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World premiere of iQ300 at
EUROMOLD:
Smart solution for economical machining of miniature parts
Up to now, precision micro machining centres have mainly been built by re-search institutes and some machine tool makers with little thought to pro-duction costs. To meet the growing demand for a machine that can produce very fine part geometries with superb accuracy at acceptable cost levels, Ma-kino has launched its iQ300 Precision Machining Centre at EUROMOLD in Frank-furt, Germany from December 2nd 5th. This innovative new machine is on view to the trade public for the first time at this exhibition.
iQ by name, iQ by performance:
this new precision micromachining centre from Makino is the smart
response to the ever-greater miniaturisation and more complex
functionality seen, for example, in mobile phones, other portable
digital devices, medical equipment and optical products. The iQ300
delivers precision micromachining with the required accuracy at
practical cutting feed rates something that has been difficult
to accomplish with con-ventional vertical machining centres.
Roundness accuracy to within 0.65 µm has actually
been measured for a micromachin-ing toolpath radius of 0.1 mm
executed at a cutting feed of 100 mm/min. At high cutting feeds
of 2,000 mm/min in circular machining (50 mm hole) roundness
accuracy was measured to within 0.6 µm with a toolpath radius
of 28 mm.
The feed axis mechanism features ultra-precision rolling
guideways and linear drive motors. This combination ensures fast
responsiveness and a smooth feed action similar to that of sliding
guideways. The lubrication supply system has been designed to
accommo-date machining programmes involving long hours of repeated
tiny feeds. The XYZ axes all feature linear motors that are optimally
positioned to ensure that their push/pull effect does not affect
the rolling guideway straightness. The iQ300 is equipped with
a 0.005 µm scale feedback system. The feed mechanism provides
excellent responsiveness, moving faith-fully to command increments
of just 0.1 µm, and minimises tiny undulations to deliver
high-quality machined surfaces. The lines that occur in a machined
surface at the time of quad-rant reversal and the striped patterns
due to fine undulations are suppressed to a level that cannot
be discerned by the human eye.
The iQ300 is fitted with a newly developed 45,000 min-1 spindle,
based on the highly reliable V Series spindle of which 6,500 have
been installed around the world since 1996. The top spindle speed
has been increased by a further 5,000 min-1 and the HSK-E32 spin-dle
taper hole adopted. The cooling efficiency of the spindle motor
and bearings has also been improved to reduce spindle dynamic
run-out in high-speed operations. This improve-ment helps to bring
out the full performance of micro tools with increasingly small
diame-ters and contributes to a longer tool life.
The iQ300 follows Makino philosophy in machining centres, where
the first priority is to have a stable, rigid and accurate mechanical
structure. Even with its compact dimen-sions, the machine
weighs over 8,000 kg. Though all movable parts are light in weight,
they are supported by a strong, heavy structure.
Thermal stability is important in ensuring precision machining
over long periods. The iQ300 comes with a number of thermal stability
features: cast-iron machine construction optimally designed on
the basis of structural and thermal analyses; spindle core cooling
and under race lubrication system; double jacket cooling system
for the linear motor drive mechanism; coolant temperature controller
(optional); bed and Column Stabiliser (optional); and Makino Thermal
Chamber (optional).
Level differences between areas machined with different micro
tools are a big headache in micromachining. A standard feature
of the iQ300, the hybrid automatic tool length measuring device,
accurately measures and corrects the tool tip position and that
of the rotating spindle nose. This reduces level differences to
an absolute minimum so that the machined surfaces are of outstanding
quality and position, even with micro tools.
The table measures 600
mm x 400 mm in relation to XY-axis travels of 400 mm x 350 mm.
This practical size is conducive to the machining of multiple
same-shape items and the use of automatic chucks and precision
vices.
Last but far from least, the intelligence of the iQ300 is demonstrated
in its ease of opera-tion. A lighter door makes for easier
opening and closing an important factor in precision micromachining
where the machining chamber door is opened and closed more frequently
to check the machining condition. Large transparent polycarbonate
windows provide im-proved visibility inside the machining chamber,
even when the door is closed.
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