MAKINO a61

a61 HORIZONTAL MACHINING CENTER SPECIFICATIONS

a61 Specifications Effective January 2 2006 s/n133+ Rev 7

GENERAL SPECIFICATIONS Machine Metric Inch Pallet Size (Metric Type)........................................................... 500 mm x 500 mm 19.7" x 19.7" Axis Travel X, Column Longitudinal........................................ 730 mm 28.7" Axis Travel Y, Spindle Vertical ................................................ 650 mm 25.6" Axis Travel Z, Table Cross ...................................................... 730 mm 28.7" Spindle Center to Top of Pallet ................................................. 80 - 730mm 3.1"- 28.7" Spindle Nose to Center of Pallet................................................ 70 - 800mm 2.75"- 31.5" Spindle Drive Motor (Continuous)............................................ 18.5 kW AC 25 HP AC Spindle Speed ...................................................................... 50 to 12,000 RPM Floor Space (L x W) w/o Accessories ....................................... 2,600 mm x 4,602 mm 102" x 182" ................................................................... (does not include Spindle Temperature Controller) Weight with ATC 60 ................................................................. 9700 kg 21,400 lb. Workzone Limitations ............................................................... 800 mm dia. x 1000 mm ht. 31.5" x 39.4" Bed Construction .............................................................................. One Piece Meehanite Casting Three (3) point support Number of Guides X, Y & Z-axes............................................. 2 Size of Guides X, Y & Z-axes................................................... #55 Table (Z-Axis) Time to full rapid ...................................................................... 192 msec Distance to full rapid ................................................................. 80 mm 3.1" Rapid Traverse ...................................................................... 50 m/min. 1,968 ipm Feed Rate ...................................................................... 50 m/min. 1,968 ipm Thrust Capacity ...................................................................... 2554 kg 5,619 lb. Type of Drive ...................................................................... AC Digital Servo Motor Ball Screw Diameter.................................................................. #50 Ball Screw thermal .................................................................... core cooled and pre-tensioned Axis Motor ...................................................................... 7.0 kW (alpha series) 9 HP Spindle Head (Y-Axis) Time to full rapid ...................................................................... 184 msec Distance to full rapid ................................................................. 77 mm 3.0" Rapid Traverse ...................................................................... 50 m/min. 1,968 ipm Feedrate ...................................................................... 50 m/min. 1,968 ipm Thrust Capacity ...................................................................... 1413 kg 3,109 lb. Type of Drive ...................................................................... AC Digital Servo Motor Ball Screw Diameter.................................................................. #45 Ball Screw thermal .................................................................... core cooled and pre-tensioned Axis Motor ...................................................................... 4.0 kW (alpha series)

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Traveling Column (X-Axis) Time to full rapid ...................................................................... 216 msec Distance to full rapid ................................................................. 90 mm 3.54" Rapid Traverse ...................................................................... 50 m/min. 1,968 ipm Feedrate ...................................................................... 50 m/min. 1,968 ipm Thrust Capacity ...................................................................... 1550 kg 3,410 lb. Type of Drive ...................................................................... AC Digital Servo Motor Ball Screw Diameter.................................................................. #45 Ball Screw thermal .................................................................... core cooled and pre-tensioned Construction ...................................................................... One Piece Meehanite Casting Axis Motor ...................................................................... 4.0 kW (alpha series) 5.4 HP Accuracies (with proper environment control): Positioning (Full Travel): X-Y-Z: Standard......................................................... ± 0.0025mm ± 0.000100 " With Scales (opt.) ........................................................ ± 0.0020 mm ± 0.000080 " Repeatability: X-Y-Z: Standard......................................................... ± 0.0015 mm ± 0.000060 " With Scales (opt.) ........................................................ ± 0.0010 mm ± 0.000040 " Optional Specification Die/Mold Package: Developed for high performance machining of 3D surfaces to achieve superior finish, contour accuracy, and reduction in cycle time. (includes: “S-class” geometries, high response feed axis, SGI.4) Ultra Precision Machining Package: Developed to achieve superior accuracy for 2D, ultra precision applications such as mold base machining. (includes: “S-class” geometries, high response feed axis, Moire scale feedback 0.01 micron, SGI.4) Inquire separately for detailed specifications 360º Index Pallet Table Workpiece Positioning on Pallet ............................................... 24 - M16 Tapped holes and 2 precision edge locators Center Hole ...................................................................... 50 mm 1.97" Pallet/Table Positioning Range ................................................. 360 positions, bi-directional Programming Increment ............................................................ 1 degree Positioning Time (500 kg payload) ........................................... 90°/180° 1.6/2.1 sec Positioning Time (700 kg payload) ........................................... 90°/180° 1.7/2.2 sec Pallet Indexing Accuracy .......................................................... ± 2.0 arc seconds Table Indexing Repeatability..................................................... ± 1.0 arc seconds Pallet to index table Clamp Force.............................................. 94.1 kN 21,160 lbs. NC Rotary Table (Option) Pallet/Table positioning range ................................................... 360,000 positions, bi-directional Programming Increment ............................................................ .0001 degree NC Rotary Positioning Time (500kg payload).......................... 90°/180° 1.2/1.65 sec Positioning Time (700 kg payload) ........................................... 90°/180° 1.25/1.7 sec Pallet Indexing Accuracy .......................................................... ± 3.0 arc seconds Table Indexing Repeatability..................................................... ± 2.0 arc seconds NCRT clamp torque .................................................................. 4432 Nm 3261 ft. lb.

