total solution 5-axis universal machining center · hwacheon total solution meets machining...

M2-5AX Total Solution

5-Axis Universal Machining Center

HS-M272-R8.12-20120925

HWACHEON TOTAL SOLUTION

MEETS MACHINING EXELLENCE

Hwacheon's universal 5-axis center gives you the total machining solution everything from tool selection to final product.

Also, the Machining Optimization system configures itself to fit your machining condition and application to give you the best product result.

The 2-axis rotary table at ø500 lets you create a product either by 5-axis or 3+2 axis processing method. M2-5AX is built from 3D FEM

analysis, and the software components specially created in-house by Hwacheon will increase the machine's productivity and process speed.

The machine comes with many functional options that will make your production more efficient.

※Main Features

1. Integration of Multiplex Process (Hybrid MC)

Advanced Tilting Rotary Table (MMK)

Complex shape can be cut by 5-axes simultaneous control

2. High-Performance Spindle

Various Spindle: 20,000rpm(Std.), 32,000rpm(Opt.)

Built-in Spindle Motor: 22/18.5kW (30/25HP)

Oil-jet lubrication with Special Hi-YUN oil

3. High-Accuracy Axes

Linear scale (X/Y/Z) & Rotary encoder (A/C): Std.

High-Rigid Roller LM guide for every axes

4. High-Rigidity Structure

1 piece casting with Bed and Column Frame

Optimized Structure for Stable Moving

5. Unique Technology

Hwacheon Original Function - Std.: HAI(600block)/HECC/HTLD/OPTIMA/HTDC(HFDC+HSDC)

- Opt.: HAI(1000block)/HRCC

Find out what we mean by machining optimization

HS-M272-R8.12-20120925

M2-5AX

Tilting Rotary Table

M2-5AX 32,000rpm

Tool storage capacity 30ea

Oil-Jet Lub. + Jacket Cooling

32,000rpm 20,000rpm M2-5AX 20,000rpm

BT-40 (Std.) BBT-40(Opt.) CAT-40(Opt.)

HSK-E40

◀ Hi-YUN Oil

Machine Line-up 【M2-5AX】 HS-M272-R6.8-20120925

ITEM M2-5AX 20,000rpm M2-5AX 32,000rpm

Travel X-axis Stroke (longitudinal movement of Spindle) mm(inch) 750 (29.53”)

Y-axis Stroke (Cross movement of Spindle) mm(inch) 650 (25.29”)

Z-axis Stroke (Vertical movement of Spindle) mm(inch) 500 (19.69”)

A-axis Stroke (Tilting)/C-axis Stroke (Rotary) deg. +30 ~ -120 / 360

Distance from table surface to spindle gauge plane(Long nose type) mm(inch) 75~575 (2.95”~22.64”)

Distance between columns to spindle Center mm(inch) 120 (4.72”)

Distance between columns mm(inch) 1,480 (58.27”)

Table Working surface mm(inch) Ø 500 (Ø19.69”)

Table loading capacity kg(lb) 300 (661.39)

Table surface configuration (T slots WxP –No. of slots) mm(inch) 14x80 (0.55x3.15)-5ea

Spindle

Max. spindle speed rpm 20,000 32,000

Spindle Motor kW(HP) 22/18.5 (30/25) 18.5/13 (25/18)

Type of spindle taper hole - ISO#40, 7/24 Taper (BT-40) HSK-E40

Spindle bearing inner diameter mm(inch) Ø 70 (Ø2.76”) Ø 45 (Ø1.77”)

Method of Spindle lubrication & cooling - Oil-Jet Lub. + Jacket Cooling

Feedrate

Rapid Speed (X/Y/Z) m/min(ipm) 50/50/50 (1,969/1,969/1,969)

Rapid Speed (A/C) rpm 8.3/33.3

Feedrate (X/Y/Z) mm/min(ipm) 1~24,000 (0.04~945)

Motor Feed motor (X/Y/Z) kW(HP) 4.0/7.0/4.0 (5.5/9.5/5.5)

Feed motor (A/C) kW(HP) 4.0/4.0 (5.5/5.5)

Coolant motor (Spindle/chip flushing) kW(HP) 0.4 (0.55) / 0.9 (1.2)

Spindle cooler (50/60Hz) – Inverter type kW(HP) 5.0/5.6 (7/7.5)

Machine Specification 【M2-5AX】 HS-M272-R6.8-20120925

ITEM M2-5AX 20,000rpm M2-5AX 32,000rpm

ATC

Type of tool shank - BT-40 (Opt.: BBT-40, Cat-40) HSK-E40

Type of pull stud - MAS P40T-1 (45˚) -

Tool storage capacity ea 30

Max. tool diameter [without adjacent tools] mm(inch) Ø 80(Ø 3.15)/Ø 170(Ø 6.69) Ø 60(Ø 2.36)/Ø 90(Ø 3.54)

Max. tool length mm(inch) 300 (11.81“) 250 (9.84“)

Max. tool weight kg(lb) 8 (17.64) 3 (6.61)

Method of tool selection - Technical memory random

Method of operation (Magazine/Swing arm) - Servo / Servo

Tool changing time (Tool to Tool/Chip to Chip) sec 1.5 / 4 2.5 / 5

Power Source

Electric power supply kVA 65

Compressed air supply (Pressure x Consumption) - 0.5~0.7MPa x 690Nℓ/min

Tank capacity

Spindle cooling / Hydraulic/ Lubrication ℓ(gal) 60 / 20 / 12 (15.85 / 5.28 / 3.17)

Coolant ℓ(gal) 400 (105.67)

Machine size

Height mm(inch) 3,090 (121.65”)

Floor space (length × width) mm(inch) 3,025x3,695 (119.1”x145.47”)

Weight kg(lb) 11,000 (24,251)

NC controller Fanuc 31i-A5

Machine Specification 【M2-5AX】 HS-M272-R6.8-20120925

Item Specification

Controlled Axis Controlled axis (Cs axis) 5-axes S

Simultaneously controlled axes 5-axes S

Least input increment 0.001mm, 0.001deg, 0.0001inch S

Least input increment 1/10 0.0001mm, 0.0001deg, 0.00001inch O

inch/metric conversion G20, G21 S

Stored stroke check 1 S

Stored stroke check 2 S

Mirror Image S

Stored pitch error compensation S

Backlash compensation S

Operation Automatic & MDI operation S

DNC operation by memory card PCMCIA card is required S

Program number search S

Sequence number search S

Dry run, single block S

Manual handle feed 1unit S

Manual handle feed rate x1, x10, x100 S

Handle interruption S

Interpolation Function Positioning G00 S

Linear interpolation G01 S

Circular interpolation G02, G03 S

Dwell (Per seconds) G04 S

Cylindrical interpolation 4-axis interface option is required S

Helical interpolation Circular interpolation plus max.2axes linear interpolation S

