Multi-axis milling/turning system IMTA 320 T2 320 T3. Interaction Milling Turning Application

Transcription

1 Multi-axis milling/turning system IMTA 320 T2 320 T3 Interaction Milling Turning Application T e c h n i c a l D a t a s h e e t

2 The consistent 75 step bed design allows the near rectangular arrangement of X-, Y-, and Z-axes to each other, which has a positive effect on stability and accuracy. Good accessibility, particularly for loading of the machine, and the ideal chip flow are other highlights of this design. By basic structure with main spindle and sub-spindle plus two or three turrets with Y axis, most of complex parts are possible to be finished in one machine setup. Not only for the different workpiece and lot sizes but also for the mass production, IMTA series of modular design concept will create the best machining solution with best investment combination. The automation is easily fulfilled by a bar feeder or a robotic arm with parts storage. The compound machine functions including turning, milling and even off-center machining plus the automation solution make long-term manless operations possible and guarantee investment return. 3D Interference Protection Multi-axes machining places considerable demands on the user. To prevent expensive downtime, the IMTA 320 has 3D interference protection simulation software as standard. This avoids collisions when new programs are inserted and thus ensures max. availability of your investment. Optional configuration: n FANUC 31i CNC-control n Spindl blow-out unit n Collet chuck n Programmable tailstock n Bar feeder unit n Automatic tool setting device n Precision glass scales n Automatic parts catcher n Parts-conveyor n Cut-off detector n Door-automation Standard configuration: 4 Mitsubishi M720V Navi Lathe CNC-control 4 Hydraulic Ø 200 mm (7.9 ) 3-jaw power chuck (main-spindle ) 4 Hydraulic Ø 200 mm (7.9 ) 3-jaw power chuck (sub-spindle ) 4 Mainsindle C-axis with resolution 4 Sub-spindle C-axis with resolution 4 T1 & T2: two12-pos. tool turrets with driven tools (IMTA 320 T2) 4 T3: third 12-pos. tool turret with driven tools (IMTA 320 T3) 4 Y1: Y-axis for T1-tool turret (IMTA 320T2) 4 Y1 & Y3: 2nd Y-axis for T3-tool turret (IMTA 320T3) 4 Tooling system BMT-65 4 High pressure coolant pump 4 Automatic central lubrication 4 Chain type chip conveyor (chip exit height 1 mm (43.3 )) 4 Elektronic handwheel 4 Interface for bar feeder 4 LED working light 4 3-color signal light 4 Hard jaws, Soft jaws (1 set) 4 Auxiliary service tools 4 Operation manual Multi-tasking machining with up to three turrets in parallel provides for outstanding cycle times, particularly with complex workpieces. With the Y-axis and the counter spindle, combined turned/milling parts can also be produced off-center, efficiently in one clamping, thus providing for quick return on the investment. The lower tool changer can serve as a steady rest for long and thin turned parts for prevention of vibrations and sagging caused by the cutting pressure.

3 Camshaft Material : S45C Raw material size : Ø50 mm L0 mm Finished size : Ø32 mm L365 mm Other manufaturer Top two turret with two Y axes Type 272 sec IMTA 320 T3 With use of three turrets, the cycle times are also reduced by up to 50 % up to 50 % time savings IMTA 320 T3 IMTA 320 T2 Linear Y-axis Y-axis designed as complete linear axis. This provides maximum accuracy and stability, ensuring dimensional accuracy and surface quality, particularly for milling applications Machining methods on the 1st turret (6 tools) 1 O.D. and end face roughing 2 O.D. and end face finishing 3 Groove roughing 4 Groove finishing 5 Keyway milling (Ø10 R0.3) 6 Chamfering (Ø10 90 ) Machining methods on the 2nd turret (5 tools) 1 O.D. and end face roughing 2 O.D. and end face finishing 3 Taper face finishing 4 Threading(M30 P1.25) 5 Keyway milling (Ø10 R0.3)

