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DUGARDMachine Tools That Create Solutions Since 1939
www.dugard.com [email protected] 01273 732286DUGARDMachineTools
Dugard X5-8005 Axis Gantry Type Machining Centre 5 Axis
DUGARD
A fusion of German technology and Taiwanese competitiveness
Dugard X5-800 A fusion of German technology and Taiwanese competitiveness5 Axis Gantry Type Machining CentreThe Dugard X5-800 uses Gantry Construction giving the best rigidity performance possible. The 18,000rpm Built-In Spindle gives superb concentricity and accuracy that is required for high-speed 5 Axis simultaneous machining. Five axis machining reduces set up times by eliminating sequential positioning and fixturing thereby saving on setting times and eliminating errors which can be caused by multiple set up methods. Heidenhain absolute encoders on X/Y/Z and Rotary axes (A&C) eliminate integration errors between conventional positioning methods and guarantee perfect accuracy that is required for true 5 axis machining in today’s modern industries. The Dugard X5-800 is used extensively in Aerospace, Automotive, Die & Mould, Medical, Energy and Shipbuilding Industries, and can fulfil all the criteria that those Industries demand.
DUGARD X5-800 5 Axis Vertical Machining Centre
1 2
Dugard X5-800Machine Features
Benefits for Customers
• Dual drive system with four linear guideway design on Y axis guarantee high-rigidity and high-precision machining.
• Dual linear guideways on Z axis driven by servo motor.• All five axes are equipped with absolute encoders as standard to ensure precise complex 5 axis
simultaneous machining.• Being driven by three Kessler direct drive torque motors the A and C axes give maximum power
transmission with excellent acceleration and deceleration performance whilst eliminating all the disadvantages of traditional worm and gear transmission systems which are vulnerable to backlash and mechanical wear.
• The Kessler built in spindle is equipped with intelligent protection functions and can achieve 198Nm torque.
• The second tool magazine (opt) is available on request. 32T + 32T this large capacity of dual tool magazines are compact in design and space saving. Driven by a servo motor, automatic tool changing is fast and precise.
• High torque built in spindle gives speeds up to 18,000 rpm.• The gantry structure of the machine features high rigidity giving the best cutting performance and
vibration reduction.• The control pendant with its swivel arm feature are ergonomically designed to assist the operator
during set up and monitoring the machines status during machining and component prove out.
• Suitable for most complex shapes and high precision parts or moulds machining.• Simplifying production processes and saving on fixturing costs.• No special cutting tools required.• Machining by a single pass instead of many small increments can improve the surface finish to give
better machining quality.• The combination of rigidity and superior spindle design gives superb cutting performance and
increases tool life, thus saving on tool costs.• Because of superior performance, fewer machines are required. This saves shop floor space and
simplifies the management of machines in your production.• Decreases machining costs and increases productivity.
3 4
DUGARD X5-800 5 Axis Vertical Machining Centre
Dugard X5-800 Dugard X5-800Machine Structure Spindle Designed with Intelligent Technology
-+
-Z
+Z
C
-+
A
+X
-X-Y
+Y
Spindle with intelligent protection function
Y axis dual driving system with four linear guideways
Absolute encoders as standard on 5 axis feed system
Dual tool magazines Large capacity 32T + 32T (opt)
Spacious working area free movement for 5 axis machining with large components
A/C axis torque motors
Topology Analysis & Finite Element Method (FEM)
Simulation uses topology analysis & FEM methods to calculate load displacements and stresses in the machine design during machining.
Axis arrangement ISO 841
German made Kessler built in spindle with torque overload protection, thermal growth compensation, anti-thermal expansion, vibration monitoring and anti-collision features. That, combined with 5 axis machining technology ensures high quality machining and continuous 5 axis operation.
Built-In Spindle Design
Power & Torque chart
Leakage monitoring
Minimum lubrication
Vibration sensor
Temperature compensation
Coated spindle nose
Special tool taper
Retaining clamping set
Control of surface contact
Temperature sensorPT-100
Integrated clamp Cooling jacket
0
10
20
30
40
50
60
70
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000
Pow
er [k
W]
Speed [rpm]0
50
100
150
200
250
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000
Torq
ue [N
m]
Speed [rpm]
S1 Star
S1 DeltaS6 40% Star
S6 40% Delta
S6 20% Star
S6 20% Delta
S6 max Star
S6 max Delta
• The rear support bearings are roller type, which allow any thermal growth to move away from the spindle nose, thus protecting the bearings from excessive axial load. The spindle nose has an efficient cooling system which minimizes thermal growth.