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Automatic Pallet Changer (APC) Pallet Change Time (500kg payload) ........................................ 8.5 seconds Pallet Change Time (700kg payload) ........................................ 10 seconds Pallet Clamp Confirmation – for process error checking .......... 2 seconds (Total APC time = 10.5 / 12 seconds) Pallet to pallet Repeatability after Pallet Change ...................... ± 0.002 mm ± 0.00008" Pallet compatibility (pallet master concept) .............................. .005mm 0.0002" Distance Floor to Pallet Top...................................................... 1,200 mm 47.20" Pallet Load Capacity.................................................................. 500/700 kg option 1100/1540 lbs. Pallet handling options: ............................................................. 8-Pallet Magazine High Power Spindle (Standard) Spindle Nose ...................................................................... No. 40 Taper (HSK63A optional) Tooling ...................................................................... CAT V-flange (HSK63A optional) Tool Clamp Force (mechanical) ................................................ 9.8 kN (No. 40 taper) 2,200 lb. Tool Clamp Force – HSK63A................................................... 29.4kN 6,600 lb. Spindle Speed Range................................................................. Two Range, 50-12,000 RPM Spindle Acceleration Time (50 to 12,000 rpm) ........................ 1.5 sec / 1.1 sec deceleration (50 to 6,000 rpm) .......................... .6 sec / .5 sec deceleration Spindle Orientation.................................................................... Electric Servo Control Drive Motor (5,000 ~ 10,000 rpm) 15 min ...................................................................... 22 kW AC 29.5 HP AC Continuous .................................................................. 18.5 kW AC 24.8 HP AC Torque Characteristics: 25% ED Rating (50 ~1,060 rpm).................................... 166 N⋅m 122.4 ft lb Continuous Rating (50 ~ 1,500 rpm) .............................. 95 N⋅m 70.1 ft lb Obtain Full HP: ...................................................................... 5,000 rpm Constant Torque Range .............................................................. 50 to 1,500 rpm Spindle Bearing Design: Front ............................................................................ Two (2) Angular Contact Bearings with Ceramic Balls Rear ............................................................................. Two (2) Angular Contact Bearings Steel Balls and Rings Bearing: Inner Diameter ............................................................ 85 mm 3.34" Outer Diameter............................................................ 130 mm 5.11" Spindle Temperature Control .................................................... Oil Air Lubrication with Jacket Cooling, Referenced

to Bed Rigid Tap ...................................................................... 3,000 RPM High Acceleration Spindle (Option) Nose Taper...................................................................................... 7/24 No. 40 Taper (HSK63A optional) Tool Shank Types .......................................................................... Cat 40 V-Flange (HSK63A Optional) Retention stud specification ........................................................... MAS403-P40T(MAS1) Tool Clamp Force (mechanical) ................................................ 9.8 kN (No. 40 taper) 2,200 lb. ...................................................................... 29.4 kN (HSK63A) 6,600 lb. Speed Range ...................................................................... Two Range, 50 to 12,000 RPM Spindle Acceleration Time (0 to 12,000 rpm)..................... 0.9 sec / .9 sec deceleration (0 to 6,000 rpm)....................... 0.4 sec / 0.4 sec deceleration Spindle Orientation.................................................................... Electric Servo Control Drive Motor (6,000 ~ 12,000 rpm) 10 min ...................................................................... 18.5 kW AC 25 HP AC 30 min ...................................................................... 15 kW AC 20 HP AC Continuous .................................................................. 11 kW AC 15 HP AC Torque Characteristics:

