Hwacheon Machine Tools has introduced two new machine centers for “heavy duty” tasks in energy production, as well as general machining activity. The machine builder offers several machines that suit the production demands of industrial sectors like oil-and-gas, aerospace, and die molds, and demonstrated these recently.
The Vesta 1050B vertical machining center is capable of heavy machining and pocket milling using Hwacheon’s Optima cutting feed optimization, Vortex pocketing, and HTLD tool load detection software.
The Vesta line is designed with wide, hand-scraped, four-box guide ways in the Y-axis and wide box ways in the X and Z-axes to maximize machine rigidity. A two-speed gear-driven spindle with integrated drive provides stable high-speed cutting and high torque values. All Hwacheon spindles are oil-cooled, including the gearbox, to minimize thermal displacement and promote long spindle life.
It is designed with a geared-headstock machining center and capable of heavy roughing cuts as well as fine finish machining. The builder calls it a “true universal” machine available with 40 or 50-taper 6,000 or 8,000-rpm spindles, the 1050B produces micron-accuracy in heavy-duty cuts.
The Vesta has a work surface measuring 1,150x600x600 mm. Its travel is 1,050 mm (41.34 in.) in the X-axis; 600 mm (23.62 in.) in the Y-axis; and 600 mm (23.62 in.) in the Z-axis. The table load capacity is 1,000 kg (2,205 lb.)
Users have a choice of 24- or 30-tool storage magazines with chip-to-chip tool change times of 5 sec. or less.
Control Software
The machines’ program software monitors variables related to work environment and machining conditions, and makes adjustments for quality and machining efficiency. It’s a software program developed specifically to improve thermal accuracy and machining performance.
Tool load detection (HTLD) software performs in real time, ensuring consistent and safe machining. Constantly monitoring tool load (e.g., every 8 msecs) to prevent tool failure ensures accuracy and performance.
Optima cutting-feed optimization software uses an adaptive control method to regulate the federate 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.
Thermal sensors mounted at various locations in the machine castings where thermal displacement is possible permit software monitoring and correction of detected thermal displacement.
Spindle displacement control is possible with standard Hwacheon software. As a spindle rotates at high speed, centrifugal forces and heat expand the spindle taper, causing errors in the Z-axis. This axial accuracy is vital to precision mating of die components.
In addition to a high precision cooled spindle, software can be used to monitor temperature constantly at several points within the spindle assembly, to predict thermal displacement. Then, the system can make necessary adjustments and effectively minimize thermal displacement, preventing Z-axis error due to taper expansion as the spindle rotates at high speed.
High Power, High Torque
Another new heavy-duty machining option from Hwacheon is its Hi-Tech 400 turning center, with a high power, high torque spindle drive that achieves 2,500 rpm (22/18.5 kW.) The tailstock has a quill diameter of 3.94 in., and a stroke of 120 mm (4.72 in.)
With turret indexing time of 0.35 sec. per position and rapid feed in X and Z of 20m/min, the Hi-Tech 400 adds speed to its heavy-duty cutting capability, making it a good choice for oil-and-gas component production, aerospace turning, and general machining work. Adding high-speed mill-turn or sub-spindle capability.
The Hi-Tech 400 has an integrated, rigid 45˚ slanting cast iron bed/frame to minimize heat distortion during heavy machining. The polished, wide guide surface and rigid bed design absorb vibration, supporting high precision during hard turning. All guide surfaces are hand-scraped and rectangular to assure rigidity and accuracy in prolonged operation.
This machine has a servomotor directly coupled to the shaft without a driveline, such as a gearbox or a belt, eliminating the backlash that may occur during a feed.
