ENGINEERING A SUBSIDIARY OF GIDDINGS & LEWIS, INC. VERTICAL MACHINING CENTERS BOX WAY SERIES

Transcription

1 ENGINEERING A SUBSIDIARY OF GIDDINGS & LEWIS, INC. VERTICAL MACHINING CENTERS BOX WAY SERIES

2 ..,... ~.,_eo gearl ess drive system =--: -~2'-:e performance at a -- _-: 5 e o- RP_ I by reducing E.:i'a- ibration and power _ c tool changer,-.::don tandard ;:15 optional, simple - ;:::: 2ehers dependable - ~ated ool changing 22.5 H.P.* spindle motor state-of-the-art closed loop Vector Drive technology maintains consistent torque at full range of RPM 32 bit control architecture up to 9 computer,, or no in parallel allow up to nine imulraneou proce ~e for optimum performance 1000 blk _ ec_ 32 :b -ec_ processing peed allo,, smaller program incremen - to improve surface imemf\ without sacrificino peed High per1ormance axis motors combij1ed.-ic:1 lomrn pitch ball s :-..--s pro".i e lbs. o: ;.:'1rLs; e;:- c.:\is ;o!landle the ' ' / VMC 4020 HT Pr-oven field performance on standard 10,000 RPM spindle: thermally controlled by refrigeration unit.-\bec 7 bearings for smooth operation throughout speed range patented locking drawbar insures tool ~e emion under severe cutting conditions Box Way (X,Y,ZJ construction heavy cast iron box ways provide large surface area contact tor maximum vibration dampening and rigidity Large 40mm diameter ball screws: high traverse rates at lm,- ball crew RPM provide longer sef\ice life greater load capacity all o\\ s operation at longer duf\- C\Tle thermally controlled ball -cre... - reduce thermal grmnh to sure consistent positionino accurac~ pe.

3 Axis Drive System High performance axis motors combined with Large 40mm diameter ball screws provide 3,800 lbs of thrust per axis, to handle the toughest cutting conditions. Fadal's servo controlled system uses parallel processing to create a fast response system. Dedicated computers on all axes provide the agility you need to maintain accuracy even when the feed rate is turned up. Throughout the day machining conditions vary and that is why Fadal VMCs have cooled ball screws. A refrigeration system is used to maintain ± 1 degree of ambient temperature by recirculating a refrigerant through the center of each ball screw to reduce the risk of thermal growth. This uniquely engineered feature insures consistent positioning accuracy to help maintain part tolerances throughout the day. Constant velocity direct couplers between the axis motor and ball screw provide smooth power transmission for a uniform surface finish. Rigid, vibration dampening cast iron construction ol all major components help create a machine ol unsurpassed structural integrity Flame hardened and ground integral box ways provide maximum vibration dampening characteristics and durability Inside view of cast iron base shows structural webbing providing extra strength and rigidity

4 Non-metallic way liner [=:=] Stationary machine member Adjustable gibs Traveling machine member c=j c=j c=j Box Way Construction Non-metallic way liners that are super tough and virtually friction-free are used on all gibs and way surfaces. The result is consistently closer machine tolerances over more years of heavy-duty machining. Positive displacement lubrication over the full length of the way surface preserves accuracy, extends machine life, and virtually eliminates machine stickslip. typical box way accelerometer reading Integral cast iron box ways with non-metallic way liners provide faster absorption of the vibrations inherent to machining operations. typical linear guideway accelerometer reading Linear guideways lack the absorption capacity of a box way machine configuration.

5 The spindle cartridge and machine headstock are refrigerated and monitored to maintain consistent positioning accuracy over a wide range of ambient temperature variations. This closed loop refrigerated system circulates continuously and is isolated from contaminants in the machining environment. Patented locking drawbar for tool retention provides 2000 lbs. of force to hold the tool under the most severe cutting conditions. ABEC 7 bearings are positioned in the spindle cartridge for stability and smooth operation throughout the entire speed range. temperature controlled spindle High precision balanced spindle insures longer life and improved surface finishes. State-of-the-Art AC Vector Drive system maintains consistent torque at full range of RPM (from 10-10,000) with closed loop feedback. Automatic, two speed gearless system delivers higher performance at a wider range of RPM resulting in reduced noise, heat, vibration and power losses associated with a gear box. automatic two speed spindle drive system Rigid tapping provides accurate high speed tapping without the need for costly attachments. rigid tapping Thread pitch and precise depth control are maintained at speeds up to 3,000 RPM.

