simultaneous 5-axis control processing...

Simultaneous 5-axis Control Processing Machine

Simultaneous 5-axis control revolutionizes the shop f loor

Mi-8

1

Medical equipment part Material : Titanium

Aircraft equipment part Material : Titanium

More than 70 years since the production of the first lathe. AMADA MACHINE TOOLS has won the trust of the customers by supplying excellent machine tools in the field of small precision part processing. This is testimony to their sincere and hard work in devising solutions to the problems the customers have to overcome. We continue to thoroughly examine what we can do as a leading machine tool builder in relation to the problems arising in the production field, where the demand to improve is getting increasingly more severe, and have developed a brand new turning center, the Mi-8, by reviewing the machine from the customers' standpoint. This simultaneous 5-axis control processing machine dedicated to the production of small complex parts is a creative integration of new technology, innovative design, and traditional expertise. Please take a look at the Mi-8, which integrates the lathe engineering technology of AMADA MACHINE TOOLS acquired through long years of tough work in this field.

2

Rigid Turret The 5-station turret and the independently operated tool spindle are mounted on the turret. The combination of a turret secured with a coupling and an 8000 min-1 high-speed turning spindle realizes high-speed and high-accuracy turning operation.

Improved Processed Face Accuracy Since tools can be tilted as required, the most appropriate processing position can be selected, which reduces chattering and shortens processing time. In addition, this feature allows processing of curved surfaces so that complex-shaped parts can be processed. The turning axis is used for processing and further accuracy improvement is possible by carrying out processing within the appropriate surface speed range.

ATC and High-speed Spindle The ATC can hold up to 20 rotary tools. Tool changes can be accomplished in a time as short as 5.5 sec. tool-to-tool without interference with adjacent tools. The high-speed tool spindle, featuring a maximum speed of 20000 min-1, can process small-diameter holes smaller than φ1 mm to high accuracy. Center through coolant is standard.

Simultaneous 5-axis Control Simultaneous 5-axis control is realized by adding a turning axis (A-axis) to the tool main spindle. This enables slanted hole processing, which is not achievable on a conventional turning center. In addition, the "complete in one chucking" feature eliminates dimensional error caused by re-chucking of a workpiece.

Compact Form through the Pursuit of Functional Beauty Designed based on ergonomics, with ease of operation in the machine in focus, the machine is built compactly with a low center of gravity. Installation requires a mere 4.62 m2 of floor area while high rigidity and sophisticated functions are realized. The low overall height of the machine, approximately 1.7 m, does not obstruct visibility in the workshop. A compact rotary stocker integrated with a robot can be installed to automate the production flow. X-axis

Z-axis

C-axis

Y-axis

A-axis

Tilt the tool

Short protrusion

3

As with the turning spindle, the tool spindle, which features minimized thermal displacement and high rigidity, operates at a maximum speed of 20000 min-1 to process holes as small asφ0.5 mm at a surface speed of 32 m/min. To hold rotary tools, an HSK shank suitable for high-speed operation is used. The two-face (end face and tapered face) constraint structure reduces positioning error in repeated operation to ensure high accuracy processing.

Tool Main Spindle

Axis Configuration

A built-in spindle, making the most of the experience we have acquired through manufacturing lathes, has been adopted to achieve high-accuracy processing. Four rows of bearings support the front part of the spindle to assure rigidity. In addition, a dedicated cooling unit is installed to minimize thermal displacement.

High-accuracy Built-in Spindle for Turning Operation

The introduction of the A-axis enables processing of slanted holes with the standard specification, without using the conventionally required angle unit. The "complete in one chucking" feature eliminates dimensional errors caused by re-chucking.

Axis

X-axis

Z-axis

Y-axis

C-axis

A-axis

Stroke

250mm

305mm

345mm

360deg

270deg

Minimum unit of setting

0.001mm

0.001mm

0.001mm

0.001deg

0.001deg

Turning spindle

NC unitFANUC 31i-A5

A-axis: 270 deg.A-axis: 270 deg.

Ｙ-axis:345mm

Z-axis: 305 mm

X-axis: 250 mm

Ｙ-axis:345mm

Z-axis: 305 mm

X-axis: 250 mm

C-axis: 360 deg.C-axis: 360 deg.

