Multi-purposed Large sized Bridge Type Machining Center

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Aileen McKenzie
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1 Multi-purposed Large sized Bridge Type Machining Center

machining capabilities, the BM series provides unrivalled

2 In accordance with enhanced acceleration/deceleration characteristics due to a rigid machine structure, and high speed machining capabilities, the BM series provides unrivalled productivity for the production of plate materials and large parts for general industries. 02

Multi-purposed Large sized Bridge Type Machining Center BM 2740 series BM 2740 (BT 50) (BT 40) Powerful, high torque spindles have been applied to ensure the highest productivity in the entire

Large parts for general industries Large vehicle parts Large plate material (LCD) Features 1 Spindle with high capability and high power effective for high-speed machining and powerful cutting

3 Multi-purposed Large sized Bridge Type Machining Center BM 2740 series BM 2740 (BT 50) (BT 40) Powerful, high torque spindles have been applied to ensure the highest productivity in the entire process from rough machining to fine machining. Spindle with a highest speed of 12,000 rpm is optimal for machining large-size plate materials. Large parts for general industries Large vehicle parts Large plate material (LCD) Features 1 Spindle with high capability and high power effective for high-speed machining and powerful cutting Built-in spindle offering high speed and precision ensures optimal productivity and precision in parts machining. 2 Guaranteed highest capabilities The world-leading capability and specifications deliver excellent machining capabilities mm (107.9 inch) Workpiece passing width largest in equivalent models 3 Optimal stabilized structure Stable structure guaranteed by the application of a high-rigidity roller LM full axis and ball screw nut cooling standard. Roller LM guide 03

High Performance Spindle The heavy duty spindle assembly and face/taper contact spindle nose reduces vibration and improves workpiece surface finish during high speed machining.

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

4 High Performance Spindle The heavy duty spindle assembly and face/taper contact spindle nose reduces vibration and improves workpiece surface finish during high speed machining. BM 2740 series Built-in Main Spindle 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. BM 2740 Max. spindle speed r/min r/min Spindle motor 25/30 kw (33.5/40.2 Hp) 18.5/22 kw (24.8 / 29.5 Hp) Spindle power- torque diagram Taper contact Torque : N m(ft lb) 500 (369.0) 420 (310.0) 400 (295.2) (258.2) 300 (221.4) (175.7) 200 (147.6) BM 2740 Selection of dual contact connecting spindle (73.8) (6.7) Spindle speed (r/min) Power : kw(hp) 30 Minutes 35 (46.9) Continuous S3 25% 30 (40.2) 25 (33.5) 20 (26.8) 15 (20.1) 10 (13.4) Torque : N m(ft lb) 204 (150.6) S3 25% S3 25% 147 (108.5) 119 (87.8) 60 (44.3) 50 (36.9) 15 (11.1) 0 S2 15min S1 Cont. S2 15min S1 Cont Rotational Speed (r/min) Power : kw(hp) 22 (29.5) 18.5 (24.8) 15 (20.1) Flange contact 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) 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 04

Rapid Traverse Strong traverse system structure Roller guide

2740 16 m/min (629.9 ipm) 16 m/min (629.9 ipm) 24 m/min (944.

3 ipm) Ball screw nut cooling The accuracy of the axis traverse is

the effect of reducing thermal transfer.

and reliable CAM type tool change mechanism for high speed and long

5 Rapid Traverse Strong traverse system structure Roller guide applied Rigid coupling X-axis Y-axis Z-axis Rapid traverse speed BM m/min (629.9 ipm) 16 m/min (629.9 ipm) 24 m/min (944.9 ipm) 24 m/min (944.9 ipm) 24 m/min (944.9 ipm) 36 m/min ( ipm) 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. Tool Magazine Tool changing takes place using a highly efficient and reliable CAM type tool change mechanism for high speed and long term reliability. BM 2740 Tool storage capacity 40 ea (60 ea ) 30 ea (40 ea ) Tool change time (T-T-T) 1.5 s 1.5 s 05