6 4020, 6030 an - automatic tool changer Optional coolant-thru spindle provides high pressure coolant at the cutting edge to increase machining performance and extend tool life. coolant-thru spindle

7 Standard Machine Specifications Specifications Table Size Floor to Table Surface T-Slots (No. x Width x Span) Cutting Feed Rate (X/Y/Z) Rapid Feed Rate (X/Y/Z) Max. Weight on Table Axis Drive Motor (X/Y/Z) Ball Screw Size Longitudinal (X Axis) Cross (Y Axis) Vertical (Z Axis) Spindle Nose to Table Spindle Center to Column Ways Main Motor- Automatic 2 speed Vector Drive Torque* Accuracy, Axis Positioning** Accuracy, Axis Repeatability** Glass Scales (X, Y, Z) Spindle Speed Spindle Orientation Spindle Taper ATC, Number oftools ATC, Tool Selection Max. Tool Diameter (Without Adjacent Tools) Max. Tool Length Max. Tool Weight Machine Width x Depth Machine Maximum Height Machine Weight Air Pressure Requirement (Momentary) Power Requirement (3-Phase) Single Phase (Optional) VMC 2216 VMC 2216HT 39" X 16" 30" 3 X.562" X 4.33".01 "-250" (375" at 150%) 700 ipm (X, Y) 600 ipm (Z) 2,006 Lbs. DC, 3,800 Lb.* Thrust 40mm Dia. X/Y/Z 22" 16" 20" (0ptional28") 4"-24" (4"-32" With Z option) 16" 15 HP* 11.2 KVV/22.5 HP* 16.8 I0N 160 Ft-lbs./220 Ft-lbs ±.0002" ±.0001" Optional 10-10,000 RPM Electromechanical No Random/Bi-directional 3" 4.5" 15" 15 Lbs. 98"Wx77" D 103" H 8,300 Lbs. 80 PSI, 15 SCFM 40/45 Amps, 230VAC 60 Amps, 230 VAC IN.A. VMC 3016 VMC 3016HT 39" X 16" 30" 3 X.562" X 4.33".01 "-250" (375" at 150%) 700 ipm (X, Y) 600 ipm (Z) 2,736Lbs. DC, 3,800 Lb.* Thrust 40mm Dia. X/Y I Z 30" 16" 20" (0ptional28") 4" -24 " (4"-32" With Z option) 16" 15 HP* 11.2 KVV/22.5 HP* 16.8 KW 160 Ft-lbs./220 Ft-lbs. ±.0002" ±.0001 " Optional 10-10,000 RPM Electromechanical No Random/Bi-directional 3" 4.5" 15" 15 Lbs. 98"Wx77" D 103" H 8,550 Lbs. 80 PSI, 15 SCFM 40/45 Amps, 230 VAC 60Amps, 230VAC /N.A. * Peak ** All accuracies are quoted at 68 F. Fadal reserves the right to change standard and optional machine accessories.