Nano smoothing O

Reference position return check G27 S

Reference position return G28, G29 S

2nd reference position return G30 S

Skip G31 S

NURBS interpolation O

Item Specification Feed Function Rapid traverse override F0, F25, F50, F100 S

Feedrate (mm/min) S

Feedrate override 0-150% S

Jog feed override 0-4,000 mm/min S

Override cancel M48, M49 S

Program Input Tape code EIA RS244/ ISO840 S

Optional block skip 1ea S

Program number O4-digits S

Sequence number N8-digits S

Decimal point programming S

Coordinate system setting G92 S

Workpiece coordinate system G54-G59 S

Workpiece coordinate system preset O

Additional workpiece coordinate pairs 48ea S

Additional workpiece coordinate pairs 300ea O

Extend program edit function Copy/move/.. S

Manual absolute on and off S

Chamfering / corner R S

Programmable data input G10 S

Sub program call 10 folds nested S

Custom macro B S

Addition of custom macro common variables #100-#199, #500-#999 O

Canned cycles for drilling S

Small-hole peck drilling cycle O

Automatic corner override O

Feedrate clamp based on arc radius S

Scaling O

Coordinate system rotation S

Programmable mirror image O

Tape format for Fanuc series 15 O

※ ㅡ : Not available S: Standard O: Option

NC Specification 【Fanuc 31i-A5】 HS-M272-R5.7-20120925

※ ㅡ : Not available S: Standard O: Option

Item Specification

Data input/output

Reader/Puncher interface CH1 RS232C S

Reader/Puncher interface CH2 RS232C S

Data server 256MB S

Data server 1,024MB O

Ethernet interface Embedded Ethernet S

Memory card interface S

Auto data backup SRAM + Part program S

Others

Display unit 8.4" color LCD S

HWACHEON Machining Software

High-speed HRV3 function S

Hwacheon AI Nano Contour Control System (HAI): 600 Block (AI contour control Ⅱ+ High speed processing)

S

Hwacheon AI Nano Contour Control System (HAI): 1000 Block (AI contour control Ⅱ + High speed processing +Lock-ahead blocks are up to 1000 blocks)

O

HECC (Hwacheon Efficient Contour Control System) S

HTLD (Hwacheon Tool Load Detect) S

OPTIMA (Cutting Feed Optimization System) S

HTDC (Hwacheon Thermal Displacement System) - HSDC (Hwacheon Spindle Displacement Control System) + - HFDC (Hwacheon Frame Displacement Control System)

S

5Axis Intelligence

Smooth Tool Center point control S

Tilted working plane command with guidance for 5 axis S

Work piece setting error compensation for 5 axis S

Tool radius compensation for 5 axis O

Item Specification

Spindle Speed Function Spindle serial output S

Spindle override 50-120% S

Spindle orientation S

Rigid tapping S

Tool function / Compensation Tool function T4-digits S

Tool offset pairs ±6 digits, 200ea S

Tool offset pairs ±6 digits, 400ea, 999ea O

Tool offset memory C S

Tool length compensation S

Cutter compensation C S

Tool life management O

Tool length measurement S

Editing Operation

Part program storage length/ Number of register able programs

128kb/250ea S

Part program storage length Number of register able programs

256kb/500ea, 512kb/1000ea, 1MB/1000ea, 2MB/1000ea O

Background editing S

Extended part program editing S

Play back O

Setting and Display Clock function S

Self-diagnosis function S

Alarm history display S

Help function S

Run hour and parts count display S

Graphic function S

Multi-language display (English, German, French, Italian, Chinese, Spanish, Korean, Portuguese, Polish, Hungarian, Swedish)

S

NC Specification 【Fanuc 31i-A5】 HS-M272-R5.7-20120925

NC Instruction 【Fanuc 31i-A5】

Item Explanation

Control axes 3 Axes (X,Y,Z), 4axis/5axis(M2-5AX)

Increment system Least input increment X, Y, Z-Axes : 0.0001 mm

Least command increment X, Y, Z-Axes : 0.0001 mm

Maximum command value ± 9999.9999 mm

Program memory capacity 128kB(250ea), Opt.(256kB/500ea, 512kB/1,000ea,

1MB/1,000ea, 2MB/1,000ea)

Part program edit Part program editing as follows is possible by MDI

operation.

1) Insert, Alter, Delete of word.

2) Delete of block or until the block designated.

3) Register, delete of program.

Input format

Block, word, address, format, can be altered (inch

format)

N4 G90 G2 X4.3 R4.3

Decimal point edit The following addresses can be used with a decimal

point: X,Y,Z,R,C,I,J,K,A,B

Cutting federate Feed per minute and feed per spindle revolution is

possible.

G94 : Feed per minute. (mm/min)

G95 : Feed per revolution. (mm/rev)

Feed rate range (Feed override 0 - 150% every 10%)

Feed per minute 0 - 1,260 (mm/min)

Auto acceleration

/deceleration

Rapid Feed : Linear type acceleration/deceleration

Cutting Feed : Exponential acceleration/deceleration

Coordinate system setting By means of this command, a certain position of the

tool for example, a coordinate system whereby the tip

of the cutting edge becomes (X,Y,Z) of the coordinate

system. This coordinate is called as work coordinates.

Command method G90: Absolute command

G91: Incremental command

Work coordinate system shift When the coordinate system actually set by the G92

command or the automatic coordinate system setting

deviate from the programmed work coordinate system,

the set coordinate system can be shifted

Item Explanation Reference point return 1) Manual reference point return.

2) Automatic reference point return (G27, G28).

Positioning Each axis can independently feed rapidly and

position by G00 command

Interpolation function Linear interpolation : Done by G01 command at

feed rate code designated.

Circular interpolation : Any circular arc is

interpolated by G02 or G03, at feed rate F code

designated. G02 : ClockWise.

G03 : Counter ClockWise.