6 Machining Capacity BM series provides high processing performance in various cutting procedures. BM 2740 Face mill Carbon steel (SM45C) Face mill Gray casting(gc25) Tap Carbon steel (SM45C) ø125mm Face mill (8Z) ø80mm Face mill (6Z) 8.0 mm (0.3 inch) 100 mm (3.9 inch) 8.0 mm (0.3 inch) 100 mm (3.9 inch) Machining rate Spindle speed Feedrate 784 cm 3 /min (308.7 in 3 /min) 500 r/min 980 mm/min (38.6 ipm) Machining rate Spindle speed Feedrate 960 cm 3 /min (378.0 in 3 /min) 500 r/min 1200 mm/min (47.2 ipm) Machining rate M42 x P4.5 Spindle speed Feedrate 180 r/min 810 mm/min (31.9 ipm) Face mill Carbon steel (SM45C) Face mill Aluminum (AL6061) Tap Aluminum (AL6061) ø80mm Face mill (6Z) ø80mm Face mill (6Z) 3.0 mm (0.1 inch) 64 mm (2.5 inch) 6.0 mm (0.2 inch) 64 mm (2.5 inch) Machining rate Spindle speed Feedrate 768 cm 3 /min (302.4 in 3 /min) 1200 r/min 4000 mm/min (157.5 ipm) Machining rate Spindle speed Feedrate 2688 cm 3 /min ( in 3 /min) 1200 r/min 7000 mm/min (275.6 ipm) Machining rate M3 x P0.5 Spindle speed Feedrate 3600 r/min 1800 mm/min (70.9 ipm) Attainment of High Precision Surface roughness Ra 0.15 μm Spindle speed : r/min Feedrate : 1200 mm/min Machine : BM2740P Since data above is collected in accordance with test standards of our company, it is changeable along with the conditions. 06

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

9 inch) B The distance from the table surface to the spindle nose has been minimised to allow for shortest possible tools and provide optimum rigidity. A Model A B BM 2740 580 mm (22.

7 Specification and Performance Optimized for LCD/LED Consumer Market 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 energysaving and environmental-friendly elements during the product s development. Passage Width & Height 2740 mm (107.9 inch) B The distance from the table surface to the spindle nose has been minimised to allow for shortest possible tools and provide optimum rigidity. A Model A B BM mm (22.8 inch) 950 mm (37.4 inch) 80 mm (3.1 inch) 580 mm (22.8 inch) The widest distance between columns & table size in its class Model Distance between columns Table size Loading capacity BM mm (107.9 inch) 4000 X 2500 mm (157.5 x 98.4 inch) kg ( lb) 3000 kg ( lb) Selection of High Column (Raising Block) specification Optional high column specification (using raising blocks) can accommodate increased workpiece height. Model A B C D BM mm 950 mm 300/450 mm 1100/1250 mm (5.9 inch) (37.4 inch) (11.8/17.7 inch) (43.3/49.2 inch) 80 mm (3.1 inch) 580 mm (22.8 inch) 230/380 mm (9.1/15.0 inch) 730/880 mm (28.7/34.6 inch) A B C D Standard Optional [150 / 300 mm (5.9 / 11.8 inch) Raising] 07

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

BM 2740 series Major features of machine structure The BM series has been designed from the beginning using Finite

This ensures minimum vibration levels during machining the workpiece.

This guarantees the same accuracy and performance across the entire table surface area.

8 Special Features of the Machine Structure 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. BM 2740 series Major features of machine structure The BM series 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. 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. Crossrail structure 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. 08

Column structure Column bed connection structure The column

extra-wide base to optimise stability and reduce column

The column and bed are connected in two planesside and upper

propping structure In order to minimise displacement of the

supported by a 3 lane LM guide block structure.

is optimised by reducing the distance from the Z axis to the

9 Column structure Column bed connection 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. 870 mm (34.2 inch) 670 mm (26.3 inch) Connection structure of column and bed rear face 1070 mm (42.1 inch) BM mm (42.1 inch) Saddle and spindle structure High strength Z-axis propping 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. A B 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. A : 280 mm (11.0 inch) (BM2740) B : 270 mm (10.6 inch) (BM2740P) 09

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.

Hinge type Scraper type Coolant Chiller Drum filter type Coolant Chiller The coolant chiller lowers coolant temperature, helping to cool both the workpiece and tool during the machining

Coolant tank Operation Many features are included which makes the machine operation easier for the operator.