8 11, 116" VMC 4020 VMC 6030 VMC 8030 VMC 4020HT 47.94" X 20" 62.5" x30" 82.5" X 30" 31" 35.25" 35.25" 5 X.687" X 3.75" 5 X.687" X 5.5" 5 X.687" X 5.5".01 "-250" (375" at 150%).01 "-250" (375" at 150%).01"-250" (375" at 150%) 700ipm (X,Y) 600ipm(Z) 400 ipm 400 ipm 3,641 Lbs. 4,120 Lbs. 3,751 Lbs. DC, 3,800 Lb.* Thrust DC, 5,000 Lb.* Thrust DC, 5,000 Lb.* Thrust 40mm Dia. X/Y/Z 1.75" Dia. X/Y, 1.50" Dia. Z 1.75" Dia. X/Y, 1.50" Dia. Z 40" 60" 80" 20" 30" 30" 20" (0ptional28") 30" 30" 4" -24" (4" -32 " With Z option) 5.5" -35.5" 5.5"-35.5" 20" 30" 30" 15 HP*\ 11.2 KW/22.5 HP* 16.8 KW 22.5 HP* 16.8 KW 22.5 HP* 16.8 KW 160 Ft -lbs. I 220 Ft -lbs. 220Ft -lbs. 220 Ft-lbs. ±.0002" ±.0003" ±.0004" ±.0001" ±.00015" ±.0002" Optional Optional Standard on X/Y axes 10-10,000 RPM 10-10,000 RPM 10-10,000 RPM Electromechanical Electromechanical Electromechanical No. 40 No. 40 No (30 Tools Optional) 21 (30 Tools Optional) 21 (30 Tools Optional) Random/Bi-directional Random/Bi-directional Random/Bi-directional 3" 3" 3" 6" 6" 6" 15" 15" 15" 15 Lbs. 15 Lbs. 15 Lbs. W x 87" D 158" Wx 103" D 209" W x 103" D 104" H 122" H 122" H 10,500 Lbs. 17,000 Lbs. 18,000 Lbs. 80 PSI, 15 SCFM 80 PSI, 15 SCFM 80 PSI, 15 SCFM 40/45 Amps, 230 VAC 45 Amps, 230 VAC 45 Amps, 230 VAC 60 Amps, 230 VAC IN.A. N.A. N.A

9 Increased Automation The shop floor can never be too productive, that is why Fadal offers you a wide range affordable and powerful options to customize the VMC you purchase. Several of our most popular options are shown on the following pages. --- >~' Servo Coolant Fadal's Servo Coolant Unit assists unattended machining operations. Featuring automatic nozzle positioning (the CNC calculates required cooling line positions by using the tool length offset) the unit increases productivity by eliminating extra setup procedures. Tool Load Compensation This feature dynamically compensates for varying cutting conditions by automatically adjusting the feedrate (either up or down), both improving production and minimizing the time to manually "tune" the programed feedrates. This feature also helps to avoid tool breakage without the need for constant operator monitoring. Optional Accessories Tool Load Compensation (TLC) Servo Coolant Automatic Pallet Changer (APC) HYDRO SWEEP Rigid Tapping 15,000 RPM High Speed Servo Turret 30 Tool Turret Remote Manual Pulse Generator Digitizing Package Coolant Thru Spindle Mist Coolant Heidenhain Glass Scales 4th Axis Rotary Head -VHSC - VH65 - VH 65T Servo Indexer -VHSC - VH65 4th & 5th Axis Tilt Rotary In-Process Measurement Tool Breakage Detection Extended Z Axis Travel Automatic Doors 32MP/Fadal Visualizer Expanded Memory Levels: l) 422k (3061 ft.) 2) 4 Megabyte (29,000 ft.) 3) 8 Megabyte (58,000 ft.) 4) 16 Megabyte (116,000 ft.)

10 HYDRO SWEEPTM Chip\Removal System Fadal's computer-controlled HYDRO SWEEPTM Chip Removal System utilizes coolant jets to transfer chips from inside the machine, thus eliminating the need for augers and belts. The conveyor lifts the chips from the side of the machine and then deposits them in a drainage tray. At regular intervals a ram moves the chips from the drainage tray into a 55 gallon barrel. The system is much more efficient and dependable than a chip conveyor. AUTOMATIC PALLET CHANGER Our Pallet Changer meets the requirement for higher production jobs which involve multipart fixturing and long part changes. The CNC continues to run parts on the on-line pallet while the operator loads parts on the off-line pallet. Workers are isolated from the machining area by the automatic door which helps protect them from flying chips and spraying coolant. TS-27R Probe The TS-27 can establish tool diameter, length offsets and be used in conjunction with the setup utility or under program control. This probe can also detect broken tools. IN-PROCESS MEASUREMENT Probing allows the CNC to perform various measurement tasks required during a machining process.

