The D500: New 5-axis for Complex, Demanding Parts

Makino’s newest addition to its family of 5-axis machining centers, the D500, is designed for speed, quality, and versatile part production.

“This machine combines the agility of a full 5-axis machining center with the accuracy inherent in every Makino,” says Bill Howard, Makino product manager. “Add Makino’s unmatched applications engineering to the mix, and this is a very powerful offering for any job shop.”

The work zone for the D500 is 500mm by 450mm. The X-, Y-, and Z-axes provide strokes up to 550mm, 1000mm, and 500 mm, respectively. Rotary table axes A and C provide rotational motion of +30 to -120 degrees on the A-axis and a full 360 degrees on the C-axis. The D500 is capable of rapid rates up to 50m per minute and is equipped with a 14,000rpm high-power spindle. Also available on the D500 are 20,000-rpm and 30,000-rpm spindles.

In addition to the D500, Makino offers 5-axis machining centers based on both a vertical machining center and horizontal machining platform, including specialty 5-axis machining centers designed to machine large aerospace structural components.

Direct-Drive Rotary Table

Makino utilizes three direct-drive (DD) motors for the D500’s 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 important, twist and torsion in the trunnion are eliminated to achieve superior dynamic accuracy. The ultrahigh-torque DD motors also provide superior acceleration characteristics that can slash cycle time of complex 5-axis simultaneous machining applications.

The D500 axis configuration is unique and provides added performance. The length of the trunnion assembly runs parallel to the X-axis motion only, making the trunnion assembly deflection-free during quick axis motion for greater accuracy than traditional 5-axis designs.

The machine features roller linear guides across all linear axes for extra rigidity. Y- and Z-axes are located above the work zone, and the X-axis is located in the bed side of the machine. Greater accuracy was achieved with independent axes, in which movement remains uninfluenced by the characteristics of combined axes.

Engineered for Accuracy

The architecture of the D500 is a “closed loop” design that increases overall stiffness and rigidity of the machine structure. This means all force-impacted points of the machine are in close proximity to its support structure. Simply put—a high stiffness, minimum overhang design.

This new 5-axis machine includes Makino’s Thermal Stabilizer system that includes core-cooled ball screws and heat insulation systems. This system allows for sustainable dynamic accuracy in unstable shop environments. Internal base coolant efficiently removes chips from the work zone, where they are evacuated from the machine by a lift-up chip conveyor.

Easy Control, Automation

The D500 incorporates control enhancements to improve 5-axis machining performance and operability. Tool Center Point (TCP) control allows programming based on the tool tip so that tool compensation features can be applied. Further TCP developments improve the cutter path to achieve greater surface quality. Dedicated, user-friendly screens simplify the user interface for 5-axis machining. Easy-to-apply functions are included to prevent interference between the spindle and trunnion during automatic operation.

The D500 provides convenient operator access to the work table for machine interaction and setup purposes, with a ceiling opening to allow easy crane access to the machine. The machine can be easily upgraded for automation. An automatic pallet changer can be added at any time, and can be integrated into Makino’s MMC2 pallet system that includes Makino a51 400mm horizontal machining centers.

For more information on the topics covered in this article, view these webinars: New 5-Axis Machining Solutions from Makino, Automated 5-Axis Machining