Vertical Machining Centers

Before investing, every shop must know where vertical machining centers will work best for their operation in terms of process application fit, production costs and purchase investment. For example, power, speed and accuracy are absolute necessities tied to close examinations of the spindle drive system, CNC machine operating system and axis drive system. The types of materials being machined require evaluations of the spindle rpm, low speed torque and high speed horsepower. Machining soft materials demands higher speeds for finishing. Hard materials require low-speed torque and rigidity to reduce the impact of side thrust.

Volume is everything. Prototypes and short runs dictate faster setups, quick and easy program editing, practical work envelope access and table height, and proper system cooling for thermal stability. Long production runs demand effective chip removal and are ideal for automated loading. Consider these factors and many more as you review the features these new vertical machining centers have to offer your shop.

AFFORDABLE, COMPACT FIVE-AXIS MACHINING
Doosan Infracore America Machine Tools (Pine Brook, NJ) introduces the all-new DNM 200/5AX compact, reliable and affordable purpose built five-axis vertical machining center. This newest member of the wildly popular DNM Series is ideal for machining complex prismatic parts by reducing set-up time and ensuring consistent accuracy without taking up too much valuable space on the shop floor. The DNM 200/5AX is a purpose built 5-axis machining center, featuring a built in 4th and 5th axis trunnion table allowing for the machining of multiple faces on complex prismatic workpieces, without having to re-fixture. This unique design provides for more available Z-axis clearance than a traditional VMC with a rotary system placed on the standard table. Precision and repeatability are superior as well, due to the reduction in stacked tolerances. The platter size is 7.87 in diameter, allowing for a maximum work piece of 11.81 in diameter and 7.87 in tall. The maximum table load is 88 lb.

All linear guideways feature roller type bearings, delivering three times more rigidity and double the lifespan. Additional benefits include optimal weight and force distribution, superior stiffness, accuracy, and surface finish. The direct-coupled spindle drive system is a true cartridge type unit supported by high precision ceramic ball bearings that offer minimal noise, vibration and thermal growth due to the absence of gears or belts inside the spindle head body. The powerful 12,000 rpm, 15/25 hp motor has 86 ft-lb of torque with a spindle accel\decel time of 0-12 k (2.16 sec)/ 12k-0 (2.21 sec).

The bed is a rigid, one piece casting made from fine grain Meehanite cast iron with heavy ribbing to help prevent vibration and deformation during heavy cutting.  Extra wide spacing of the roller guideways provide for excellent support of the saddle, regardless of the load distribution on the table.  The table is fully supported by the saddle in all positions with no overhang.  The rigid box type column casting is heavily ribbed to help prevent twisting or distortion as well as helping to dampen vibration during high speed or heavy machining.

Doosan Infracore America Machine Tools, 19A Chapin Road, Pine Brook, NJ 07058, 973-618-2500, www.doosanmachinetools.com.

INCREASE PROFIT MARGINS WITH 5-AXIS
With the introduction of five 5-axis models, Hurco Companies, Inc. (Indianapolis, IN) announced a major initiative called “Take 5 for 5-axis” to galvanize manufacturers to evaluate the merits of 5-sided machining for traditional 3-axis parts with features on all five sides. “We are dedicated to helping shops increase profit margins by developing sophisticated control technology that is intuitive, easy to learn, and easy to use. Adopting a 5-sided process is the most efficient way to instantly increase profit margins on existing parts,” said Maggie Smith, the marketing manager for Hurco.

“Purchasing a 5-axis machine is truly an investment in the future that pays dividends today,” she continued. “When a shop invests in a 5-axis mill and runs their existing parts on that 5-axis by employing 5-sided machining, or 3+2 as it is sometimes called, they immediately reduce setup time, increase accuracy, and reduce cycle time on those parts. In the future, they can bid on more complex work. Not only do they expand their capabilities and customer base, their employees expand their own skills.” As part of this initiative, five 5-axis models have been introduced: the VMX30UHSi, VMX42HSRTi, VMX84SWi, VMX60SWi, and VMX60Ui.