Indoor operation foothold Provision of table front face and left/ right indoor foothold The MPG makes set up easier for large size workpieces Indoor lamp (LED) Cross lower working lamp

10 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 Internal screw conveyer Chip conveyor 2-lane screw is adopted. Hinge type Scraper type Coolant Chiller Drum filter type Coolant Chiller The coolant chiller lowers coolant temperature, helping to cool both the workpiece and tool during the machining operation. When using insoluble cutting oils, a coolant chiller is recommended to cool heated oil and preserve machining precision. Coolant tank Operation Many features are included which makes the machine operation easier for the operator. Coolant Gun MPG Semi splash guard Full splash guard MPG Position Display MPG (LCD) The coolant gun allows the operator to quickly clean the working area of the machine and the workpiece Indoor operation foothold Provision of table front face and left/ right indoor foothold The MPG makes set up easier for large size workpieces Indoor lamp (LED) Cross lower working lamp Signal tower Alarm lamp (indicating abnormal condition of machine) Processing completion light (Indicating completion of processing) Processing ongoing light (Indicating ongoing process) Full splash guard in consideration of workplace environment Convenient absolute positioning system 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. 10

Easy Operation Package These Doosan software packages have been customised to

Tool Date Registry Table Sensor Status Monitor Table Moving for Setup ATC

for display and conveyance of machine, and single button input in jog mode

replacement and arbitrary command tools and conveyance to the designated

Power Saving Power saving function This function saves electricity when the

Automatic machine light turns off The operating lamp is automatically turned

the condition of no switch input in control panel, a function herein is

11 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 ATC Recovery Help M-code Help G-code Help Tool Load Monitor 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. Power Saving Power saving function This function saves electricity when the machine is not in use. Automatic machine light turns off The operating lamp is automatically turned off. 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. Automatic machine sleep The axis shaft servo AMP power and PSM power are shutdown. Chip conveyer motor operation is stopped. 11

12 External Dimensions BM 2740 Unit : mm (inch) Top View Front View 10825(426.2) 958(37.7) 3700(145.7) 873(34.4) 4013(158.0) (60 TOOL) (116.3) 2740(107.9) (40 TOOL) 1095(43.1) (118.0) (16.7) (24.1) 149 (5.9) (116.9) (24.3) (27.9) (22.1) (20.7) 5531(217.8) 1070 (42.1) 523 (20.6) 2550 (100.4) 4914(193.5) (20.7) (70.0) (32.9) (69.9) 4142(163.1) 5600(220.5) 2432(95.7) 2369(93.3) Side View 487 (19.2) 5031(198.1) 1132(44.6) 4238(166.9) 669(26.3) 1936(76.2) 455(17.9) 1750(68.9) 4810(189.4) Table Tool Shank BT (4.9) (9.8) (9.8) (4.9) ø TAPER GAGE LINE 7/24 10 TAPER 7/24 TAPER M24 x 3 TAP M16 P (98.4) 4000(157.5) 42 (1.7) 24H8 (0.9) 18 (0.7) 42 (1.7) ø100 ø85 ød D L > Ø63 Ø L L 3 GAGE LINE 2 Ø44.45 ø Ø17 13 M24x3 THREAD ø Ø23 Ø7 HOLE ø M16 P Ø17 30 Ø14 30 Ø MAS403 P50T - I (45 ) ø23 12

13 Unit : mm (inch) Top View Front View 415(16.3) 4250(167.3) 10400(409.4) (6.8) (14.5)(26.4)(7.3) (43.3) (25.9) (118.0) 830 (32.7) 3400 (133.9) 530 (20.9) 2970(116.9) (183.0) (16.3)(10.4)(11.8) 2738(107.5) 571 (22.5) (20.9) (11.8) (68.0) (32.9) (70.3) 3308(130.2) 418 (16.5) 718 (28.3) 5178(203.9) (16.3) (197.2) (111.4) (100.8) Side View 10815(425.8) (16.3) (203.1) (38.0) (168.3) (77.9) (6.9) (45.5) (17.8) 2103(82.8) 3760(148.0) Table Tool Shank BT40 MAS 403 BT (4.9) (9.8) (9.8) (4.9) TAPER GAGE LINE 7/24 TAPER 16.1 M16 P (98.4) 4000(157.5) 42 (1.7) 24H8 (0.9) 18 (0.7) 42 (1.7) Ø63 Ø53 60 L 2 Ø Ø17 Ø23 Ø7 HOLE Ø17 M16 P Ø Ø19 Pull Stud 15 Replacing the standard required by PS BT40 M16 JIS B or PS (NIKKEN) 13