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25% ED Rating................................................................ 98 N⋅m 72 ft lb Continuous Rating........................................................... 42 N⋅m 31 ft lb Obtain Full Horsepower................................................................. 6,000 rpm Constant Torque Range.................................................................. 50 to 2,500 rpm Spindle Bearing Design: Front ................................................. Two (2) Angular Contact Bearings Steel Balls and Rings Rear ................................................... Two (2) Angular Contact Bearings Steel Balls and Rings Bearing: Inner Diameter ............................................................ 70 mm 2.76" Outer Diameter............................................................ 110 mm 4.33" Spindle Temperature Control .................................................... Oil Air Lubrication with Jacket Cooling, Referenced

to Bed Rigid Tapping ...................................................................... 4,000 rpm Optional High Speed 18k Spindle Spindle Nose ...................................................................... HSK63Aonly Tooling ...................................................................... HSK63A Tool Clamp Force (mechanical) ................................................ 29.4 kN (HSK63A) 6,600 lbs. Spindle Speed Range................................................................. Two Range, 50-18,000 RPM Spindle Acceleration Time (50 to 18,000 rpm) ........................ 3 sec / 2.4 sec deceleration Spindle Acceleration Time (50 to 9,000 rpm) .......................... 1.1 sec / 1.1 sec deceleration Spindle Orientation ...................................................... Electric Servo Control Drive Motor 15 min ...................................................................... 15 kW AC 20 HP AC Continuous .................................................................. 11 kW AC 15 HP AC Torque Characteristics: 25% ED Rating (50 ~2180 rpm)..................................... 66 N⋅m 48 ft⋅lbs Obtain Full 20 HP:......................................................................6,000 rpm Constant Torque Range .............................................................. 50 to 2,500 rpm Spindle Bearing Design: Front ................................................. Two (2) Angular Contact Bearings with Ceramic Balls Rear ................................................... Two (2) Angular Contact Bearings Steel Balls and Rings Bearing: Inner Diameter ............................................................ 70 mm 2.76" Outer Diameter............................................................ 110 mm 4.33" Spindle Temperature Control .................................................... Oil Air Lubrication with Jacket Cooling, Referenced

to Bed Rigid Tap ...................................................................... 4,000 RPM Optional Core Cooled 20k High Accuracy Spindle Spindle Nose ...................................................................... HSK63Aonly Tooling ...................................................................... HSK63A Tool Clamp Force (mechanical) ................................................ 29.4 kN (HSK63A) 6,600 lbs. Spindle Speed Range................................................................. Two Range, 50-20,000 RPM Spindle Orientation ...................................................... Electric Servo Control Spindle Acceleration Time (to 20,000 rpm) ............................. 2.8 sec / 2.4 sec deceleration Spindle Acceleration Time (to 10,000 rpm) ............................. 0.6 sec / 0.5 sec deceleration Drive Motor 10 min ...................................................................... 18.5 kW AC 25 HP AC Continuous .................................................................. 11 kW AC 15 HP AC Torque Characteristics: 25% ED Rating (50 ~2180 rpm)..................................... 66 N⋅m 48 ft⋅lbs Obtain Full 25 HP:......................................................................6,000 rpm Constant Torque Range .............................................................. 50 to 2,500 rpm Spindle Bearing Design: Front ............................................................................ Two (2) Angular Contact Bearings with Ceramic Balls Rear ............................................................................. Two (2) Angular Contact Bearings Steel Balls and Rings

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Bearing: Inner Diameter ............................................................ 70 mm 2.76" Outer Diameter............................................................ 110 mm 4.33" Spindle Temperature Control .................................................... Core Cooled/Under race lubrication, Referenced to