11 Rotary Products Fadal o - er- m er ni.e mo el: o- rotary product to help automate your shop. In addition to the three rotary tableshmm here 'Se also o -er the\ 1-I -651 \\ hich has two tables that work in tandem, and dual-hh axis rotan for the pallec changer. The 5C. \ 1-I-65 and VH-65T are available in the servo indexer configuration. Servo controlled 4th & 5th axis Provides 360 rotation and 120 tilt TR-65 4'"/5'" Tilt Rotary Hydraulic braking for both axes to insure stability during heavy cuts Small overall footprint with large 6.5" fa ceplate Load capacity up to 110 lbs. Glass scale feedback on B axis for greater accuracy Servo controlled 4th axis Fast 90:1 ratio yields a maximum rotational speed of 22.2 RPM Indexing accuracy to 25 seconds provides high precision positioning A-axis brake is standard providing 300ft. lbs. of brake force Pallet changer compatible VH-65 4'" Axis Rotary Table Full bearing spindle allows greater machining load Air collet and brake are standard Adjustable collet draw force from lbs. 4'" Axis Rotary Head Oil bath lubrication Fast 90:1 ratio yields a maximum rotational speed of 22.2 RPM

12 World Class Motion/ Fadal CNC Overview Parallel processing promotes machine performance by using up to nine microprocessors working simultaneously to achieve precise servo control. Our control is able to move 128 bits of information at one point in time. This is equivalent to four 32 bit processors. User Friendly BBHS Menu prompting displays all the machine functions in English, eliminating the need to remember tedious keystrokes. This powerful and easy to use feature steps you through the entire setup process from start to finish. Setup Utilities allow quick and easy part setup by automating the many steps you would normally take to establish offsets. Program Verification A graphic representation of the machining operation is displayed on the screen before the machine is actually run. This helps detect geometry errors or other programming mistakes prior to machining the part. Zoom in/out allows you to focus on any specific detail. Each move can be displayed, as well as absolute position and modal G codes. Quick Keys Functions Menu Comprehensive geometric and trigonometric functions are provided to program the part profile at the machine. Whether you need to blend a radius between two circles, find a parallel line, establish tangents, or create a circle using three known points, it is all here.!!1 1 Program Verification IIIIGl[ I llll!ii!h1 RS (T!OI! L - X!!I 1/ltiWI1 g!iij]0111\11111s u CIIKL C)<() :0: 0!!I TRlAt«;l[ I 1111ilCIIll 111 FIX DC\Cl S OR OR D IJ1DQfi'IIOOII\ll SIJ!!IIWl!N 5 S l C1 OPl!OH OR PR ' 10 R!ll/Rl! 10 ED!JOR( Functions Menu

13 Optional 32MP with Fadal Visualizer The 32MP provides a shop floor PC interface to our CNC 88HS control. It is equipped with a 486 DX4 loomhz processor with 16Mb RAM, 546Mb hard drive, two 3.5" diskette drive, SVGA video card with 1Mb of memory and a color monitor. This PC has expansion slots allowing network and system upgrade capabilities. Bundled with the 32 MP Control, Facial VisualizerD 1 a unique CAM package allows the user to program from print to part with minimal training and documentation. Having a simple graphic interface means productivity, because the user can program parts quickly and easily. Tool List Tools required by the part program can be defined at any time, simply by selecting from a graphical list of tools and then entering flute length and shank size. There is an option button that allows the programmer to define more complex tools, such as endmills with shapes or undercuts, fly cutters, drills and many others. Tool List Geometry Creation All geometry is created vvith graphical icons using standard geometric shapes such as points, lines and circles. Predefined rectangles, squares (multi sided), slots and hole patterns are provided to enable rapid prototyping of these common shapes. Tool Path Geometry Solid Model Rendering With solid model rendering, the user can visually see their part cut on the screen in real time. This feature has detection for tool shank interference, tools rapiding through walls and non bottom cutting tools attempting to bore in with Z-axis. Any area that has tool interference is shown in red (not shown here). Solid Model Rendering