• The spindle bearings are FAG or NSK ceramic ball bearings with high rigidity and high precision.
• A temperature sensor is installed on the bearing housing for thermal compensation, monitoring and protecting the bearings.
• The temperature sensor effectively prevents motor overheating and protects against motor damage.
• The spindle has an air purge system to protect the bearings and internal components from damage by coolant ingress and any other contaminants.
• Optional vibration sensor and recorder can be provided to monitor the spindle operational status and wear conditions.
• 198Nm (S6 10%) high torque built-in spindle.
5 6
DUGARD X5-800 5 Axis Vertical Machining Centre
Dugard X5-800 Dugard X5-800Kessler High Precision Direct Drive Torque Motors on A/C Axis Kessler Rotary Table with High Torque and Heavy Load Capacity
Dual Drive Four Linear Guideway Design on Y Axis
Maximum workpiece dimensions
Work Range
Advantages of Direct Drive Torque Motor• The A axis is driven by two DD motors. The rotary table speed is up to 80rpm.
• With 3,500 Nm x 2 clamping force, 90° angle table clamping is rigid and stable.
• C axis is driven by one DD motor. The rotary speed is up to 100rpm to provide high efficiency machining, with a clamping force of 2,500 Nm.
• The rotary table disk is easy to change over. Allowing different designs of hole patterns or T-Slots. These can be manufactured and changed according to customer’s needs in their own factories.
• With flanges on both sides of A axis, accuracy and angular deviation can be adjusted at the customers site.
With 1300kg super high loading capacity, the rotary table is a one-piece design of rotating mandrel and a heavy duty 3-piece cross roller bearing, which provides high rigidity and reduces angular error giving an excellent part loading and machining capability. With Ø800mm diameter rotary table on X axis, 900mm and 650mm travels on Y and Z axes, the spacious working area gives free component movement for a complex multi-axis machining
Double driven four linear guideway design of the Y axis reduces vibration during high speed machining and increases machine rigidity prolonging ballscrew life. Dual Y axis linear scales on both sides of the machine ensures exact positioning under fluctuating temperatures. Absolute encoders are used on X/Y/Z and A/C axes for precise execution of complex part machining.
• Lower noise – with fewer mechanical parts, the motor maintenance is minimised and the service cost is reduced.
• High torque & low speed – strong cutting force and high drive rigidity.
• Excellent reliability and long lifetime – directly coupling results in no mechanical wear, such as gearbox, timing belts, speed reducers and worm gear drives.
• Rapid positioning and high positioning accuracy – the direct-drive permanent magnet synchronous servo motor gives faster positioning time. With direct coupling design, the errors from mechanical transmission can be reduced significantly, which guarantees high accuracy machining especially for the complex 5 axis applications.
Ø800mm (31.5”)
600m
m (2
3.6”
)510 (20.1”) 390
(15.4”)
Y travel 885 (34.8”)
Ø1100 (43.3”)
510 (20.1”) 390(15.4”)
Y travel 900 (35.4”)
Ø1100 (43.3”)
30°30°
390(15.4”)
510 (20.1”)
Y travel 900 (35.4”)
Ø1100(43.3”)Rotating
center
400(15.7”) 400(15.7”)X travel 800 (31.5”)
Z tra
vel 6
50(2
5.6”
)
Ø800 (31.5”)
600
(23.
6”)
150(
5.9”
)
Ø450 (17.7”)
45°
100
(3.9
”)
Rotatingcenter
120°
510 (20.1”) 390(15.4”)
Y travel 900 (35.4”)
Ø1100(43.3”)
Rotatingcenter
±360°
±120°
Ø800mm
7 8
DUGARD X5-800 5 Axis Vertical Machining Centre
Dugard X5-800 Dugard X5-800Dual Tool Magazines (opt) Dimensional Drawings
Applications
• The 2nd tool magazine (opt): 32T + 32T large storage capacity
• The flat type tool magazine is compact in design to maximise the utility of space available
• Driven by servo motors, the automatic tool changing system provides fast and precise tool changing
• Easy tool loading design• Max tool dia with adjacent tool: Ø75mm• Max tool dia without adjacent tool: Ø125mm• Max tool length: 350mm• Max tool weight: 7kg
The 2nd Tool Magazine (opt)The 2nd tool magazine is available as an option. The flat tool magazines are mounted at the rear of the machine, 32T plus 32T giving a large tool storage capacity that is required for the more complex five axis components.