4 Turning Material: S45C O.D. turning Material removal rate Cutting depth Cutting speed 330 cm 3 /min 5mm 763 rpm 0.5 mm/rev 120 m/min I.D. turning Material removal rate Cutting depth Cutting speed 303 cm 3 /min 5mm 637 rpm 0.55 mm/rev 120 m/min O.D. turning Cutting width Cutting speed mm 637 rpm 0.1 mm/rev 120 m/min Milling Material: S45C Endmilling Material removal rate Tool Cutting speed Cutting width Cutting depth 96 cm 3 /min end mill Ø20 mm (4 teeth) 500 rpm 0.1 mm/rev/tooth 200 mm/min 20 mm 24 mm Endmilling Material removal rate Tool Cutting speed Cutting width Cutting depth 96 cm 3 /min end mill Ø20 mm(4 teeth) 500 rpm 0.1 mm/rev/tooth 200 mm/min 20 mm 24 mm Drilling Material removal rate Tool Cutting speed 25 cm 3 /min drill Ø20 (2 teeth) 39 rpm 0.2 mm/rev 25 m/min Drilling Material removal rate Tool Cutting speed 25 cm 3 /min drill Ø20 (2 teeth) 39 rpm 0.2 mm/rev 25 m/min

5 90 Turning accuracy Scale 1µm/div. Material Tool Turning diameter Brass Diamond cutting tool mm 3000 rpm 0.05 mm/rev Roundness Cylindricity Roughness 0.7 µm 5 µm 0.2 µm 10 0 * The above data is measured in-house. The test result may not be obtained due to differences cutting conditions and environment 270 The upper and lower turrets are turning the part together to save cycle time. The machining process is continued by one turret after the other to save tool changing time. The reaction force against each other may reduce the vibration when both upper and lower turrets are processing simultaneously. The lower turret can be used as a steady rest to avoid vibration for the long shaft machining. The lower turret can be used as a center to support the shaft.

6 96 Turret 1 Turret Working area Distance between spindle noses Max. tool length of reverse tool 96 mm 125 mm (T1,T3) mm (T2) Unit:mm Spinlde/Sub-spindle CS axis with brake unit The CS axis is fed back by a rotary encoder with multipoints positioning function. The minimum indexing increment of degrees allows various machining needs with different angles. Sub-spindle cooler With synchronous temperature control, the spindle cooler prevents sub-spindle from thermal distortion. This ensures high precision machining for long-term operation.

7 Swivel-type operation panel The operation panel is able to swivel from 0 to 90 degrees, which improves visibility during operation. Accessibility The access to spindles or turrets is short and comfortable to operator. 900mm Door opening width The wide door opening makes machine operation and maintenance more convenient. Easier daily maintenance Through centralized management of pneumatic solenoid and lubricant pump, daily maintenance becomes easy. Chip conveyor According to different materials and chip size, KAAST provides various chip conveyors for the best chip disposal. : Suitable : Non-suitable Steel Cast iron Aluminum/Non-ferrous metal Specification Long/Curl chips Short chips Powder chips Short chips Long/Curl chips Short chips Powder chips Hinge type Scraper type Magnetic scraper type Drum type Integrated type Short chips : Chips shorter than mm or ball type chips smaller than Ø40 mm. Curl long chips : Chips length is longer than short ones.

8 Manual tool presetter (Optional) Disc type oil skimmer (optional) Oil mist collector (Optional) Automation solution Bar feeder working area Part catcher Bar feeder & part catcher Bar feeder Workpiece change Unloading conveyor belt Automatic robotic arm 1st operation 2nd operation Gantry type robot system & part storage system Part storage system Robotic arm Gripper Item Unit Specification Max. load kg 5 ( 2) Rapid traverse X-axis (equipped in the up side and the down side of arm) m/min 120 Z-axis (equipped in the right and the left side of machine) m/min 120 Type Rotary gripper Outer diameter mm Ø30~200 Workpiece size Length mm 10~150 Weight kg 5