14 Facial Vertical Machining Centers are clearly the best in their class because of price, performance and an outstanding list of standard features. The VMC 15 and VMC 15XT come fully equipped with all these features: 15 HP'' Motor 7,500 RPM Spindle 1000 Blocks Per Second Unsurpassed Safety Standards UL Listed- Nationally Accepted CE Norm- European Safety Std. FANUC Compatible State of the art Multi processor Buss Architecture (6 computers) High Speed DNC-XModem Protocol Tool Life Management (Time Usage) Part Shape Geometric Functions Real Time Background Editing Fast and Easy Setup Utilities Feed Forward Servo Control 240 or 480 Volt Transformer Part Engraving and Serializing Graphic Part Verification High Gain Servo System Spindle Taper Air Blast Real Time Clock Timers 48 XYZAB Fixture Offsets Six Parallel Processors Menu Diagnostics 21 Tool Storage Program Rotation BASIC Macros And more!!,), lj.i./1~ IH: ~ ~ ~~ Iii - MADE IN USA '

15 ~-- VMC 15/15XT SPECIFICATIONS GENERAL Floor to table Surface Machine Width x Depth W x D XT Wx77 11 D Machine Height Machine Weight... 5,500 lbs. 101'' FULL TRAVEL HEIGHT TABLE Size x XT X T-Slots (No. x Width X Span)... 3 x.562 x Cutting Feed Rate (X/Y/Z) ipm Rapid Feed Rate ipm (X/Y/Z) Max. Weight on Table lbs. Longitudinal (X Axis) I XT / Cross (Y Axis) Vertical (Z Axis) Spindle Nose to Table Spindle Center to Column... 17" T ' r=~ 1 10" ~~~ 7 5"~- ~-- 90"!J TABLE SPECIFICATIONS VMC 15 (Left) & VMC 15XT (Right) +----~~ 26.0''~~-t I 34.5" ~ l " " -f 14.33" -f " J3.67" _I,}I ACCURACY -~~- 29.5" I 38.0" Positioning ±.0002 II (@ 68 F) Repeatability ±.0001 (@ 68o F) 11 SPINDLE Speed RPM Orientation Electro:Uechanical Taper No. 40 TOOLS ATC, Number of Tools A TC, Tool Selection.... Random/Bi-directional Max. Tool Diameter (w/o Adjacent Tools ) Max. Tool Length Max. Tool Weight lbs. MOTOR Main Motor HP''- WYE/DELTA Torque ft.-lbs.,,_ Axis Drive Motor (X/Y/Z)... 3,500 lbs.''- Thrust MISCELLANEOUS Air Pressure Requirement PSI 15 SCFM (Momentary) CNC Memory... 38K (277ft.) Standard OPTIONS: I II 10,000 RPM Spindle Automatic Hi/Lo.625" 2,000 RPM Rigid Tap High Speed Servo Turret --*.390" Remote Manual Pulse L ~~ j j Generator '~ Digitizing Package Servo Coolant Unit T-SLOT Coolant Thru Spindle Mist Coolant Extended Z Axis Travel Expanded Memory Levels: Automatic Doors 1) 422k (3061 ft.) 32 MP I Facial Visualizer 486 DOS Platform with 3 2) 4 Megabyte (29,000 ft.) available slots 3) 8 Megabyte (58,000 ft.) Ability to network 4) 16 Megabyte (116,000 ft.) 4th Axis Rotary Head In-Process Measurement Tool Breakage Detection Tool Load Compensation 120 Megabyte hard drive 8 Megabyte RAM Shop floor programming VGA Color Monitor Continuous equivalent A-weighted sound pressure at workstation is 77 db( A) or less during normal cutting operations. We reserve the right to change standard and optional accessories. '"Peak :- ''-Extended column add 8'' to height Plummer Street Chatsworth, CA / Printed in USA, September 1995