HSK shank

φ32

mm

Close contact with tapered face

Basic Machine Structure The ultimate machine, taking up the challenge of extreme accuracy without compromise

Close contact with end face

4

Processing Performance

Processing accuracy

■ Roundness 0.259 μm ■ Cylindricity 0.832 μm

■ Grooving in turning Groove width: 3 mm

(Workpiece material (JIS): S45C (Carbon steels for machine structural use), Size: φ50 x 70 mm)

■ Rigid tapping M6x1.0 (spiral tap) ■ End milling Width 10 mm, Depth 5 mm

■ Drilling φ10 mm

■ Disturbance of tool nose 0.15μm

90.00°

0.00° 180.00°

270.00°

×10,000 (1.000μm) ×5,000 (2.000μm)

0.15μm

Disturbance of tool nose

A-axis: 270 deg.

Ｙ-axis:345mm

Z-axis: 305 mm

X-axis: 250 mm

C-axis: 360 deg.

(Processing conditions)

Turning main spindle speed : 8000 min-1

Feedrate : 0.05 mm/rev

Cutting speed : 1250 m/min

Depth of cut : 0.025 mm (in radius)

Workpiece material : A2011 (Aluminum)

Workpiece dimensions : φ50 x 30 mm

Tool : Single crystal diamond tool (Nose R 2.0 mm)

(Processing conditions)


Feedrate : 300 mm/min


Depth of cut : 0.2 mm (in radius)

Workpiece material : Brass

Workpiece dimensions : φ50 x 75 mm

Tool : φ10 flat end mill (Cemented carbide)

■ Contouring accuracy 4.037μm




Tool main spindle speed : 800 min-1









* In slanted rigid tapping, processing at tool main spindle speed of up to 4000 min-1 is possible.

Cylindricity (Z=0, 12.5, 25.0): 0.832 μm

24.997

12.503

0.002

Point of view: 90.00°

Z-axis [mm]

90.00°

0.00° 180.00°

270.00°

×500 times (20μm)

5

■ CAD/CAM software supporting simultaneous 　 5-axis control processing

● The use of the CAM software reduces the time, skill and

　 verification needed in conventional programming.

● Complex shape can be programmed in a simple operation!

　 An operator who only has experience of operations on lathes can operate the software.

Even a complex shape can be programmed in a short time using the latest CAM software. The programmer’s load due to concentration for a long time, skills and verification steps, which were all necessary for conventional programming, can be reduced.

Software

FANUC 31i-MODEL A

NC Unit

■ OperabilityThe operation panel has been completely redesigned to improve operability by arranging the buttons in groups according to use.

Technology The Most Advanced Technology to Support Our Customers

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■ Tool breakage detector

■ Robot FANUC Robot LR Mate 200iC

The 16-station stocker and the articulated robot, installed in an area 630 mm wide, serves as an automatic loading / unloading system. Multiple types of workpiece material can be handled since a CCD camera automatically recognizes the shape of the workpiece material.

Mi-8 [16-station stocker + Articulated robot specification]

The tool breakage detector provides the following two functions.

Detects breakage of a tool by receiving the light emitted from the photoelectric sensor.

Detects the length of a tool using the skip signal.

Detection of tool breakage

Automatic tool offset

Number of controlled axes

Reach

Wrist load capacity

Repeatability

Weight of robot body

6 axes

704 mm

Max. 5 kg*

±0.02 mm

Approx. 27 kg

* Includes the weight of hand, transport fixture and workpiece.

Standard accessories Special accessoriesCoolant unit Sub tank with spindle cooling unit Totally enclosing guard Machine light Hydraulic pump unit Foundation plate Air panel Safety guard Chuck air blow Tool main spindle coolant Lubricating oil level monitor Hydraulic pressure monitor Cycle time monitor CRT multi-counter 3-color signal tower OD turning tool holder Face turning tool holder Boring bar holder Chip pan 5″ hollow chuck (including cylinder)

Coolant pump of 250W (Tank capacity: 178L) 250W, Tank capacity: 120L

400W trochoid pump, with filter

Red / Yellow / Green □16 2 pcs. □16 2 pcs. φ25 2 pcs.