5,420mm2,594mm3,450mm
700mm
3,82
0mm
Dugard X5-800 Description Specification
Heidenhain TNC640 control
Travel
X axis travel 800mm
Y axis travel + travel for tool change 900 + 150mm
Z axis travel 650mm
Spindle nose to table surface 100~750mm
Work table size (diameter) Ø800mm
Maximum workpiece dimensions Ø800 x H600mm
Maximum work table loading 1300kg
T slot (width x number) 14mm x 7
Feed RateRapid feed rate X / Y / Z 48 mmin
Cutting feed rate 15 m/min
Rotary Axis
A Axis
Rotation range ±120°
Rotation speed 80rpm
Rotation torque S1/max 1870Nm x 2/3,740Nm x 2
Rotation power S1/max 6.9kW x 2/15.7kW x 2
Holding torque 3500Nm x 2
C Axis
Rotation range 360°
Rotation speed 100rpm
Rotation torque S1/max 1870Nm / 3740Nm
Rotation power S1/max 6.9kW / 15.7kW
Holding torque 2500Nm
Spindle
Spindle type Built-in
Spindle speed 18,000rpm
Spindle taper HSK 63
Spindle motor power (S1/S6 40%) 25 / 35kW
Maximum spindle torque (S1 / S6 40%) 86 / 130Nm
Accuracy
X/Y/Z positioning (VDI3441) 0.008mm
X/Y/Z repeatability (VDI3441) 0.004mm
A/C axis positioning ±4 seconds
ATC & Tool Magazine
Tool magazine type Flat type tool magazine
Tool change mode Pick up type
Tool storage capacity 32 tools (64 / 120)
Maximum tool diameter with adjacent tool Ø75mm
Maximum tool diameter without adjacent tool Ø125mm
Maximum tool length 350mm
Maximum tool weight 7kg
General
Cutting fluid capacity 750 L
Air capacity 6kg/cm2
Power capacity 80KVA
Machine weight 20,000kg
Machine dimensions (L x W x H) 5600 x 2600 x 3600mm
9 10
DUGARD X5-800 5 Axis Vertical Machining Centre
Dugard X5-800 Dugard X5-800Optical Type Non Bar 5 Axis Machine Tool Dynamic Accuracy Measurement and Compensation System
Optional Accessories
Standard Accessories
Tool Length MeasurementSystem
Workpiece MeasurementSystem
Specification
This measurement technology includes measuring and compensating the static/dynamic backlash of the transmission and the rotary axes. The static backlash error of the transmission axis can be compensated within 1µm, and the rotary axis static backlash error can be compensated to within 0.001°, increasing the machining accuracy.
• Siemens 840D control with 19” LCD screen
• 15,000rpm direct drive spindle• 24,000rpm built-in spindle• 64 / 120 tools• Oil skimmer• Chain type chip conveyor
• Tool length measurement system
• Workpiece measurement system
• Transformer• Pneumatic / hydraulic unit for
rotary table fixture
• Heidenhain TNC640 control with 19” LCD screen
• 18,000rpm built-in spindle• Thermal growth spindle
protection sensor• Spindle oil cooling system• Spindle lubrication system• Spindle air purge system• Spindle air blast chip blower• Through spindle coolant• 32 tool magazine and ATC
system• Wash gun• Air gun• Chain type swarf conveyor on
Y axis• Coolant tank• Swarf conveyor• Fully enclosed splash guard• Air conditioner for electric
cabinet• LED work light• LED pilot lamp• RS232 interface• Absolute encoder for X/Y/Z
axis and A/C axis• Chip flushing system• Foundation levelling bolts and
pads• Tool box with tools• 3D anti collision function• Central correction function• CE conformity
The tool setting and tool monitoring system is specially suitable for 5 axis machine applications, which can perform reliable automatic wear control of tools, compensation of temperature drift of spindle and axes, runout control, tool tip control to enhance machining quality, prevent tool breakage, shorten tool setting time, decrease workpiece defect rate, minimise production cost and maximise productivity and profit.
The workpiece measurement system can precisely detect workpiece orientation. Also, the system can be applied for thermal compensation and perform contour measurement.
DUGARD75 Old Shoreham RoadHoveEast SussexBN3 [email protected] 732286
MachineTools
2017 -
V1
Certificate Number 14739ISO 9001 : 2015