Precision Die-Mold Machining Center is……..unbelievable
Hwacheon Machinery America has introduced the newest member of its high-precision machining centers for die-mold applications. Hwacheon’s Sirius UL+ 3-axis vertical machining center (VMC) features a 20,000 RPM high-speed spindle and Hwacheon’s adaptive software suite.
“A number of useful options make mold-die machining more efficient with Sirius machines,” said a company spokesperson. “Equipped with integral motor spindles with jacket cooling, oil jet cooled bearings and rigid roller linear guide ways, the machines deliver stable performance over long cycles.”
The Sirius UL+ features a 1,200 mm (47.2”) x 600 (23.6”)work table with 800 kg (1,764 lb.) load capacity, XYZ strokes of 1,050 mm (41.3”) x 600 mm (23.6”) x 550 mm (21.6”) and rapid positioning of 40 m/min.(1,575 ipm) The 40-taper (BBT and HSK optional) tools are changed in 2.5 seconds.
“The bilateral gate structure effectively distributes the vibration, weight and heat throughout the entire frame,” said the spokesperson. “Finite element analysis methods help to minimize frame distortion, which may be caused by machining conditions or environment. The distance between the spindle and the body is designed short, so the machine stays stable after prolonged operation.”
The spindle is integrated with the motor to limit vibration, noise and power loss at high speed rotation. The cooled jets of oil are injected directly onto the spindle bearing for effective cooling, and the motor and the spindle assembly are jacket-cooled to limit the displacement caused by heat. To achieve greater precision, standard Hwacheon software (HSDC) monitors the spindle for possible thermal displacement and makes necessary adjustment in real time.
SIRIUS-UM provides enhanced feed performance using the Z-axis 6-block LM guide. The servo motor is coupled directly to the drive. According to the company, the tensile preload ball screws provide smooth operation while the roller linear guide allows for rapid feed and rigid performance.
Before final finish passes, Sirius machines can, with Hwacheon HFDC (Hwacheon frame displacement control system) software, dynamically compensate for any changes that may have occurred in machine kinematics due to temperature, vibration or changes in the tool itself.
Hwacheon moldmaking machine tools feature standard integrated software developed in conjunction with FANUC CNC for thermal displacement control and compensation. Software measures thermal conditions in the machine during the cycle and uses the information collected to dynamically verify and control accuracy. In this way, a Hwacheon machine can control the kinematics of the machines for contour machining, optimizing machine performance for roughing, semifinish and finish machining without employing a number of different programs.
Sirius machines include the following software:
HTLD: Tool Load Detection software provides real time measurement of tool load to help ensure consistent and safe machining. It constantly monitors tool damage and deterioration for prevention of complete tool failure causing workpiece damage. Such a system will measure tool load very frequently, such as every 8 msecs.
HECC: The Hwacheon high efficiency contour control system offers an easy to use programming interface system that provides a precise, custom contour control for the selected workpiece while supporting longer machine life and reduced process time, according to the company. Such software will offer different options for cutting speed and accuracy and for surface finish and geometry. A customizable display provides real time monitoring and easy access. This software may be used with existing NC systems and is compatible with G-code programming.
OPTIMA: A cutting feed optimization routine utilizes an adaptive control method to regulate the feedrate in real time to sustain a consistent cutting load while machining. As a result, cutting tools are less prone to damage and machining time is reduced. The system controls the feed velocity to maintain consistent cutting load. Features include a graphic display of tool load and feedrate, convenient operation using G-code programming, and a number of data sets for specific tool and process control.
Additionally, sensitive thermal sensors mounted at various locations in the machine castings where thermal displacement is possible permit software monitoring and correction of detected thermal displacement.
HSDC: Hwacheon spindle displacement control is also possible with software. As a spindle rotates at high speed centrifugal forces, heat expands the spindle taper, causing error in the Z-axis. This axis accuracy is vital to precision mating of die components. In addition to a high precision cooled spindle, software can be used to constantly monitor temperature at a number of points within the spindle assembly, predicting thermal displacement. The system can then make necessary adjustments and effectively minimize thermal displacement, preventing Z-axis error due to taper expansion as the spindle rotates at high speed.
Hwacheon is one of the leading Die Mold Machine manufactures in the World!
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