Bed Rigid Tap ...................................................................... 4,000 RPM Automatic Tool Changer Capacity: Standard.......................................................................... 40 Tools Optional ........................................................................... 60 (consult factory for larger ATC) Tool Change Time......................................................................0.9 seconds Chip-to-Chip Time (Std Spindle) ...............................................2.5 seconds (MAS Method) Maximum Tool Size Diameter Adjacent Pockets Empty.............. 170 mm 6.7" Maximum Tool Size Without Limitation ...................................... 70 mm 2.76" Maximum Tool Length .................................................................. 360 mm 14.2" Maximum Tool Length (HSK63A with 40/60 atc) ....................... 420 mm 16.5" Maximum Tool Weight (use med. Speed mode over 8kg) ........... 12 kg 26.4 lb. Maximum Tool Moment ................................................................ 11.76 N·m 8.7 ft lb Tool Preparation Time (Shortest/Longest) .................................... ATC60 4/7 seconds ..................................... ATC40 3.8/5.7 seconds Tool Selection Method ................................................................... Fixed Address Rack Type ATC for Large-Size Tools (Optional) Note: Requires HSK-A63 spindle and 60-Tool Magazine Tool Storage Capacity ............................................................... 3 Tools (2 long tools and 1 large diameter tool) Long Tool - Max tool diameter without limitation.......................... 100mm 3.9" Max tool length ........................................................... 560mm 22" Max tool weight .......................................................... 15kg 33 lbs. Large diameter tool – Max tool size ............................................................... 300x250x300mm (X x Y x Z) Max tool weight .......................................................... 30kg 66 lbs. Tool – to – Tool changing time ................................................ 20s (not including shutter motion) Chip and Coolant System Chip Discharge ...........................................................................Rear Discharge Center Trough.............................................................................Base Coolant Chip Collection...........................................................................Lift up conveyor & tank. Lift-up Conveyor Discharge Height ...........................................1,024 mm 40.3" Chip & Coolant Separation Method .......................................... Rotating Drum with permanent Media Mesh ..................................................................................... Continuous Back Flush Cleaning Rotating drum filtration ............................................................. 20 micron mesh (90% fine removal) Coolant Tank Capacity (total cap/effective cap): ...................... 800/400 l 211/106 gal. Through Spindle Coolant Pressure ............................................ 2.2 MPa 300 psi Flow Rate .................................................................... 30 l/min. 8 gal/min. Spindle Nozzles - Quantity........................................................ 8 Overhead Shower Nozzles - Quantity ....................................... 14 Base Coolant Wash Nozzles - Quantity .................................... 2

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Utility Requirements Air: Air Pressure..............................................................0.5 ~ 0.8 MPa 72 – 116 psi Volume (without Air Blow) .....................................410 l/min. 14.4 cfm (with Air Blow) ..........................................660 l/min. 23.3 cfm Electrical Specification: Volts 240 or 480 Phase 3 Cycle 60 kVA, Sum of All Equipment 50 minimum, 90 kVA with all available options Main Circuit Breaker 240V 225 Amps 480V 125 Amps Tank Capacities Hydraulic Tank ........................................................................... 26 Liters 6.9 gal. Spindle Cooling Oil........................................................................ 25 Liters 6.6 gal. Spindle Lubrication Oil .................................................................. 1 Liter .26 gal. Automatic Grease Supply Unit (Optional) Daikin ........................................................................... 1 Liter .26 gal. Trabon ........................................................................... 2 Liter .53 gal. Home Positions X-Axis ...................................................................... Center of Stroke Y & Z-Axis ...................................................................... Stroke (+) End B-Axis ...................................................................... Edge Locator Parallel to X

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Horse Power Curves: Optional: High Acceleration Spindle: Standard: High Power Spindle: Optional: High Speed 18k Spindle: •25/20 HP •Torque: 49 ft. lb •Rigid Tap: 4,000 RPM.

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Optional Core Cooled 20k Spindle:

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General View: Note: Prior to installation check for drawing updates

General View (40/60 ATC)

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Stroke Limitation (High Acceleration Spindle): Option

Stroke Limitation (High Torque Spindle): Standard

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Pallet Drawings: Standard

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Pallet Drawings: Option

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Tool Size Drawings:

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Spindle Head Dimensions:

High Acceleration Spindle High Power Spindle

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Operator Control Panel Located conveniently to the work area. This panel includes the following: FS310is Fanuc Series Control