9 Without interference protection system, complex machine configurations operated in manual mode can result in collisions with tools and workpieces. With 3D interference protection system and cutting simulation function, operators can guarantee collision free setups by verifying through prerun testing. Characteristics Improves user interface with simple parameter setting procedures for tools, workpiece, chucks, jaws and fixtures. Checks for interference in 3D for machine cover, turrets, spindles, tools, workpieces, chucks, jaws and fixtures. Model data for machine is installed as standard. The machine will stop before collision when interference is detected in manual or in automatic mode. Advanced preview of turning/milling simulation and collision protection. Work piece change from main spindle to second spindle can be simulated and checked. During 3D interference check, cutting simulation shows how material is removed as machining proceeds. When the tool position is set accurately, the 3D cutting simulated machine part can be checked with theoretical 3D model without machining a real workpiece for process verification. Spindle output and torque chart Main spindle motor (Belt drive) Standard : spindle speed 4500 rpm Horsepower [kw] Torque [N. m] 25 9 N. m 250 Optional : spindle speed 00 rpm Horsepower [kw] Torque [N. m] min, S3 % operating zone 30min, S3 % operating zone N. m 15 kw N. m 140 N. m 15 Kw kw Continuous operating zone 11 Kw 10 Continuous operating zone (rpm) (rpm) 0 Sub-spindle motor (Built-in motor)

10 Sub-spindle motor (Built-in motor) Horsepower [kw] S3 25% operating zone S3 40% operating zone 1.5 Kw Torque [N. m] N. m S3 25% operating zone N. m S3 40% operating zone Kw Continuous operating zone 7.5 Kw 5.5 Kw N. m S1 Con. Continuous operating zone 59 N. m 32 N. m 12 N. m. N. m (rpm) (rpm) Live tool motor Horsepower [kw] 35 N. m S3 % operating zone Torque [N. m] Kw N. m Kw 20 2 Continuous operating zone spindle speed (rpm) Tool interference (Turret 1) ID tool holder with center height 5 mm / () ID tool holder with center height mm (Turret 1) spindle side 5 Ø650 Ø SP1 Ø5 Ø610 X2-Stroke Ø20 5 Ø690 () Ø530 Ø320 Ø250 Ø250 5 X1-Stroke Ø570 5 Ø Ø530 Ø520

11 (Turret 1) ID tool holder with center height mm / () ID tool holder with center height mm (Turret 1) Ø670 Ø50 () Ø610 Ø610 SP1 Ø690 spindle side 40 7 X2-Stroke Ø20 Ø550 Ø320 Ø2 5 Ø2 5 X1-Stroke Ø Ø5 Ø540 (Turret 3) ID tool holder with center height 5 mm / () ID tool holder with center height mm (Turret 3) Ø650 SP () Ø50 Ø5 Ø610 X2-Stroke Ø690 sub-spindle side 40 7 Ø Ø530 Ø250 Ø320 Ø X3-Stroke 3.5 Interference 5 Ø Ø530 Ø520 (Turret 3) ID tool holder with center height mm / () ID tool holder with center height mm (Turret 3) Ø670 Ø50 SP () Ø610 Ø610 X2-Stroke Ø690 sub-spindle side 40 7 Ø20 5 Ø550 Ø320 Ø2 5 Ø2 5 5 X3-Stroke 3.5 Interference Ø Ø5 Ø540

12 Tool system BMT65 O.D. tool Facing tool holder O.D. tool holder O.D. tool holder Cutting holder I.D. tool Ø40 Turret (upper) I.D. tool Ø32 Ø25 Ø20 Ø16 Ø12 Ø10 Ø Sleeve I.D. tool holder Drill MT#3, MT#2, MT#1 Sleeve Radial live tool holder Reamer Face milling Sleeve ER32 (Ø2~Ø20) Axial live tool holder Turret (lower) Center drill Drill Dual-heads axial live tool holder Turret 1 Turret 3 Center height of ID tool holder 5 mm (opt. ) mm 5 mm (opt. ) Center height of axial live tool holder 5 mm mm 5 mm