When circular radius is command as R, any circular

arc of 0°- 180°is interpolated, and when circular

radius is command as address I, K., any circular

interpolation of 0°- 360°can be command

Dwell Dwell is executed by the P, X commands. Setting

Range 0 - 999.999 sec. Decimal point be used with

P address

Back lash compensation This function compensations for lost motion of the

machine.

Compensation value (0-2,550 mm) is set by

parameter, for each axis (by least command

increment).

MDI & LCD All kinds of data information is input and displayed

such as LCD character display, program alarm,

diagnosis program, etc.,

Program No. search Program number of 4 digit continuous to 0 is

searched by MDI & LCD Panel

Miscellaneous function

(M function)

By the command of 3 digit figure after the address

M, ON/OFF control from the machine is possible.

Only one M code can be command per block

Spindle function (S function) Spindle speed is commanded by the 4-digit figure to

address S.

Tool function (T function) Tool position can be selected by the command of 4

digits after the address T

HS-M272-R3.3-20120925

Item Explanation Tool offset The Tool length & diameter compensation offset are

operated by G code. Each function has 200 pairs.

G40: Cutter compensation cancel

G41: Cutter compensation Left

G41: Cutter compensation Right

G49: Tool length compensation cancel

G43: Tool length compensation “+” direction

G44: Tool length compensation “-” direction

Dry run Feed rate becomes jog speed (for both cutting feed

and for rapid moves).

Single block Program can be executed one step at a time

Optional block skip Turning on the optional block skip switch ignores

the block including "/" code at the beginning.

Machine lock When the switch is set to the Machine Lock position,

move command pulses are suppressed.

Consequently the display is updated as specified by

the program, but the tool does not move. The M, S,

T and 2nd auxiliary function are executed. This

function is used to check a program

Feed hold Temporally, machine can stop during the operation

by Feed hold S/W.

Canned Cycle G73: Pack Drilling Cycle

G74: Counter Tapping Cycle

G76: Fine Boring

G80: Canned cycle cancel

G81: Drill cycle

G82: Counter Boring cycle

G83: Pack Drilling cycle

G84: Tapping cycle

G85,G86: Boring cycle

G87: Pack Boring cycle

G88,G89: Boring cycle

Item Explanation

Run hour display 2 items, moving time and the number of parts are

displays on the position screen.

Part counter : The total number of parts are

displayed . . . counted by either M02, M30.

Run hour : Accumulated running to hour display . . .

accumulated running to hour of automatic

operation.

Cycle time : Cycle time display . . . Running hour

display of one automatic cycle.

Plane Selection G17 : XY Plane

G18 : XZ Plane

G19 : YZ Plane

Portable tape reader Program, Parameter and etc., are used for reading

out of NC

Diagnostic function Input/Output of alarm display can be signaled by

pressing alarm, DGNOS key of MDI panel

Stored stroke limit 1 An area inside the area set by parameter is deemed

as prohibited area, when stroke is commanded into

this area, this function makes the axis decelerate

and stop than OT alarm displayed

inch / Metric conversion inch system and Metric system are selected to input

by G code cutting

G20 : inch input. G21 : Metric input

Changing of tool offset

amount Offset value can be set program command (G10).

Custom macro Having registered macro commands as sub

program, in memory.

This function is able to recall at anytime the NC

command program by this simple procedure

External tool compensation This is the function to offset the tool offset value

from out side the CNC. Offset value is automatically

added to the input data of NC

Additional tool offset This number of tool offsets compensation is

400/900 pairs available.

NC Instruction 【Fanuc 31i-A5】 HS-M272-R3.3-20120925

Accessories 【M2-5AX】

Standard Accessories

1) Addition of Jig and Fixture Hydraulic Grooving for Rotary Table (4 / 6part)

2) Air Gun

3) Auto Door

4) CNC-Integrated 3-Dimensional Interference Check System

5) Coolant Gun

6) Data Server (1,024MB)

7) Data Server Interface

8) Lift up Chip Conveyor (Hinge type, Scraper type)

9) Mist Collector

10) NC Cooler

11) NURBS Interpolation

12) Nano Smoothing Interpolation

13) Oil Mist(Semi Dry Cutting System, Eco booster)

14) Oil Skimmer

15) Signal Lamp (R/G/Y, 3Colors)

16) Spindle Through Coolant (30 bar, 70 bar)

17) Tool Life Management

18) Tool Measuring System – Renishaw / Blum (Touch type, Laser type)

19) Tool Radius Compensation for 5 axis

20) Workpiece measuring system-Renishaw / Blum (Touch type)

21) Transformer

22) Hwacheon AI Nano Contour Control System (HAI): 1000 Block

23) Hwacheon Rotation Center Calibration System (HRCC) - Include work measuring system-Renishaw (touch type)

1) Adjust Bolt, Block & Plate

2) Air Dryer

3) Air Blower

4) Coolant System

5) Cutting Diameter Correction for 5-axis Tools

6) Door Interlock

7) Data Server (256MB)

8) Hydraulic System

9) Lubrication System

10) MPG Handle (1ea)

11) Operation Manual & Parts List

12) Pneumatics System

13) Rigid Tapping

14) Scale (X / Y / Z / B / C)

15) Signal Lamp (R/G, 2Colors)

16) Slant Control for 5-axis Guidance Installation

17) Spindle Cooler

18) Tool Kit & Box

19) Work Light

20) Workpiece Coordinate System 48 Pairs

21) Workpiece Setting Error Compensation for 5 axis

22) 5-axis Tool Cutting Point Control

23) 8.4” LCD Color Screen

24) Cutting Feed Optimization System (OPTIMA)

25) Hwacheon AI Nano Contour Control System (HAI): 600 Block

26) Hwacheon Efficient Contour Control system (HECC)

27) Hwacheon Tool Load Detect system (HTLD)

28) Hwacheon Thermal Displacement Control system (HTDC) - Hwacheon Spindle Displacement Control system (HSDC)+

- Hwacheon Frame Displacement Control system (HFDC)

Optional Accessories

HS-M272-R5.7-20120925

※ Unit: mm(inch)

Wid

th: 3,6

95 (

145.4

7”)

445 (17.52”)

1,300 (51.18”) 2,580 (101.58”)

820

(32.2

8”)

Length: 3,025 (119.1”)

2,5

90

(101.9

7”)

In

ca

se

of m

oto

r re

mo

va

l o

f Z

axis

Heig

ht: 3

,090 (

121.6

5”)

