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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

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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.

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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.

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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

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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

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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 7BXwww.dugard.comsales@dugard.com01273 732286

MachineTools

2017 -

V1

Certificate Number 14739ISO 9001 : 2015