14 Machine Specifications Description Unit BM 2740 X-axis mm (inch) 4000 (157.5) 4000 (157.5) Travel distance Y-axis mm (inch) 2700 (106.3) 2700 (106.3) Travels Z-axis mm (inch) 800 (31.5) 500 (19.7) Effective width between columns mm (inch) 2740 (107.9) 2740 (107.9) Table to spindle nose mm (inch) 150~950 (5.9~37.4) 80~580 (3.1~22.8) Feedrates Rapid Traverse Rate X-axis m/min (ipm) 16 (629.9) 16 (629.9) Y-axis m/min (ipm) 24 (944.9) 24 (944.9) Z-axis m/min (ipm) 24 (944.9) 36 (1417.3) Cutting feedrate m/min (ipm) 8000 (315.0) 8000 (315.0) Table Table size mm (inch) ( ) ( ) Table loading capacity kg (lb) ( ) 3000 (6613.8) Tool shank - BT50 BT40 Spindle Ram size mm (inch) ( ) - Max. Spindle speed r/min Tool storage capa. ea 40 {60} 30 {40} Max. tool diameter mm (inch) 125 / 220 (4.9 / 8.7) 85 / 125 (3.3 / 4.9) ATC Max. tool length mm (inch) 350 (13.8) 300 (11.8) Max. tool weight kg (lb) 15 (33.1) 8 (17.6) Tool selection memory random memory random Motors Spindle motor power kw (Hp) 25 / 30 (33.5 / 40.2) 18.5 / 22 (24.8 / 29.5) Power source Electric power supply (rated capacity) kva Tank capacity Coolant tank capacity L (galon) 660 (174.4) 660 (174.4) Lubrication tank capacity L (galon) 4.3 (1.1) 4.3 (1.1) Height mm (inch) 4810 (189.4) 3760 (148.0) Machine Dimensions Length mm (inch) 4914 (193.5) 4648 (183.0) Width mm (inch) (425.8) (425.8) weight kg (lb) ( ) ( ) Standard Feature Optional Feature { } : option Spindle head cooling system Easy operation package Coolant gun - Renishaw GUI (Screen only) Flood coolant - Tool management system Air curtain - Pattern cycle & Operation rate Ball screw nut cooling system DTMM Coolant tank & Chip pan (Tool Load Mointoring System) Potable MPG DAFT (Apative Feed Control) Semi splash guard Working step (BM 2740) Air gun Side anchoring Auto. workpiece measurement DHC (Doosan Heat Control) Spindle thermal compensation Auto tool breakage detection Full splash guard Air blower Linear scale Coolant chiller Lift up chip conveyor & bucket Working step () MPG (LCD type) The specifications and information above-mentioned may be changed without prior notice. For more details, please contact Doosan 14

15 NC Unit Specifications Fanuc 32i AXES CONTROL - Controlled axes 3 (X, Y, Z) - Simultaneous controlled axes Positioning(G00)/Linear interpolation (G01) : 3 axes Circular interpolation (G02, G03) : 2 axes - Backlash compensation - Least command increment 0.001mm / (inch) - Least input increment 0.001mm / (inch) - 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 3 digits - Spindle orientation - Spindle speed command S5 digits - 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, G49sation - Tool number command T2digits - 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 500 ea - 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 - Ethernet function - 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 15

$http://www.doosaninfracore.com/machinetools/ Head Office Doosan Tower 20th FL.$ erica Corp. 19A

16 Head Office Doosan Tower 20th FL., 18-12, Euljiro-6Ga, Jung-Gu, Seoul, Korea Tel : / 8671 / 8680 Fax : Doosan Infracore America Corp. 19A Chapin Rd. Pine Brook, NJ 07058, U.S.A. Tel : Fax : Doosan Infracore Germany GmbH Emdener Strasse 24 D Dormagen Germany Tel : Fax : Doosan Infracore Yantai Co., LTD 13 Building, 140 Tianlin Road, Xuhui District, Shanghai, China (200233) Tel : (808, 805) Fax : EN 1304SU - The specifications and information above-mentioned may be changed without prior notice. - For more details, please contact Doosan.

High Speed Double Column Machining Center

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