. - Simultaneous contact of tools to main shaft section and taper Enhancing the strength and reducing vibration - Enhancement of processing capability and surface resolution in severe conditions - Possible to utilize conventional tools (100% compatible) Taper contact 60 (44.3) 50 (36.9) 15 (11.1) 0 S1 Cont Rotational Speed (r/min) Major advantages Strength enhancement with increment of standard diameter Dramatic enhancement of ATC cyclic precision degree Prevention of Z-axis displacement at high speed rotation Increased durability of tools Flange contact 06 High speed double column machining center for large-sized workpieces

Rigid coupling X-axis Y-axis Z-axis High

9 ipm) 24 m/min (944.9 ipm) 36 m/min (1417.

for high speed and long term reliability.

the axis traverse is improved by applying

7 High Conveyance Speed Strong conveyance system structure Roller guide applied Rigid coupling X-axis Y-axis Z-axis High conveyance speed 16 m/min (629.9 ipm) 24 m/min (944.9 ipm) 36 m/min ( ipm) Tool Magazine Tool changing takes place using a highly efficient and reliable CAM type tool change mechanism for high speed and long term reliability. Tool storage capacity 30 ea 40 ea opt. Tool change time (T-T-T) 1.5 s Ball screw nut cooling The accuracy of the axis traverse is improved by applying a cooling jacket to the ballscrews which has the effect of reducing thermal transfer. 07

Machining Capacity BM 2740P BM 2740P provides high processing performance in various cutting procedures.

15 µm Spindle speed : 12000 r/min Feedrate : 1200 mm/min Face mill ø80mm Face mill (6Z) Machining rate Carbon steel

0 mm Face mill ø80mm Face mill (6Z) 64 mm 1200 r/min Feedrate 4000 mm/min (157.

8 in 3 /min) Since data above is collected in accordance with test standards of our company, it is changeable along

0 mm Tap 64 mm 1200 r/min Feedrate 7000 mm/min (275.6 ipm) Aluminum (AL6061) Vacuum Chamber Susceptor Tool M3 x P0.

8 Machining Capacity BM 2740P BM 2740P provides high processing performance in various cutting procedures. Actualization of High Precision For increased repeatability and reliability Surface resolution Ra 0.15 µm Spindle speed : r/min Feedrate : 1200 mm/min Face mill ø80mm Face mill (6Z) Machining rate Carbon steel (SM45C) 768 cm 3 /min (30.2 in 3 /min) Spindle speed 3.0 mm Face mill ø80mm Face mill (6Z) 64 mm 1200 r/min Feedrate 4000 mm/min (157.5 ipm) Machining rate Spindle speed Aluminum (AL6061) 2688 cm 3 /min (105.8 in 3 /min) Since data above is collected in accordance with test standards of our company, it is changeable along with the conditions. All major components for LCD products can be machined on the BM2740P 6.0 mm Tap 64 mm 1200 r/min Feedrate 7000 mm/min (275.6 ipm) Aluminum (AL6061) Vacuum Chamber Susceptor Tool M3 x P0.5 Spindle speed 3600 r/min Feedrate 1800 mm/min (70.9 ipm) Since data above is collected in accordance with test standards of our company, it is changeable along with the conditions. Chamber Probe Frame Upper Electrode Arm Tube 08 High speed double column machining center for large-sized workpieces

Operation Many features are included which makes the machine operation easier

Coolant gun The coolant gun allows the operator to quickly clean the working

size workpieces MPG Position Display MPG (LCD) opt.

from the working area into a lift up chip conveyor positioned at the end of the

Penetration type cutting oil spray device opt.

and left/right indoor foothold Full splash guard opt.

Machine operation is possible without the need to reference return to machine

9 Operation Many features are included which makes the machine operation easier for the operator. Coolant gun The coolant gun allows the operator to quickly clean the working area of the machine and the workpiece MPG The MPG makes set up easier for large size workpieces MPG Position Display MPG (LCD) opt. Chip Disposal The machine includes two screw-type conveyors ot remove chips from the working area into a lift up chip conveyor positioned at the end of the machine. Cutting oil device Flood Coolant Std. Penetration type cutting oil spray device opt. Internal screw conveyer Indoor operation foothold Provision of table front face and left/right indoor foothold Full splash guard opt. Full splash guard in consideration of workplace environment 2-lane screw is adopted. Convenient absolute positioning system Indoor lamp Cross lower working lamp Machine operation is possible without the need to reference return to machine origin when powering on. The machine location is saved by battery backup while in power off condition. Signal tower Chip conveyor opt. Alarm lamp (indicating abnormal condition of machine) Processing completion light (Indicating completion of processing) Processing ongoing light (Indicating ongoing process) Hinge type Scraper type Drum filter type 09

Easy Operation Package These Doosan software packages

Moving for Setup Power Saving Power Saving Function

and shaft conveyance in the condition of no switch

There is an input button for using the power saving

ATC Recovery Help M-code Help G-code Help Automatic

automatically turned off. Tool Load Monitor opt.