HO37M-5 (Howa)

(Hydraulic cylinder FR25 (Nikko))

Tool breakage detector Automatic tool diameter / tool length measuring unit Chip conveyor 4″ hollow chuck (including cylinder) Round bushing Mist collector Mist collector duct Energy saving related taxation system* compatible specification hydraulic pump unit*3

Automatic power OFF device Automatic fire extinguisher Chip cart Through-spindle air blow Through-spindle high-pressure coolant

Includes chip pan for chip conveyor HO37M-4 (Howa)

(Hydraulic cylinder FR25 (Nikko)) Various sizes of bushing

DM-3

Energy saving related taxation system* compatible inverter specification

*3 This hydraulic pump substitutes for the standard hydraulic pump unit

* Energy Demand Structure Reform Investment Promotion Taxation System

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■ Accessories

■ Machine specifications

Standard workpiece size

Motor

Number of speed changes

Max. speed

Spindle nose

Number of ATC tools

Travel

Rapid traverse

Travel

Rapid traverse

Travel

Rapid traverse

Minimum setting unit

Rapid traverse

Minimum setting unit

Rapid traverse

Center height

Spindle nose

Bore

Number of speed changes

Max. speed

Motor

Positioning

NC unit

Type

Number of mountable tools

Turning tool size

Max. boring bar diameter

Turret swing

Machine height

Floor space

Machine weight

Power capacity

Voltage and frequency of power source

Unit

mm

kW

－

min-1

mm

pcs

mm

m/min

mm

m/min

mm

m/min

deg

min-1

deg

min-1

mm

－

mm

－

min-1

kW

－

－

－

pcs

mm

mm

mm

mm

mm×min

kg

kVA

－

Item Mi-8

□70 x 70 (swingφ100)

1.5/2.2 (Cont. / 5-min. rating)

Infinitely variable

20000

E32

20

250

20

345

23

305

20

0.001

28

0.001

300

900

φ80 Flat

φ32

Infinitely variable

8000*1

2.2/3.7 (Cont. / 30-min. rating)

NC Control (Cs-axis)

FANUC-31i-MODEL A5

V5

5*2

□16

φ25

φ390

1760 (Operation panel: 1850)

W1560XD2100 (3.28m2)

2700

21

200/220 VAC +10%, -15%, 3-phase 50/60 Hz ±1 Hz

Capacity

Numerically controlled axes

Tool spindle

X-axis

Y-axis

Z-axis

A-axis

C-axis

Turning spindle

Turret

*1 The maximum speed is limited by the type of chuck to be used.　*2 The number of tools that can be mounted may be limited according to tooling.

Specifications

■ NC functions ○ Std. ▲ Opt.

■ NC unit

8

Backlash compensation

Stored pitch error compensation

Stored stroke check

Mirror image

Inch / metric switching

Single block

Manual pulse handle feed

Sequence number search

Dwell

Reference point return

Thread cutting / feed per revolution

Continuous thread cutting

Helical interpolation

Polar coordinate interpolation

Rapid traverse override

Feed override

Jog override

Plane selection (G17, G18, G19)

Canned cycles

Canned cycles for drilling

Custom macro B

Automatic coordinate system setting

Program number search

Program edit

Subprogram call

Coordinate system setting (G50)

Decimal point input / Calculator type input

Chamfering / Corner rounding

Work coordinate system G52 - G59

Block delete

Dynamic switching of diameter / radius specification

Direct input of drawing dimensions

Multiple repetitive cycles

Spindle orientation

Rigid tapping

Constant surface speed control

Tool position offset

Tool geometry / wear offset

Nose R compensation

Addition of tool offset pairs 64 / 69 sets

Number of registered programs 63

Program storage capacity 4 / 8MB

Number of registered programs 1000 / 4000

Background editing

Self-diagnostic function

Alarm history display

Operating time / Parts count display

Help function

External message function

Axis control

Operation

Interpolation function

Feed function

Program input

Miscellaneous function / Spindle function

Tool function / Tool offset function

Program edit operation

Setting display

Data input / output

Mi-8

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Control method and number of controllable axes

Least input unit (in diameter)

Command method

Input code

Number of tool offset pairs

Tool offset value

Feedrate command Feed per revolution

Spindle function

Preparatory function

Miscellaneous function

Tool function

Program storage capacity

*1 The range may be restricted according to rapid traverse rate and other factors.

Unit

-

mm (°)

-

-

sets

mm

mm/rev (°/rev)

-

-

-

-

Mbyte

Name FANUC 31i-MODEL A5

5 axes (simultaneous 5-axis control)

0.001 (X axis : Diameter / radius switchable)

Combined use of absolute and incremental

EIA / ISO automatic determination

32

0～±9999.999

0.001～500.000

S : 5 digits

G : 2 digits

M : 3 digits

T: 3 digits (tool) / D : 1 digit (offset)

2 (equivalent to approx. 5120 m)

Remarks

Unit in ( ) : C and A axes

Override : 0 to 150%　Unit in ( ) : C axis*1

9

Stroke diagram

Tooling system drawing

4.4Nm

24Nm S2 30min.