13 Working area IMTA 320 T3 Turret 1 Turret () (5) S.T Turret 3 Turret (5) 3 () Interference Interference 0.5 Unit : mm

14 Working area IMTA 320 T2 Turret 1 Turret (5) (5) Turret 1 Turret Interference Turret Interference 0.5 Unit : mm

15 Dimensions Technical specifications Machine capacity Max. turning dia. over bed Max. turning dia. over slide IMTA 320 T2 IMTA 320 T3 mm Ø 720 (2 ) Ø 720 (2 ) mm BMT-65 (opt. VDI-40) 310 (12 ) Ø 310 (12 ) Max turning diameter mm Ø 320 (12 ) Ø 320 (12 ) Max. turning length mm 0 ( ) 0 ( ) Spindle Spindle nose A2-6 A2-6 rpm 4500 (opt. 00) 4500 (opt. 00) Chuck O.D. mm 203 (7.9 ) 203 (7.9 ) Spindle bore mm Ø 76 (opt. Ø 62) Ø 76 (opt. Ø 62) (2.9 (opt. 2.4 )) (2.9 (opt. 2.4 )) Bar capacity mm Ø 65 (opt. Ø 51) Ø 65 (opt. Ø 51) (2.5 (opt. 2 )) (2.5 (opt. 2 )) Spindle bearing dia. mm Ø (3.9 ) Ø (3.9 ) Spindle center to floor mm 1300 (51 ) 1300 (51 ) Min. CS axis indexing increment Counter-spindle Spindle nose A2-6 A2-6 rpm Chuck O.D: mm 203 (7.9 ) 203 (7.9 ) Spindle bore mm Ø 62 (2.4 ) Ø 62 (2.4 ) Bar capacity mm Ø 51 (2 ) Ø 51 (2 ) Spindle bearing dia. mm Ø (3.9 ) Ø (3.9 ) Min. CS axis indexing increment Power turret Tool shank BMT-65 (opt. VDI-40) BMT-65 (opt. VDI-40) Numpers of positions pc. 12x2 12x3 Technical specifications IMTA 320 T2 IMTA 320 T3 Motor kw 5.5/3.7 (7.4/5 Hp) 5.5/3.7 (7.4/5 Hp) Tool outside diameter mm 25x25 (0.9 x0.9 ) 25x25 (0.9 x0.9 ) Tool inside diameter mm Ø 40 (1.5 ) Ø 40 (1.5 ) Max. Speed rpm Max. tool diameter mm Ø 20/M16 (0. ) Ø 20/M16 (0. ) Travel X1/X2/X3 mm //- ( / /) //- ( / / ) Y1/Y2/Y3 mm ±51/-/- (±2 /-/-) ±51/-/±51 (±2 /-/±2 ) Z1/Z2/Z3/B Feed Feed X/Y/Z/B axis mm mm /rev 0/0/-/60 ( / /-/26 ) ( /rev) 440/0/440/60 (17 / /17 /26 ) ( /rev) Hydraulic Hydrl. tank capacity l 40 (10 gal) 40 (10 gal) Hydrl. motor kw 2.2 (3 Hp) x 4P 2.2 (3 Hp) x 4P Coolant system Coolant tank capacity l 700 (14 gal) 700 (14 gal) Coolant motor kw 0.55x3 (0.7x4 Hp) 0.55x4 (0.7x5.4 Hp) Motor Spindle motor kw 15/11 (20/14 Hp) 15/11 (20/14 Hp) Counter-spindle kw 1.5/11 (25/14 Hp) 1.5/11 (25/14 Hp) X/Y/Z/B axis servo 4/3/4/3 4/3/4/3 kw motor (5.4/4/5.5/4 Hp) (5.4/4/5.5/4 Hp) Dimensions 4x20x2450 4x20x2450 LxwxH mm (161 x102 x96 ) (161 x102 x96 ) Weight kg 200 (1040 lbs) 9000 (1900 lbs) Item-No