1ST Tool Change Index Tool Change Setting Position

for display and conveyance of machine, and single

whole shaft to a designated location with calling

conveyance to the designated location for the

10 Easy Operation Package These Doosan software packages have been customised to make setup and diagnostic operations easier for the customer. Tool Date Registry Table Sensor Status Monitor Table Moving for Setup Power Saving Power Saving Function This function saves electricity when the machine is not in use. Operating condition In case of no spindle rotation and shaft conveyance in the condition of no switch input in control panel, a function herein is operated. There is an input button for using the power saving function. ATC Recovery Help M-code Help G-code Help Automatic machine light turns off The operating lamp is automatically turned off. Tool Load Monitor opt. Hot key Tool No. Table REF. 1ST Tool Change Index Tool Change Setting Position Move Setting Position Table A Hot key is separated for display and conveyance of machine, and single button input in jog mode allows conveyance of the whole shaft to a designated location with calling tool replacement and arbitrary command tools and conveyance to the designated location for the structure setting and manual tool length setting. Automatic machine sleep The axis shaft servo AMP power and PSM power are shutdown. Chip conveyer motor operation is stopped. 10 High speed double column machining center for large-sized workpieces

11 Machine Specifications NC Unit Specifications Fanuc 32i-A Description Unit BM 2740P X-axis mm (inch) 4000 (157.5) Travel Y-axis mm (inch) 2700 (106.3) Z-axis mm (inch) 500 (19.7) Effective width between columns mm (inch) 2740 (107.9) Distance from spindle nose to table top mm (inch) 80~580 [230~730 / 380~880] (3.1~22.8 [9.1~28.7 / 15.0~34.6]) Guide way mm (inch) LM Table Table size (width x length) mm (inch) 4000 x 2500 (157.5 x 98.4) Load capacity kg (lb) 3000 (6613.9) Spindle Taper - BT40 Spindle Driving method - Built - in Max. spindle speed r/min Feedrate Rapid traverse rate (X / Y / Z) m/min (ipm) 16 / 24 / 36 (629.9 / / ) Cutting feedrate mm/min (ipm) 8000 (315.0) Tool storage capacity ea 30 [40] Automatic Max. tool diameter mm (inch) 85 / 125 (3.3 / 4.9) tool changer Max. tool length mm (inch) 300 (11.8) Max. tool weight kg (lb) 8 (17.6) Motor Spindle motor kw (Hp) 18.5 / 22 (24.8 / 29.5) Machine height (H) mm (inch) 3760 [3910 / 4060] (148.0 [153.9 / 159.8]) Machine Machine dimension (L x W) mm (inch) x 4648 (425.8 x 183.0) size Machine weight kg (lb) ( ) The specifications and information above-mentioned may be changed without prior notice. For more details, please contact Doosan. Standard Feature Spindle air purge Flood coolant Coolant gun X,Y,Z Absolute pulse corder Coolant tank and chip pan Optional Feature Linear scale (X, Y, Z axis) Through spindle coolant Raising block (150, 300mm) Chip conveyor & chip bucket Air gun Spindle head cooling system Internal screw conveyer Signal tower (yellow, red, green) Portable MPG Full splash guard Test bar Oil skimmer Automatic tool measurement Semi guard Work light Assmbly & operation tools Door interlock 4-axis preparation Spindle thermal compensation Position display MPG (LCD) AXES CONTROL - Controlled axe 3 (X / Y / Z) - Simultaneously controllable axes Positioning (G00) / Linear interpolation (G01) : 3 axes Circular interpolation (G02, G03) : 2 axes - Backlash compensation - Least command increment 0.001mm / " - Least input increment 0.001mm / " - Machine lock all axes / Z axis - Mirror image Reverse axis movement (setting screen and M - function) - Stored pitch error compensation Pitch error offset compensation for each axis - Stored stroke check 1 Overtravel controlled by software INTERPOLATION & FEED FUNCTION - 2nd reference point return G30 - Circular interpolation G02, G03 - Exact stop check G09, G61 (mode) - Feed per minute mm / min - Feedrate override (10% increments) 0-200% - Jog override (10% increments) 0-200% - Manual handle feed(1 unit) - Manual handle feedrate 0.1/0.01/0.001mm - Override cancel M48 / M49 - Rapid traverse override F0 (fine feed), 25 / 50 / 100% - Reference point return G27, G28, G29 - Skip function G31 - Helical interpolation - AICC I 30 block preview - Machine condition selection function - Thread cutting, synchronous cutting - Program restart - Automatic corner deceleration - Feedrate clamp by circular radius - Linear ACC/DEC before interpolation (Specify AI Contour control I) - Control axis detach - Rapid traverse bell-shaped acceleration/deceleration - Smooth backlash compensation SPINDLE & M-CODE FUNCTION - M- code function M 3digits - Spindle orientation - Spindle speed command S5digits - Spindle speed override (10% increments) % - Rigid tapping G84, G74 TOOL FUNCTION - Tool nose radius compensation G40, G41, G42 - Number of tool offsets 64 ea - Tool length compensation G43, G44, G49 - Tool number command T2 digits - Tool life management Geometry / Wear and Length / Radius offset - Tool offset memory C memory - Tool length measurement PROGRAMMING & EDITING FUNCTION - Absolute / Incremental programming G90 / G91 - Auto. Coordinate system setting - Background editing - Canned cycle G73, G74, G76, G80 - G89, G99 - Circular interpolation by radius programming - Custom macro B - Inch / metric conversion G20 / G21 - Label skip - Local / Machine coordinate system G52 / G53 - No. of Registered programs 500ea - Optional stop M01 - Part program storage 640m (2,100ft) [256k]byte - Program number O4-digits - Sub program Up to 4 nesting - Tape code ISO / EIA Automatic discrimination - Work coordinate system G54 - G59 - Additional work coordinate system (48 Pair) G54.1 P1-48 pairs - Coordinate system rotation G68, G69 - Optional angle chamfering / corner R - Macro executor OTHERS FUNCTIONS (Operation, Setting & Display, etc) - Alarm display - Alarm history display - Dry run - Embeded Ethernet - Graphic display Tool path drawing - Help function - Memory card interface - MDI / DISPLAY unit 10.4" Color LCD, Keyboard for data input, soft-keys - Operation functions Tape / Memory / MDI / Manual - Operation history display - Program restart - Run hour and part number display - Search function Sequence NO. / Program NO. - Self - diagnostic function - Single block - Multi language display OPTIONAL SPECIFICATIONS - 3D coordinate conversion - 3D tool compensation - Addition of tool pairs for tool life management 1024pairs - AICC II 80 block preview - Data server with1gb PCMCIA card - Automatic corner override G62 - Additional work coordinate system G54.1 P1-300 (300 pairs ) - Dynamic graphic display Machining profile drawing => When the EZ Guide i is used, the Dynamic graphic display cannot application - Exponential interpolation - Interpolation type pitch error compensation - EZ Guide i (Doosan infracore Conversational Programming Solution) with 10.4" Color TFT => When the EZ Guide i is used, the Dynamic graphic display cannot application - High speed skip function - Involute interpolation G02.2, G No. of Registered programs 1000 ea - Number of tool offsets 99 / 200 / 400 ea - Optional block skip addition 9 blocks - Part program storage 512K / 1M / 2M byte - Polar coordinate command G15 / G16 - Polar coordinate interpolation G12.1 / G Programmable mirror image G50.1 / G Single direction positioning G60 - Tool load monitoring function(doosan) - Tool position offset G45 - G48 11