2.6Nm

14Nm S1 Cont. 2.2kW S1 Cont.

3.7kW S2 30min.

Turning tools OD turning tool holder

Turning tool size□16

Round bushing

* Turning tools and boring bars should be prepared by the customer.

Turning tool□16

Boringφ25

Boring bar φ6φ8φ10φ12φ16φ20φ25

φ25×φ6φ25×φ8φ25×φ10φ25×φ12φ25×φ16φ25×φ20

Face turning tool holder

Turning tool size□16

Boring bar holder

Bore diameterφ25

250

5 (+X-axis stroke)

φ100

φ490

φ540

65 47

80 (3)

(20)

(20)

35

105

59

38

0

55

245 (-X-axis stroke)

X-axis home position

OD turning tool holder Face turning tool holder

End face of turning main spindle

97 63 145 90

105 105 (3)

4

16

10

1070

70

305

7

Headstock

φ135 (OD of 5″ chuck)

φ110 (OD of 4ﾓ chuck)

φ390 Max. swing of turning tool

φ540 Arm swing

φ490 Tool turning

diameter

φ500 Max. swing of rotary tool

φ100

5 (+Z-axis stroke) 300 (-Z-axis stroke)

345

125

(130)

90

7550

134.5 134.5

(250)

340 (-Y-axis stroke)

5 (+Y-axis stroke)

180° (+A-axis stroke)

90° (-A-axis stroke)

ロ16

Z-axis home position

Y-axis home position

End face of rotary tool spindle

Boring bar holder

A-axis home position

155 90

160 Max. tool length (tool stored in the magazine)

Center of ATC arm rotation

Spindle cover

6.590

40°

Rotary tool

Rotary tool spindle end face

15

ATC arm stroke

ATC arm

(130) (90)

3.7kW S3 25%

1.5kW S1 Cont.

4,5003,000 4,760

7.0Nm S3 25%

3.2Nm S1 Cont.

4,7604,500

3,000

Round bushingTo be mounted to boring bar holder Various sizes of round bushing

OD turning tool holder

N1V001000A(□16)

Boring bar holder

N1V002000A(φ25)

Face turning tool holder

N1V003000A(□16)

Drawings

10

Floor requirement drawing

Spindle torque / Output characteristics

■ Tool spindle - Output characteristics (Automatic winding changeover)

■ Turning spindle - Output characteristics

4.4Nm

24Nm S2 30min.

1,5000 0

10

20

30

5,000 8,000 12,000

1.7

4.4Nm

2.6Nm 1.1

Torque(Nm)

Motor speed(min -1 )

14Nm S1 Cont.

24Nm S2 30min.

2.6Nm

14Nm S1 Cont.

0 0

1

2

3

4

5

5,0001,500

2.2kW S1 Cont.

3.7kW S2 30min.

2.2kW S1 Cont.

3.7kW S2 30min.

10,00012,000

1.5

2.2

Output(kW)


