Makino’s new DA500: The best of two worlds

One of the DA500’s most significant advances is its ability to combine milling and turning operations in a single machine. This eliminates the need for multiple set-ups – and the risk of associated errors – as well as reducing cycle times. This makes the DA500 ideal for a wide range of applications, including aerospace engine and semiconductor manufacturing.

High accuracy and speed

Following on from Makino’s successful DA300, the DA500 has also been designed with a symmetric structure to minimise thermal influence on the machine and maximise rigidity. At the same time, elements taken from Makino’s a1 series, like the slant column design, have reduced moving inertia and increased Z axis rigidity. The ring-type tool magazine with CAM ATC also enables the fastest possible tool changes, while Makino’s own Two Vision technology reduces the risk of operator set-up errors through visual checks on the tool and workpiece. 0.05 µm scales, a direct-drive motor and Makino’s Super GI 5 control technology ensure the best possible pitch accuracy and repeatability.
 
Working environments in the toughest production shops place immense demands on a spindle. For the DA500 Makino therefore designed a new 20,000 rpm spindle with 50% more torque, twice the power and just a third of the accelerating time of the D500 spindle. Coupled with an axis speed similar to the DA300 (60,000 mm/min), the DA500 spindle performs extremely well when using fast milling techniques with constant chip thickness. As a result, parts can be produced in very short cutting times with minimal non-cutting periods. Another key feature of the DA500 is the tried-and-tested shaft cooling method for the main spindle, which manages the heat generated when the table rotates at high speed. As a result, this spindle has no usage time limit in contrast to some competitors’ machines that are limited to 30 minutes. All in all, the agility and chip evacuation performance of this high-precision 5-axis vertical machine are as good as any quality 4-axis horizontal machines.
 

Customisable automation

In today’s production environments automation is a key factor for most producers. For the DA500 Makino has designed an automation set-up that can be customised at the customer’s factory to different configurations ranging from four pallets with a maximum workpiece size of 800 mm to eight pallets with a maximum workpiece size of 550 mm – or any combination in between. What’s more, the compact pallet magazine enables higher productivity from the same floor space, with the workpiece size limits the same in both the stand-alone and pallet magazine set-ups.
 
Specifically designed for long-term use, this automation set-up comes with additional coolant nozzles to clean the storage area, which reduces the amount of maintenance work needed and also makes it easier to carry out. One particularly useful feature is the Work Vision System, which has a camera on top of the work-setting station to scans the pallet and inform the operator if a workpiece is within the maximum size limits. The outcome of this non-stressful automation solution and the DA500’s long-term accuracy: stable production across multiple shifts.   
 

No-compromise turning

The secret of the DA500’s dual capability is that it has been engineered so as not to lose milling performance even in the turning specifications. The spindle support for turning tools has been uniquely placed to avoid damage to the front bearing but still maintain the machine’s rigidity. The table can rotate at up to 800 rpm at a high rigidity so the DA500 can cut materials such as stainless steel for semiconductor applications or the nickel alloys needed in manufacturing aerospace engines.
 
To see the new DA500 in action at AMB, you can visit Makino at Booth B11 in Hall 7.