1,6

70

(65.7

5”)

T

o s

cre

en c

ente

r

2,3

55 (

92.7

2”)

Door Open: 945 (37.21”)

【Top View】

【Front View】【Side View】

Machine Size 【M2-5AX】 HS-M272-R3.3-20120925

Floor Space (LxW)

3,025 x 3,695 mm

Height (H)

3,090 mm

Weight

11,000 kg

Electric Power

65 kVA / 52 kW

Requirement Air pressure

0.5~0.7 MPa

Size of power cable

38 SQ

1,060 (41.73”)

530 (20.87”)

1,950 (76.77”)

630 (24.8”)

360 (

14.1

7”)

360 (

14.1

7”)

1,5

60 (

61.4

2”)

1,1

10 (

43.7

”)

1,2

00 (

47.2

4”)

Table Center

Front

50 (2”)

270 (

10.6

3”)

※ Unit: mm(inch)

Foundation【M2-5AX】 HS-M272-R3.3-20120925

※ Unit: mm(inch)

80

8

0

55

8

0

80

5

5

21

5 (

8.4

7”)

2

15

(8.4

7”)

43

0 (

16

.93

”)

Ø4

00

(15

.75

”)

18 (0.71”)

48 (1.89”)

Max. Loading capacity

300 kg (661lb)

Ø4

30

(1

6.9

3”)

-X

+X

+Y -Y

+Z

-Z

±C

±A

23

9

+1

0

14 +0.018 0

30 +1 0

Table Dimension【M2-5AX】 HS-M272-R2.2-20120925

※ Unit: mm(inch)

ATC Door ATC Door

【Top View】

Moving Range【ATC Interference】 HS-M272-R2.2-20120925

※ Unit: mm

Flat Nose Type (Opt.) Long Nose Type (Std.)

(Sw

ing M

ovin

g R

ange)

(Sw

ing M

ovin

g R

ange)

Front

Door

Front

Door

【Side View】

Moving Range【ATC Interference】

※ 별도 요청이 없을시 Long nose 주축(표준)으로 출하

HS-M272-R2.2-20120925

Moving Range【Moving Direction & Stroke 】

500

(19.7

")

(360˚)

(+30˚)

(-120˚)

X

Y

Z

C A

※ Unit: mm(inch)

HS-M272-R2.2-20120925

【Front View】

Long nose Type (Std.)

【Side View】

Long nose

+30˚

-120˚

Front

Door

ATC

Door

Moving Range【Internal Interference】

※ Unit: mm

HS-M272-R2.2-20120925

【Front View】

Flat nose type (Opt.)

【Side View】

+30˚

-120˚

Flat nose Front

Door

ATC

Door

Moving Range【Internal Interference】

※ Unit: mm

HS-M272-R2.2-20120925

Tooling【M2-5AX】

BT-40【Std.】 BBT-40【Opt.】 CAT-40【Opt.】

└ Dual contact tool └ USA specification

※ BBT-40: Based on the BIG PLUS of BIG DAISHOWA SEIK company.

1 26 BBT-40

2 25 BT-40

“Y” “X”

HS-M272-R4.4-20120925

※ HSK-E40 applied to 32,000 rpm

HSK-E40【Opt.】

└ Dual contact tool

Tooling【M2-5AX】 HS-M272-R4.4-20120925

Power : 22/18.5kW (30/25HP)

Max. Spindle speed : 20,000 rpm

Motor : αB112L/20000i

Type of spindle : Built-in

Type of tool shank : BT-40(Std.)

BBT-40, CAT-40(Opt.)

The integral spindle demonstrates outstanding performance in high precision and machining with the

reduction of noise, vibration, heat

Acceleration/Deceleration time is reduced as a result of compact integral spindle.

Advantage of Built in motor spindle

Torque Diagram 【Standard】 HS-M272-R4.4-20120925

(Electric conversion)

Power : 18.5/13kW (25/17.5HP)

Max. Spindle speed : 32,000 rpm

Motor : αB80S/40000i

Type of Spindle : Built-in

Type of tool shank : HSK-E40

The integral spindle demonstrates outstanding performance in high precision and machining with the

reduction of noise, vibration, heat

Acceleration/Deceleration time is reduced as a result of compact integral spindle.

Advantage of Built in motor spindle

Torque Diagram 【Option】 HS-M272-R4.4-20120925

X axis

• Stable slant angle structure

Z-axis

Saddle (2ea LM guide, 6ea LM block)

Y-axis

• 4ea LM guide, 6LM block

High-Torque worm shifting for tilting rotary table with OTT style

Produced together with MMK in Japan

"High-Rigidity & High-Precision"

Machine Structure HS-M272-R6.8-20120925

Unique manufacturing technology and original lubrication system

Original Technology

“Made by HWACHEON”

Built-in Motor : High power motor is assembled on the spindle

shaft directly without any parts for transmission

• Minimizing Vibration and Noise in High speed rotation

• Minimizing power loss

• Maximizing cutting efficiency

Bearing Cooling & Lubrication: Oil-Jet system

Stabilize within short time

• Direct oil-jet system to the bearing

Cooling Method : Bearing by Oil-Jet

Motor & Frame by Jacket circuit

Frame temperature synchronizing control:

• Excellent surface finish

• Minimizing effect of outer temperature

Max spindle speed 20,000rpm 32,000rpm

Tool Shank(Opt.) BT-40

(CAT-40, BBT-40) HSK-E40

Spindle Power (HP) 22/18.5 kW (30/25 HP)

18.5/13 kW (25/17.5 HP)

Bearing Inner Dia.(DmN) Ø 70 (1,800,000) Ø 45 (2,400,000)

High-Performance Spindle HS-M272-R6.8-20120925

Hwacheon’s spindle shows outstanding performance for high accuracy and high machining by minimizing

displacement with unique manufacturing technology and original lubrication system (Oil-Jet)

Real-time temperature control: Providing for optimal machining condition by maintaining spindle temperature of

±0.1℃ in interior machine temperature of through thermal sensor installed at each element, not based on

the room temperature.

