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D500

Table of Contents

The most precise 5-axis machine in its segment

The most precise 5-axis machine in its segment
The D500 provides an ideal blend of precision, rigidity and performance for complex, multi-axis workpieces in a small machine footprint. A machine that has been highly successful in delivering the utmost precision in die and mould applications as well as on ultra-high-performing aerospace engine components where materials such as Inconel are machined with ease.

Whenever 5-axis machining is required for a complex, high-precision component, the D500 gives manufacturers the competitive advantage they need.



 

Rigid, precise: Precisely!

Rigid, precise: Precisely!

The architecture of the D500 is a 'closed loop' design that increases the overall stiffness and rigidity of the machine structure. This means that all the force-impacted points of the machine are close to its support structure. The oversized linear guides, preload on the ball screw and symmetrical design of the system absorb and distribute the forces around the machine structure.

The rigidity of the complete assembly allows you to:

  • Machine difficult-to-cut materials, such as steels with over 60 HRc or titanium or Inconel materials
  • Achieve high accuracy on complicate shapes
  • Utilise high jerk values to minimise acceleration times

Direct-drive motors on the rotary axes

Direct-drive motors on the rotary axes
The machine utilises three direct-drive (DD) motors for the C-axis rotary table and the A-axis trunnion. One direct-drive motor controls the C-axis motion. Two direct-drive motors control motion in the A-axis, one at each end of the trunnion. The dual-motor design provides greater torque and rigidity. Most importantly, twist and torsion in the trunnion are eliminated to achieve superior dynamic accuracy. The ultra-high torque DD motors also provide superior acceleration characteristics that can slash the cycle time of complex 5-axis simultaneous machining applications by up to 60%.

Accuracy management

Accuracy management
Heat is the enemy of precision. That's why the D500 features a set of technologies dedicated to killing heat at source:
  • Core cooled ball screws
  • Cooling of all direct-drive motors 
  • Symmetrical design to minimise the thermal effect
  • Cooled motor flange and bearing supports
  • Cooling of the spindle (jacket cooling, core cooling and under-race lubrication)

In addition to all these technologies, the thermal guard helps mitigate thermal variations on the working area in harsh operations or environments by providing an additional layer of protection to the machine to isolate it from the exterior.

These technologies enable sustainable dynamic accuracy in unstable shop environments.

 

Intelligent functionality

With Makino’s latest Professional 6 (PRO 6) controller, the D500 is equipped with several intelligent functions to increase the machine’s productivity. The controller was developed to meet customer needs for enhanced machining processes through improved safety, ease of operation, reliability and productivity.
 
It achieves these goals by reducing the collision risk, streamlining and facilitating operability, incorporating many previously optional functions as standard features, and bettering machine performance. The controller has been designed for easy, intuitive operation via simplified menus and smartphone-like icons.
 
The new advanced motion control Geometric Intelligence (GI) functions reduce overall cycle time, especially in typical production components. GI Drilling enables the spindle and tool to arc from hole to hole instead of following a square path. This reduces non-cutting times in comparison with common hole-pattern drilling. On the other hand, GI Milling is designed to improve performance in 2-D milling. It lets the user define a corner-rounding tolerance on each milling path.
 
Other intelligent machine functions include Inertia Active Control (IAC), which is designed to further speed up machine motions based upon dynamic system attributes. The IAC gets feedback from the servomotors and sets the acceleration and deceleration of the specific pallet at the optimum level.
 
 
 

The heart of the machine: Makino spindle technology

The heart of the machine: Makino spindle technology
A machine tool is as good as the parts it can produce. But manufacturers’ requirements vary tremendously in the different markets. A die maker’s needs are totally different from an aerospace producer’s but even so, structure and design can be shared. There is, however, one component that cannot be the same – the spindle.

That's why we have different type of spindles for different type of applications:
  • 14,000 rpm standard high-torque spindle (HSK-A63):
    • The all-rounder: Its level of torque lets you cut difficult-to-cut materials such as titanium, stainless steel and casting.
  • 20,000 rpm optional spindle (HSK-A63) for applications where the speed of the spindle plays a major role:
    • Cutting with ceramic tools for materials such as Inconel 718 
    • Cutting complex shapes where small tools are needed, such as blisk components for the aeroengine industry
    • Plastic moulds: 20,000 rpm lets you rough and finish in the same spindle – a very versatile spindle for the die and mould industry
  • 30,000 rpm optional spindle (HSK-F63):
    • The ultimate finishing spindle

Ready for automation

Ready for automation

In today's production, automation is no longer an option. It's a must. And D500 has always been the perfect machine for this. The first thing we need to understand is that to automate, we need to have a high repeatability on the machine, otherwise the produced parts will vary in quality. The second thing is that the machine has to be equipped for it.


The D500 can be equipped with:

  • A large door at the rear for the robot.
  • The chip conveyour, in case of automation, is usually placed at the front to make more room for the robot on the back.
  • The machine can be equipped with a standard pallet to be able to automate with other palletised machines, although using zero point systems is not a problem either!
  • The interface to the robot is not a problem, whether we want the D500 to be the master (it controls the robot) or the slave (the robot controls it).

 

 

The second thing is to understand the production type. There are automations for all kind of situations from a low-mix high-volume type to a high-mix low volume production. The good news are that our sales consultants can help you decide which automation better fits your production.

 

What automation can we install?

  • Makino automation
    • MMC2 - Flexible pallet automation system
    • VIP - Workholding pallet automation
  • Erowa
    • Robot Easy
    • Robot Dynamic
  • Cellro
  • ...

 

Specifications

Axes
A axis 150° (+30 to -120)
C axis 360°
Spindle
Spindle RPM 14K, (20K, 30K opt) 
Feedrate
Rapid traverse 48,000 mm/min (X) 50,000 m/min (Y & Z)
Cutting feedrate 32,000 mm/min (X) 40,000 m/min (Y & Z)
Table
Maximum workpiece 650 mm x 500 mm height (conditional)
Maximum payload Table: 350 kg. , Pallet: 300 kg.
Automatic tool changer
ATC capacity 60 (80, 113,155,197,239,281,323 opt)
Tool to tool 4.2 sec
Maximum tool diameter 140 mm (conditional)
Maximum tool weight 8 kg