8,000

ＰＡＧＥ

ＰＡＧＥ

ＯＫＰＲＯＧＲＡＭＭ

ＯＦＦ

ＣＨＵＣＫＵＮＣＬＡＭＰ

ＰＲＯＴＥＣＴ

ＳＴＡＲＴＯＮ

ＮＣＯＮＯＦＦ

ＥＲＲＯＲ

ＬＩＧＨＴＡＵＴＯ

ＰＯＷＥＲ　ＯＦＦＣＹＣＬＥＥＮＤ

１００１００

ｘ１ｘ１０

ｘ１００

１００

ＣＹＣＬＥ　ＳＴＡＲＴ

ＲＥＦＥＲＥＮＣＥ

ＲＥＴＵＲＮ

ＭＡＮＵＡＬ

ＭＯＤＥ

ＭＥＭＯＲＹ

ＥＭＥＲＧＥＮＣＹ　ＳＴＯＰ

５０１５０

ＭＤＩ

（％）

０

ＥＤＩＴ

１２０

６０

（％）

５０

ＴＥＭＰＯＲＡＲＹ　ＳＴＯＰ

７０

８０

９０１１０

ＢＬＯＣＫＤＥＬＥＴＥ

ＳＩＮＧＬＥＢＬＯＣＫ

Ｍ０１

ＦＥＥＤ　ＲＡＴＥＯＶＥＲＲＩＤＥ

ＳＰＩＮＤＬＥＯＶＥＲＲＩＤＥ

ＥＭＥＲＧＥＮＣＹＲＥＳＥＴＨＡＮＤＬＥ

ＹＺＣ

ＸＢ

Ｂ

Ｙ

Ｃ

Ｚ

Ｘ

２５

（％）

ＳＥＴ

ＵＰ

５０

ＲＡＰＩＤＴＲＡＶＥＲＳＥ

０

ＦＯＲＷＡＲＤ

ＡＵＴＯＯＮ

ＣＯＯＬＡＮＴＭＩＳＴ

ＣＯＬＬＥＣＴＯＲＯＮＡＵＴＯ

ＯＮＳＴＯＰＲＥＶＥＲＳＥ

ＵＮＣＬＡＭＰＣＬＯＳＥＯＰＥＮＣＬＡＭＰ

ＥＮＡＢＬＥ

ＩＮＣＨＩＮＧ

ＴＯＯＬＤＯＯＲ

ＣＨＩＰＣＯＮＶＥＹＯＲ

Ｃ　ＡＸＩＳＭＯＤＥ

ＳＡ２ＳＡ３ＳＡ１ＳＡ４

Coolant tank draw out space

R485

R715

R450

R315R5

25

R525

Mist collector duct (Option)

Chip conveyer (Option)

Spindle center

Automatic fire extinguisher (Option)

Mist collector (Option)

Maintenance space for the spindle, the control box and the hydraulic pump

1380

1850

1760

1096

900

840

1 5 60 445500

370

2065

637

1030

1030

37

208

1 3 5°

0 0

5

4

3

2

1

5,000 10,000 20,00015,000

Output(kW)


3.7kW S3 25%

1.5kW S1 Cont.

3.7kW S3 25%

2.2kW

1.5kW S1 Cont.

8,0004,5003,000 4,7604,500

3,000 4,760

4.4Nm

8,000

5,000 10,000 15,000 20,0000 0

8

6

4

2

10

1.8

0.7

Torque(Nm)


7.0Nm S3 25% 7.0Nm S3 25%

3.2Nm S1 Cont. 3.2Nm S1 Cont.

4,7604,7604,5004,500

3,0003,000

The tool main spindle motor type is the output changeover type. When the motor speed exceeds 4760 min-1, the motor characteristics change from those of a low-speed winding to those of a high-speed winding.

0LK-10099-A002 2009.09

●The information in this brochure is valid as of September of 2009. Amada Machine Tools Co., Ltd. reserves the right to change the specifications and other data without previous notice. ●The product in this brochure may be identified as strategic goods as stipulated in the Foreign Exchange and Foreign Trade Law, and the exportation of the product may be subject to an authorization from the government. Before exportation, consult AMADA MACHINE TOOLS in advance.

●To ensure safe and correct use, read the Operation Manual before operating the machine. ●Technical data such as cutting data presented in this brochure varies depending on the room temperature, workpiece material, tool material, cutting conditions and other factors. Please note that the values in this brochure are not guaranteed values.

TEL:81-463-96-1111

TEL:1-847-797-8700

TEL:49-(0)2129-579-03

TEL:49-(0)9342-888-0

TEL:66-3846-8920

TEL:81-568-71-8821

■AMADA CO.,LTD.

　200, Ishida, Isehara-shi, Kanagawa, 259-1196, Japan

■AMADA WASINO AMERICA, INC.

　4070 Winnetka Avenue, Rolling Meadows, IＬ 60008　U.S.A.

■AMADA MACHINE TOOLS EUROPE GmbH

　［HEAD OFFICE］ Landstraße 25, D42781 Haan, Germany

　［MACHINE TOOL DEPT.］ Ludwig-Erhard-Straße 1, D97577 Wertheim, Germany

■AMADA WASINO (THAILAND) CO., LTD.

　700/146 Village No. 1, Bankao Sub-District, Panthong District, Chonburi 20160 Thailand

■AMADA MACHINE TOOLS MFG CO., LTD.

　2-158 Nakashima, Shimoobari, Komaki-shi, Aichi, 485-0051, Japan

www.amada.com

TEL:81-463-96-3351200, Ishida, Isehara-shi, Kanagawa, 259-1196, Japan

simultaneous 5-axis control processing...

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