Filter

Suction

Pump

Oil Tank

Oil Cooler

Flow S/W Flow V/V

Jacket Cooling & Suction

Oil-Jet Cooling & Suction

Rear Bearing

Front Bearing

Built-in

Motor

High-Sensitive

Temperature Sensor

※ On the Machine

Body

Spindle Cooling system【Oil-Jet】 HS-M272-R6.8-20120925

Spindle thermal distortion is significantly reduced and lubrication is increased by injecting cooled oil directly to the spindle bearing. (Oil-Jet Cooling)

This is cooling system to circulate oil to the circumference of the frame supporting motor and housing supporting each bearing. (Jacket Cooling)

Preventing heating element slight heat of bearing after Oil-Jet Cooling, and exterior thermal element such as heated chip. (Jacket Cooling)

Built-in Motor Spindle

Oil-Jet cooling

(Into the rear bearing)

Jacket cooling

(Into the housing of bearing)

Oil-Jet

Return

Oil-Jet cooling

(Into the front bearing)

Housing Jacket

cooling

Jacket cooling

(Into the motor frame)

Spindle Cooling system【Oil-Jet】 HS-M272-R6.8-20120925

Type of tool: MAS-403 BT-40 (Std.)

• 20,000rpm Opt.: BBT-40,CAT-40

• 32,000rpm Opt.: HSK-E40

Tool storage capacity: 30 ea

Max. tool diameter : Ø 80 (with adjacent tools) Ø 170 (without adjacent tools)

Max. tool length : 300 mm

Max. tool weight : 8 kg

Tool changing time : 1.5 sec (Tool to Tool) 4.0 sec (Chip to Chip)

Tool Change Type : Swing Arm

Method of tool selection: Technical memory random

Drive Type : Servo Motor

Ø 80 (with adjacent tools) Ø 170

300

(without adjacent tools)

Compact & protected ATC well placed built-in machine main body.

ATC is separated from working area, providing clean tools & manual operation easily.

Automatic Tool Changer HS-M272-R6.8-20120925

Driven type

Guide way

• Low Friction Roller Linear guide

for fast & stable moving

• Automatic Oil Supply for Lubrication

Linear guide & Ballscrew

Specification

• Servo motor Power (X/Y/Z): 4 / 7 / 4 kW

• Rapid Speed (X/Y/Z) : 50 / 50 / 50 m/min

• Directly Connected to drive

Servo motor is connected to ballscrew directly by coupling

without any transmission parts.

Maximize efficiency & minimize backlash in moving.

• Ball screw Pretension

Ball screw is assembled with pretension by double ball bearing,

then the ball screw can minimize thermal deformation for long

time moving.

• High-Accuracy axes

The Glass Linear scale applied for whole axes by standard

High Precision Axes 【X/Y/Z】 HS-M272-R6.8-20120925

• Worm Gear Transmission type

For high torque machining in rotating continuously, OTT worm

gear is applied in rotary & tilting table.

• Rotary Encoder (Scale) applied standard

High precise machining is available in rotating continuously

& in positioning.

• High Power Brake system

For heavy cutting in fixed angle, high power hydraulic brake

system is operated. (A/C-axis)

• Servo motor Power (A/C): 4 / 4 kW

• Rapid feedrate (A/C) : 8.3 / 33.3 rpm

• Table size : Ø 500 mm

• Max. Loading weight : 300 kg

• Least input unit : 0.001˚

• Advanced optional function Fluid line added for fixture: 4 / 6 port

Driven type Specification

Max. Loading capacity

300 kg (661lb)

Ø 600 (23.62”)

Ø4

30

(16

.93

”)

※ Produced together with MMK in Japan

High precision Axes 【A/C】 HS-M272-R6.8-20120925

Process Integration

• Reduction of process

• Minimizing of jig & fixture

• Reduction of setting time

Function for 5-Axis machining

• Tool radius compensation

• Tool center point control

• Tilted working plane command

Efficient multiple machining

• Under-cut machining

• Minimizing special tool

• Reduction of quantity of cutting tool

Minimizing of EDM process

Extension of tool life

• Limiting zero cutting speed

• Minimizing of tool length

Merit of 5-Axis Machining HS-M272-R6.8-20120925

Lubrication method

• Lubrication Oil

3-axes guide way & ball screws are lubricated by oil.

• Automatic Oil Supply system

Oil pump supplies lubrication oil to each parts automatically.

Stable accuracy for 3-axes

Life of parts is increase

• Alert for refill

Display message when oil is empty

Specification

• Type of Oil : ISO VG 68

• Tank capacity : 12 ℓ

• Discharge rate : 150 cc/min

• Pressure : 17 bar

• Power : 57 W

Lubrication system HS-M272-R6.8-20120925

Through coolant (Option)

Cool-Jet

• External Tank

External coolant tank is installed in the front of machine

Easy to exchange coolant, clean tank and maintain pump

• Separate Chip Bucket

Movable Chip bucket is adapted on the tank

User can remove the chips conveniently

• Variable Options on the tank

Lift-up chip conveyor : Hinge, Scraper type

High pressure coolant (Opt.): 30 bar, 70 bar

Oil skimmer

Specification

• Type of Oil : ISO VG 32

• Tank capacity : 400 ℓ (105.67gal)

• Pump power : 0.4 kW (Spindle)

0.9 kW (Chip flushing)

Coolant supplier

Coolant Equipment HS-M272-R6.8-20120925

Compressed air supplier

• Air Requirement

- Protect spindle bearing against dust

- Blow off dirt & chip in spindle taper while tool is

changed automatically

- Air blower

- Open/Close ATC door

• Using Option Parts

- Air gun

- Oil Mist (Semi dry cutting system)

- Tool measuring system

Specification

• Required pressure : 0.5~0.7MPa

• Inlet hose : Ø 12

• Max. consumption rate : 690 Nℓ/min

Pneumatic System HS-M272-R6.8-20120925

The operator panel is mounted on the right

hand side and it rotates to 90˚ for easy viewing

and accessibility during set-up and operation.

The layout and location of the panel is

ergonomically designed to be efficient and

convenient for the operator.