The VMX42HSRTi has a swivel-head design with direct drive, rotary, torque table (C-axis) and is equipped with a high-speed 18,000 rpm integral motorized spindle. It has X/Y/Z travels of 42/ 24/ 24 in and a table working surface of 50 in x 24 in. All SRTi 5-axis machines provide maximum manufacturing versatility to support a high mix of complex simultaneous 5-axis parts and 5-sided parts. The rotary torque table is embedded so the generous working surface of the table supports secondary operations, 3-axis work, or even plate work. The stout table supports heavier loads and the rotary torque table has unlimited angular movement instead of just 360 deg that is often standard throughout the industry.

The VMX30UHSi is a trunnion-style 5-axis machine equipped with a high-speed 18,000 rpm integral motorized spindle. As with all U-Series 5-axis machines, it was designed with an integrated trunnion table that provides more clearance in the Z-axis and facilitates heavier parts instead of just mounting a table on a 3-axis machine. The second new trunnion-style 5-axis machine is the VMX60Ui, which has a 12,000 rpm spindle and X/Y/Z travels of 60/ 26/ 26.5 in.

The two new SWi machines added to the lineup are the VMX84SWi with X/Y/Z travels of 84/ 34/ 30 in and the VMX42SWi with travels of 42/ 24/ 24 in. The SWi models offer 4-axis rotary functionality by utilizing the same B-axis swivel head design as the aforementioned SRTi models, but they can be equipped with an optional A-style rotary table that meets a shop’s needs instead of the C-axis table that is on the SRTi models.

Beyond the release of these models, the Take 5 for 5-axis initiative includes an educational website 5-axis.org, a webinar, and several live seminars at events throughout North America. To learn more, go to www.hurco.com/take5.

Hurco Companies, Inc., One Technology Way, PO Box 68180, Indianapolis, IN 46268, 800-634-2416, info@hurco.com, www.hurco.com.

MORE MACHINING BANG FOR THE BUCK
The new EM Series from Chevalier Machinery Inc. (Santa Fe Springs, CA) is a high-speed vertical machining center with a cost savings that hammers the competition, delivering more bang for your buck and increasing your production capabilities. It is engineered with efficiency to satisfy the need for large quantity machining with limited floor space. The series comes in three models: EM1620L, EM2033L and the EM2040L.

The major parts of the machine are constructed of high-quality Meehanite cast iron that offers superior stability. The machine base is supported by full-travel, enabling it to be suitable for high-speed machining. All three axes are built with high-speed linear ways, providing smooth quick movement without delay. The series ranges from 16 in x 20 in to 20 in x 40 in. The EM Series has a table load of up to 1,320 lb with an overall table dimension of up to 47 in x 20 in. The travel on the X-, Y- and Z-axis are up to 40 in x 20.8 in x 20 in. This machine provides fast interpolation, minimizing machining time with high rapid speeds up to 1,889.7 ipm. Its powerful 20 hp spindle motor handles up to 10,000 rpm, combining an attractive finish surface in high-speed with enough torque in lower rpm. Optional 12,000 rpm is available. Another benefit is quick pick-up speed, with high-speed rigid tapping. Tool capacity is 24 ATC arm type, with a random tool change.

The EM Series uses a FANUC 0iMD control with a color 8.4 in LCD for 4-axis simultaneous contouring, linear-circular-helical interpolation and canned cycles for drilling, tapping and profiling, plus a conversational Manual Guide 0i and much more. After final assembly, all Chevalier machines are measured and calibrated by state-of-the-art laser calibration and ball-bar test equipment. This ensures precise verification and compensation, resulting in increased accuracy and repeatability. From casting to final assembly, each completed section is thoroughly inspected to give our customers the highest level of quality control. Pricing starts at $48,500 for the EM1620L.

Chevalier Machinery Inc., 9925 Tabor Place, Santa Fe Springs, CA 90670, 562-903-1929, info@ChevalierUSA.com, www.ChevalierUSA.com.

INTELLIGENT MACHINING OF EXOTIC METALS
The GENOS M560-V vertical machining center is part of the Affordable Excellence program at Okuma America Corporation (Charlotte, NC) that combines special pricing with superb quality. Highly rigid, thermally-stable, double-column construction gives this CNC machine the ability to withstand thermal deformation, resulting in reduced thermal growth and improved machining performance. A versatile spindle with 30 hp and 150 ft-lb of torque allows this machine to cut challenging metals such as titanium and Inconel as well as stainless steel and aluminum.