II. Ultrasonic machining center: MK-500-UA
The machine is marked by high precision and stability of processing, as well as the ability to significantly reduce vibration. The machine significantly reduces the roughness of the processed surface.
Low cutting force and, as a consequence, low cutting temperature make tool more durable, and the work piece does not heat up.
Comprehensive control of surface tension during processing effectively solves the problem of warping and deformation of the work piece.
Application area
Processing Application: The machine is mainly suitable for ultra-hard materials used in smartphones, such as zirconium ceramic, silicon carbide, silicon nitride, aluminum oxide, sapphire, liquid metal, tungsten alloy. The machine is also used for processing new materials such as monocrystalline silicon, porous composite materials and carbon fibers. The machine performs the following technological operations: rapid thinning, grooving, drilling, grinding and polishing.
Application industry:
aviation, aerospace, military industry, 3С-industry (computers, communications and consumer electronics), electrical goods, various equipment etc.
Features of ultrasonic processing
1. High processing precision, stable processing process and effective elimination of chatter.
2. Significantly reduce the roughness of the processed surface.
3. Low cutting force and low cutting temperature make tool more durable, and the work piece does not heat up.
4. The processed surface is in a state of stress, which effectively improves the fatigue strength, wear resistance and corrosion resistance of the work piece.
Design features
1. High rigidity and high precision design.
- The main structural castings are made of high-quality cast iron, which has a stable structure and ensures design reliability for many years.
- The castings are calculated and analyzed by finite element analysis method. Optimal structural strength and reinforcement ribs are matched to provide high mechanical rigidity.
- 3-axis linear guides withstand the load and allow quickly moving to ensure precise positioning.
- The frame is wide and solid, the column has a box-shaped structure, the machine saddle is widened and lengthened. The machine is designed for heavy-load capacity and has a solid structure to ensure heavy-load capacity during processing.
- The structure of the spindle head is reinforced with ribs. The contact length ratio between the spindle head and the column is appropriate to provide stable support for the spindle.
2. High rigidity and high speed feeding system.
- The three-axis stepping motor and precision ball screw gear are directly connected to the transmission through a high-rigidity coupling to enhance rigidity and improve precision.
- Z-axis brake motor maintains balance and sensitivity during fast movement and ensures precise processing.
- The three axes’ linear guides, which have high rigidity, low noise and low friction, allowing for fast movement. In addition, the Ballbar system allows to pre-set parameters to achieve the best positioning accuracy.
3. Stable and reliable Automatic Tool Changer (ATC).
- Fast, simple, reliable and long-life tool exchange device, providing smooth and reliable tool exchange.
- Unique tool changer’s design, advanced cam drive mechanism, and the ability to select tools at any position, which can be controlled by PLC software quickly.
- The tool changing mechanism has been tested by the supplier for millions of operations and has a high degree of reliability.
- Quick tool changer saves non-cutting time and improves production efficiency.
- Cam-driven tool magazine ensures high rigidity of rotation and heavy tools smooth operation.
4. Spindle drive
- Direct drive, high efficiency and no transmission loss as with belt drive.
- High-speed rigid tapping without drive backlash, high speed and extended tool life.
- Mechanical tool loosening structure.
- The outer diameter of the bearing has been increased to enhance rigidity and reduce the rotation speed of the needle roller.
- Use of precision bearings of consistent high quality.
6. Friendly human-machine operation interface.
- The control panel complies with safety regulations and is easy to operate.
- The fault alarm signal is displayed on the screen, making it easy to eliminate the fault.
- Embedded operation box design for easy operation.
- Touch buttons, graphics and text logos, easy to operate.
Standard configuration
Cutting liquid/gas cooling system
Quantitative lubrication system
Gas lubrication/filtration system (Airtac)
Chip removal device at the base of the machine
Full metal casing
LED work light/3-color warning light
Pneumatic gun
Level adjustment bolts and pads
Operating manual and electrical diagram/tool box
System manual/mechanical manual
Memory card CF (510A/510B/510E)
Optional configuration
Oil mist absorption device
Oil-water separator
Four axis device (negotiate)
Automatic door (pneumatic)
BT30-16T/21 Slant disk type tool magazine with a servo drive (excluding 510E)
BT30-16T/21 Slant disk type tool magazine (excluding 510E)
Electromagnetic safety door lock
CNC system
Clamping kit (510A/510B/510E)
Tool mount instrument (Renishaw / Medron)
Work piece measuring instrument (Renishaw)
Tool trolley
Water gun
Standard configuration
Specification
Working table size (mm)
T-shaped slots (number x slot width x spacing) (mm)
Working table max. load (kg)
Stroke
X-axis stroke (mm)
Y-axis stroke (mm)
Z-axis stroke (mm)
Distance from spindle nose to table surface (mm)
Distance from spindle center to column (mm)
Linear Guides
Guides system
Linear guides width/number of guides/number of sliders (mm)
Speed
Cutting speed (mm / min)
Fast movement speed (mm / min)
Linear guides width/number of guides/number of sliders
Precision
Linear guides width/number of guides/number of sliders
Rated power (kw)
Positioning accuracy (mm)
3 axis servo motor
Motor
Spindle speed (rmp)
Spindle taper
Spindle
Repeatability of positioning accuracy (mm)
Spindle motor
Rated torque (n•m)
Rated power (kw)
Rated torque (n m)
Ballscrew
Ball screw diameter/pitch (mm)
Tool specification
Tool change method
Tool magazine capacity (T)
Max. tool diameter (mm)
Max. tool length (mm)
Max. tool weight (kg)
Tool change time (S)
Other
Power requirements
Required air pressure (kg/cm²)
Machine net weight (kg)
Machine size (L×W×H) (mm)
MK-500-UA
1,400×500
14 × 100 × 3
250
510
400
350
100~450
450
X/Y: ball guides Z: roller guides
X/Y/Z: 25/2/4
1~10,000
60,000/60,000/48,000
X/Y/Z: 0.01
X/Y/Z:0.006
BT30
20,000 (direct coupling)
αiI2/20,000
2.2/3.7
7
X:αiS 8/4,000, Y:αiS 8/4,000, Z: αiS 12/4,000
X:2.5, Y:2.5, Z:2.7
X:8, Y:8, Z:12
X: Ø32/16 / Y: Ø32/16 / Z: Ø32/16
ВТ-30
Two-way tool selection
16
Ø 60 / Ø 80
200
3
2.1
3Ф380V, 50HZ, 12KVA
6.5
2800
1840*2290*2645