12 External Dimensions Unit : mm (inch) Top View Front View Side View 415 (16.3) 4250 (167.3) 173 (6.8) (409.4) (14.5)(26.4)(7.3) (43.3) 658 (25.9) 2997 (118.0) 830 (32.7) 300 (11.8) 246 (10.4) 414 (16.3) 530 (20.9) (20.9)(11.8) 1727 (68.0) 836 (32.9) 1785 (70.3) 415 (16.3) 5158 (203.1) (425.8) 966 (38.0) 4276 (168.3) 418 (16.5) 718 (28.3) 3400 (133.9) 2970 (116.9) 4648 (183.0) 2738 (107.5) 571 (22.5) 3308 (130.2) 1978 (77.9) 174 (6.9) 1155 (45.5) 453 (17.8) 2103 (82.8) 3760 (148.0) 415 (16.3) 5010 (197.2) 2830 (111.4) 2560 (100.8) 5178 (203.9) Table 125 (4.9) 250 (9.8) 250 (9.8) 125 (4.9) Tool Shank BT TAPER GAGE LINE 10 7/24 TAPER 16.1 M16 x P (98.4) 42 (1.7) 24H8 (0.9) 18 (0.7) 42 (1.7) MAS 403 BT 40 ø63 ø53 60 L 2 ø ø17 ø23 ø7 HOLE M16 x P2.0 ø Ø19 Pull Stud 15 Replacing the standard required by PS BT40 M16 JIS B or PS (NIKKEN) 4000 (157.5) ø Head Office : Doosan Tower 23rd FL., 18-12, Euljiro-6Ga, Jung-Gu, Seoul, Korea Tel : / 8671 / 8680 Fax : Doosan Infracore America Corp.: 19 Chapin Rd. Pine Brook, NJ 07058, U.S.A. Tel : Fax : Doosan Infracore Germany GmbH : Hans-Böckler-Strasse 29, D Langenfeld-Fuhrkamp, Germany. Tel : Fax : Doosan Infracore Yantai Co., LTD : 13 Building, 140 Tianlin Road, Xuhui District, Shanghai, China (200233) Tel : (808, 805) Fax : Design and specifications are subject to change without prior notice. i-ser EX 1105SP

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