“Customization Design ”

Convenient OP panel HS-M272-R6.8-20120925

Tool Measuring & Compensation 【Option】

Model : NC4 F145

Type : Laser

Repeatability : ± 1 ㎛

Min. Tool Diameter for Measure : 0.08 mm

Model : TS27R

Type : Touch Probe


Model : LASER NT

Type : Laser

Repeatability : ± 0.2 ㎛

Min. Tool Diameter for Measure : 0.03 mm

Model : Z-3D

Type : Touch Probe


HS-M272-R6.8-20120925

Workpiece Measuring System【Option】

Model : TC50

Type : Touch Probe

Repeatability : ±1㎛

Operation : 360˚, 6 m

Transmission Type : Optical Type (Infra red)

Model : OMP60

Type : Touch Probe

Repeatability : ±1㎛

Operation : 360˚, 6 m

Transmission Type : Optical Type (Infra red)

HS-M272-R6.8-20120925

Easy Programming 【Option】

Easy Programming Based on ISO-code program

format, complex machining

motions can be created

easily by menu form

Intuitive Menu Selecting Menu can be selected easily and

intuitively by soft-key with icon

Good Affinity with CAD/CAM Most popular ISO-code program format

on CAD/CAM can be dealt as it is

Machine Status Window Machine status such as actual

position, feed rate and load meter

are displayed always

Realistic Machining Simulation 3-D solid model machining

simulation is available

CAD/CAM

(Communication Programming ☞ Manual Guide i)

All-in-one Screen Only one screen concentrated

all operations

HS-M272-R6.8-20120925

공구 마모에 대한 부하 변화

Cutting Length (Ad=0.3 Rd=20.0 1times=800mm)

6mm(20 times) 9mm(30 times) 12mm(40 times) 15mm(50 times) 18mm(60 times)

What is HTLD?

Measurement of tool load in real time for safe machining

Prevention against any accident by breakage of tool

About tool attrition load change

Protection of deterioration according to abrasion of tool

Protection of machine trouble according to tool damage

▶ When tool attrition growth up, the cutting load increase in a crack.

Tool attrition

Machining Software 【Standard】 HS-M272-R6.8-20120925

With smoothing interpolation, “the elapsed time for CAM-Data creation and mapping reduced”

With the function of overload automatic detection, “safe unattended process achieved and machine operation ratio improved ”

Choice Cycle time or Accuracy as each purpose Maximization of machining efficiency

Programmable by NC program easily (G-code)

What is the HECC?

By choosing a process mode fit to

the purpose sharply, “shorten the time for rough, medium,

or precision cutting”

Cutting time Fast (1.5~3 times) Slow

Surface No Good Good

Process Rough Finish

Tool Life Good No Good

Control of cutting speed & accuracy Control of smoothing interpolation

Level selection for Hwacheon M/C characteristic

R1.0 ~ R9.0 Automatic calculation with 90 level parameters

Level selection according to production purpose

R*.*1 ~ R*.*9 Automatic calculation with 9 level parameters

Level (R) 1.0 1.1 1.2 ~ 8.8 8.9 9.0 Level (R) *.*1 *.*2 ~ *.*8 *.*9

Precise contour control Soft contour control

What is the HECC?


With one method of adaptive control, the HTLD OPTIMA

control the feed velocity to keep the cutting load regularity.

The method of existing, the NC-DATA optimized the NC-

DATA From the PC was the method which it change to the

feed command (F) in NC-Code.

Graphic display with Load and Feedrate

Convenient operation with simple G code

Various data control according to Tool & Process

Combined with HTLD function

What is the OPTIMA?

Providing function with OPTIMA

Tool Path

Work Piece

Removal Amount

Feed : Constant

Load : Variation

OPTIMA ON

OPTIMA OFF

Reduce the cycle time

Advantage of tool break detect

High-Productivity

Reduction of cycle time because of a change

the machining environment inclusive of tool

state reacts immediately


Tool Clamp

Expended spindle taper

by centrifugal force

Rotation with high speed

Indraft of tool Holder into Spindle Taper

Compensation of spindle displacement in real time for high precision machining

Compensation

Measurement

Temperature Sensor

HSDC Board (Real time compensation)

Compensation of Dynamic deformation Compensation of Thermal Deformation

-10

0

10

20

30

40

0 5 10 15 20 25 30 35 40

Time(sec.)

Z A

xis

Displacement(μm) Not Compensation Compensation

Compensation of deformation according to the centrifugal force

Before compensation After compensation


What is the HFDC?

According to the movement of axes continuously, the heat occurs on the frame from the each integral part of the machine and

gets up the expansion or a bending of the frame as below picture.

Therefore, this displacement makes trouble which is accuracy and surface problem while processing.

The Hwacheon Frame Displacement Control system (HFDC) compensate the error according to the temperature automatically.

The high sensitivity temperature sensors are installed at integral elements and real-time perceives while processing. It is an

artificial intelligence system of next generation.

dZ dX

Error of X/Z axis

T1

T2

※The thermal deformation value of Y axis is almost 0 because symmetrical structure. So

machine hasn’t the function for Y-axis.

※ The above picture shows the displacement value excessively

for easy understanding.

X

axis

Z

axis

After compensation

Before compensation

After compensation

Before compensation


Compensation

Measurement

Temperature

Sensor

dZ dX

Error of X&Z axis

T1

T2

[Spindle Displacement Control] [Frame Displacement Control]

0 100 200 300 400 500 600 700-30

-20

-10

0

10

20

time (min)

X-a

xis

ther

mal

drif

t (m

)

0 100 200 300 400 500 600 700-25

-20

-15

-10

-5

0

5

time (min)

Z-ax

is th

erm

al d

rift (m

)

sim

exp

err

sim

exp

err

X

axis

Z

axis

After compensation

Before compensation

Before compensation

After compensation

Best

Solution

Temperature

Sensor


What is the HRCC?

Process

P2

R

Rotation Center

P1 P3

P4

P5

Probing

Optimization

Apply

Method

HS-M265X-R1.1-20100520

The HRCC (Hwacheon Rotation Center Calibration system) is used to calibrate and optimize the rotation center of 5-axis

machining equipment. By optimizing the rotation center, then managing and loading the relevant data, you can minimize the

possibility of errors during 5-axis machining.

These errors can occur most commonly from thermal effects – as a result of machining or temperature change – or movement

of the object being machined.

Machining Software 【Option】 HS-M272-R6.8-20120925

※ Recommand Workpiece measuring system: Renishaw(OMP-60)

Tool : Face mill (Ø 100 x 5 teeth)

Material : SM45C

Cutting Speed : 200m/min

Spindle Speed : 640 rpm

Cutting Width(Rd): 100 mm

Spindle Load : 100%

0

1

2

3

4

5

0 500 1000 1500 2000

Feed (mm/min)

Ax

ial

de

pth

(m

m) .

. .

Cutting Ability 【Heavy Cutting 1】 HS-M272-R2.2-20120925

Tool : Face mill (Ø 60 x 5 teeth)

Material : SM45C

Cutting Speed : 300m/min

Spindle Speed : 1,600 rpm

Cutting Width(Rd): 40 mm

Spindle Load : 45%

0

1

2

3

4

5

0 500 1000 1500 2000 2500 3000

Feed (mm/min)

Ax

ial

de

pth

(m

m) . .

.

Cutting Ability 【Heavy Cutting 2】 HS-M272-R2.2-20120925

Cutting Process Tool (Maker: Union) N (rpm) Ad (mm) F (mm/min) Time

Center R0.1 Ball 18000 0.05 F100 2H 24min

Drill Φ0.2 x 2.5 18000 2.2 F30 124H

TOTAL TIME (Number of Hole: 9216 EA) 126H 24min

• Machining completely without breakage of micro tool because machine has stable high speed and

HSDC (Hwacheon Spindle Displacement Control) function

Tool : Ø 0.2 Drill

Material : A6065 (Aluminum)

Work Size : 130 x 130 x 60(mm)


Cutting Depth : 2.2 mm

Cutting Fluid : Water Flushing

“ Machining to 9,216 holes by a Ø 0.2 Tool ”

Cutting Ability 【Micro Drilling】 HS-M272-R2.2-20120925

Cutting Process Tool (Maker: Union) N (rpm) Ad (mm) F (mm/min) Time

Center R0.1 Ball 18000 0.05 F100 2H 24min

Drill Φ0.3 x 5 18000 4.7 F100 110H

TOTAL TIME (Number of Hole: 9216 EA) 112H 24min

Tool : Ø 0.3 Drill

Material : A6065 (Aluminum)

Work Size : 130 x 130 x 60(mm)


Cutting Depth : 4.7 mm

Cutting Fluid : Water Flushing

“ Machining to 9,216 holes by a Ø 0.3 Tool ”

• Machining completely without breakage of micro tool because machine has stable high speed and

HSDC (Hwacheon Spindle Displacement Control) function

Cutting Ability 【Micro Drilling】 HS-M272-R2.2-20120925

Machine : M2-5AX

Material : SCM440

Workpiece size : Ø 387x50 (mm)

Cutting Fluid : Oil Mist

Process Tool N (rpm) F (mm/min) Time

Rough R6.0 Ball 4,000 3,600 12H

Semi Finish R5.0 Ball 2,500 1,600 2H 5min

Finish R5.0 Ball 4,500 2,400 8H 10min

Total 22H15min

Conner R5.0

Application HS-M272-R2.3-20120925

Machine : M2-5AX

Material : NAK80 (HRC 42)

Work piece size : 420 x 358 x 70 (mm)



Rough D50,R8 E/M 12,000 1,600 2H 5min

R5.0 Ball 6,000 3,600 45min

Semi Finish

R5.0 Ball 6,000 3,600 50min

R3.0 Ball 12,000 3,600 40min

R1.5 Ball 15,500 2,400 1H 11min

R2.0 Ball 16,000 2,400 30min

R1.0 Ball 16,000 1,200 1H 52min

Finish

R5.0 Ball 17,000 2,400 6H 50min

R3.0 Ball 17,000 2,400 4H 20min

R1.5 Ball 16,000 2,400 5H 50min

R1.0 Ball 17,000 2,400 1H 30min

R0.5 Ball 17,000 1,200 1H 28min

Total 27H 59min


Machine : M2-5AX


Workpiece size : 205 x 225 x 75 (mm)



Rough D50,R8 E/M 12,000 1,600 50 min

R3.0 Ball 10,000 3,600 1H 30min

Semi Finish R2.0 Ball 15,000 3,600 56min

Finish

R1.5 Ball 15,000 2,400 7H 20min

R0.75 Ball 15,000 1,200 45min

D2,R0.2 E/M 15,000 800 16min

R0.5 Ball 17,000 800 30min

D50,R8 E/M 1,500 300 5min

D16 E/M 3,000 600 5min

Total 12H 17min


• Stable high speed with compensation system of

thermal deformation

• High precision machining with Hwacheon

Efficiency Contour Control System

Machine : M2-5AX

Material : KP4M (HRC 32)

Work piece size : 109x101x182 (mm)


Process Tool N

(rpm) F

(mm/min) V

(m/min) fZ

(mm/tooth) Ad

(mm) Rd

(mm) HECC Time (min)

Rough R5.0 9000 4300 282.7 0.24 0.5 5.0 R3.0 231 min

Finish R5.0 12000 3000 377.0 0.13 0.2 0.2 R7.0 100 min

Finish (Side) D6R0.5 8000 1500 150.8 0.09 0.08 6.0 R9.0 50 min

Finish R1.0 18000 1000 113.1 0.03 0.05 0.05 R8.0 80 min

Finish R0.5 18000 800 56.5 0.02 0.05 0.05 R8.0 53 min

Total 514 min


• The merit of short tools are Reduced the

cycle time, Extension of tool life, Improved

the surface, Etc.

Machine : M2-5AX

Material : STAVAX(HRC 52)

Work piece size : 35X50X45 (mm)



Rough R1.0 Ball 18,000 2000 5min10s

Semi-Finish R0.6 Ball 18,000 1600 7min

Finish

R0.6 Ball 18,000 1200 22min

R0.3 Ball 18,000 800 6min

R1.0 Ball 18,000 2000 4min

Total 44min10s



Rough & Finish R2.0 Ball 16,000 1,200 27H30min

Total 27H30min

(*) G105 R5.0 사용 핀 상면 직경 0.12mm 높이 25mm

• Stable high speed with compensation system of

thermal deformation

• High precision machining with Hwacheon

Efficiency Contour Control System

Machine : M2-5AX


Work piece size : 68 x 33 x 40 (mm)



Machine : M2-5AX




Process Tool N

(rpm) F

(mm/min) V

(m/min) fZ

(mm/tooth) Ad

(mm) Rd

(mm) Time (min)

Rough D32R2 1800 2400 181.0 0.67 0.7 25.000 352 min

R5.0 8000 3600 251.3 0.23 0.3 3.000 130 min

Finish

R5.0 10000 3600 314.2 0.18 0.35 0.350 300 min

D12R2 2400 1000 90.5 0.21 0.2 6.000 120 min

R1.5 18000 2000 169.6 0.06 0.06 0.060 104 min

R2.0 18000 1800 226.2 0.05 0.1 0.100 120 min

R3.0 16000 2400 301.6 0.15 0.150 59 min

Total 19H 45 min


Machine : M2-5AX




Process Tool N (rpm) F (mm/min) V (m/min) Time

Rough

D32,R2 2500 2400 251.3 26 min

D32,R2 2000 2000 201.1 4 min

D12,R2 4000 1800 150.8 6 min

Finish

D12,R2 7200 2400 271.4 20 min

D32,R2 3000 2000 301.6 6 min

D4,R0.3 15000 2400 188.5 8 min

D4,R2 18000 3000 226.2 20 min

TOTAL 1H 30min


Machine : M2-5AX

Material : AL7075

Work piece size : 110x110x300 mm


Process Tool N

(rpm) F

(mm/min) V

(m/min) fZ

(mm/tooth) Ad

(mm) Rd

(mm) Time (min)

Rough Flat D12 8000 3600 301.6 0.23 2 6.000 35 min

Flat D12 8000 3600 301.6 0.23 2 6.000 28 min

Semi-Finish

R4.0 12000 4200 301.6 0.18 0.4 0.400 3 min

R4.0 12000 4200 301.6 0.18 0.4 0.400 3 min

R4.0 12000 4200 301.6 0.18 0.4 0.400 4 min

R4.0 12000 4200 301.6 0.18 0.4 0.400 25 min

R4.0 12000 4200 301.6 0.18 0.4 0.400 2 min

Finish

Flat D12 10000 2400 377.0 0.12 0.2 0.200 2 min

Flat D12 10000 2400 377.0 0.12 0.2 8.000 2 min

Flat D12 10000 2400 377.0 0.12 0.2 8.000 2 min

Flat D12 10000 2400 377.0 0.12 0.2 8.000 2 min

Flat D12 10000 2400 377.0 0.12 0.2 8.000 2 min

Flat D12 10000 2400 377.0 0.12 0.2 8.000 2 min

Flat D12 10000 2400 377.0 0.12 0.2 8.000 2 min

R4.0 18000 4200 452.4 0.12 0.15 0.150 38 min

R4.0 15000 4200 377.0 0.14 0.15 0.150 5 min

R4.0 15000 4200 377.0 0.14 0.15 0.150 5 min

R4.0 15000 4200 377.0 0.14 0.15 0.150 2 min

R4.0 15000 4200 377.0 0.14 0.15 0.150 2 min

Total 2H 48 min


Machine : M2-5AX




Process Tool N

(rpm) F

(mm/min) V

(m/min) fZ

(mm/tooth) Ad

(mm) Rd

(mm) Time (min)

Rough D12R2 5200 3600 196.0 0.35 0.5 6.000 293 min

Semi-Finish R3.0 12000 4000 226.2 0.17 0.3 0.300 208 min

Finish R3.0 15000 2400 282.7 0.08 0.1 0.100 700 min

R1.0 18000 1200 113.1 0.03 0.05 0.100 45 min

Total 20H 46 min


Machine : M2-5AX




Process Tool N

(rpm) F

(mm/min) fZ

(mm/tooth) Ad

(mm) Rd

(mm) Time (min)

Rough R5.0 4000 2400 0.67 0.5 5.0 50 min

Semi-Finish

R5.0 6000 3600 0.23 0.6 15 min

R3.0 12000 4500 0.18 0.6 7.5 min

R2.0 15000 4500 0.21 0.6 7.5 min

Finish R3.0 12000 4500 0.06 0.1 65 min

R1.5 18000 4500 0.05 0.2 65 min

Total 3H 30 min


Machine : M2-5AX




Process Tool N (rpm) F (mm/min) Ad Rd Time

Rough D32, R10 1500 2800 1.0 16 44 min

Semi-Finish R4.0 Ball 8000 3600 0.6 - 15 min

Finish

R3.0 Ball 12000 4500 0.15 - 90 min

R2.0 Ball 13000 4000 0.15 - 15 min

R1.0 Ball 15000 2000 0.1 - 15 min

R0.5 Ball 20000 1500 0.1 - 20 min

Total 3H 19min


Machine : M2-5AX

Material : SM45C

Work piece size : Ø 295.3 x 390 mm

Cutting Fluid : Air & Coolant

Process Tool N (rpm) F (mm/min) Ad (mm) Rd (mm) Time (min)

Rough

3+2 Roughing D50R8 Cutter 1,600 1800 1.5 32.5 125Min

Top Roughing D25R1 Cutter 3,600 3000 1 20 30Min

5X Swarf D50R8 Cutter 1,600 1800 2 - 23Min

Semi-Finish

3+2 Bottom D16R8 BEM 5,000 2400 4 2 15Min

Side Face D12 FEM 4,000 1200 2 - 2Min

Side Face D25 FEM 2,000 400 40 - 23Min

Finish

Out Facing D50R8 Cutter 1,800 600 2 - 7Min

Out Facing D60 Cutter 800 400 3 - 6Min

Facing(Tip) D20 FEM 1,500 200 5 - 6Min

Facing(Tip) D25 FEM 2,000 400 20 - 4Min

Angled Face R5 BEM 12,000 3600 0.5 - 18Min

Bottom Face D10R2 Endmill 8,000 3000 2 - 12Min

Top Rest D12 FEM 4,000 1200 5 - 1Min

Side Face D25 FEM 1600 400 75 - 11Min

Hole

cutting

D8 DR D8 FEM 4,000 200 6 - 6Min

D12.1 DR D12 FEM 3,000 200 8 - 3Min

D13.8 DR D14 FEM 2,500 200 6.5 - 1Min

D19.3 DR TOP D20 FEM 1,500 100 14.1 - 2Min

D19.3 DR SIDE D20 U-DR 1,500 100 14.1 - 6Min

D30.3 DR D30 U-DR 1,200 80 40 - 3Min

D26 DR D26 U-DR 1,500 80 45 - 4Min

Total 5H 8 min


Machine : M2-5AX

Material : Titanium ELI64V

Work piece size : Ø 39 x 30 mm


Process Tool N (rpm) F (mm/min) Ad (mm) Time

Rough R3.0 Ball 8000 2400 0.3 29 min

R2.0 Ball 12000 2400 0.1 6 min

Finish R1.5 Ball 12000 2400 0.1 20.5 min

R1.5 Ball 8000 2400 0.1 0.5 min

Total 56 min


total solution 5-axis universal machining center · hwacheon total solution meets machining...

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