· 12.1" color LCD · Touch screen function buttons · NC Power ON/OFF · Emergency Stop Push-button · NC Program Start/Stop · Mode Selector Switches · NC Function Switches · Coolant Control Switches · Machine Control Switch · Spindle Start/Stop · Spindle Tool Unclamp · Machine Monitoring Indicator · Over Travel Release Switch · Alarm Release Switch · Memory Protect Unlock Key Switch · Splash Guard Door Interlock Key Switch · Routine Function Switches · Jog Switch · Rotary Switch Manual Feedrate · Rotary Switch Rapid Feed Override · Rotary Switch Feedrate Override · Rotary Switch Spindle Speed Override · Main Control Panel Flexible Switch allows assignment of main control panel switches to the PC screen CONTROL SPECIFICATIONS - PROFESSIONAL 5 SYSTEM CNC Controlled Axes Simultaneous 3-axis positioning standard; Simultaneous 4-axis control optional; Programming Method Inch/metric selection (G20, G21) (5120A) (MM STD); Custom Marco Common Variables: 82 (5282C) (MM STD); Minimum increment: 0.0001 mm; 0.0001 in. Maximum programmable dimension: ±8 digits (±99999.999); Absolute/Incremental programming (G90/G91); Decimal point programming/Calculator type decimal point input; Automatic recognition of EIA/ISO code; Interpolation Positioning (G00); Linear interpolation (G01); Circular interpolation (G02, G03);

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Feeds Cutting feedrate; F-direct command; Dwell (G04); Rapid traverse override; Cutting feedrate override (0-200%); Feedrate override cancel (M49/M48); Part Program Storage & Editing Part program storage (1,050 feet, 320 m, 126 KB tape); Registerable programs (63); Background editing; Program number search; Sequence number search; Address, word search; Part program collation/comparison and stop; Cut, paste, and replace function Operation And Display 12.1" color LCD; Clock function; Manual data input (MDI); Machining Result Function Product Count Function I/O Devices PCMCIA Card; I/O interface ; Data Center Internal Memory: 4MB STM Functions S-function direct command (direct spindle programming); T-function; M-function; Tool Offsets Tool length offsets (99 total) (G43, G44/G49); Tool radius offset C (G41, G42/G40); Tool offset memory Type A; Coordinate Systems Coordinate Value Insert Function; Manual return to reference point; Automatic return to reference point (G28); Return to 2nd reference point (G30); Reference point return check (G27); Return from reference point (G29); Coordinate system setting (G92);

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Machine coordinate system setting (G53); Work coordinate system selection (G54-G59); Local coordinate system setting (G52); Operation Support Functions Label skip: Control in/out; Single block; Program stop (M00); Optional stop (M01); Optional block skip (/); Dry run; Machine lock; Z-axis feed cancel; Auxiliary function lock; Mirror image (M21, M22/M23); Manual absolute; Tool length measurement (manual); Data protection key; Follow-up; Help function; Programming Support Functions FS-15M format; Circular interpolation radius programming; Canned cycles (G73, G74, G76, G80 to G89); Rigid synchronous tapping (G84); Sub-programming (4 folds nested); Exact stop check (G09); Exact stop check mode (G61); Tapping mode (G63); Cutting mode (G64); Programming data input (G10) (offset value, parameter); Machine Error Compensation Stored pitch error compensation; Backlash compensation; Friction compensation control; Feed forward; Maintenance & Safety Emergency stop; Over travel; Stored stroke limit 1; Self-diagnostics; Interlock; Alarm history display (last 25 alarms); Low air pressure alarm; Low spindle lubricant level alarm;

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MPC Operation Specification Geometric Intelligence SM Control (GI.3); Spindle Load (SL) Upper Limit; Spindle Load (SL) Lower Limit; Tool Life Monitoring; Spindle Load Monitoring; Spare Tool Selection; Registered tool automatic selection and changing function; One touch ATC operation by push-button; All axes automatic return to reference point; Automatic return to work setting position; Self-diagnostics and instruction display; Number and position of limit switches and solenoids display for alarm; Automatic recover function for ATC-ARM standby position; Alarm history function; Automatic display for regular maintenance advice. Installation Environmental conditions for machine run-off at Makino are controlled to the following level: Temperature Warm 28+2°C 82.4+3.6°F Cool 18+2°C 64.4+3.6°F Fluctuation ≤1°C/30 min. ≤1.8°F/30 min. Humidity 65% or less Dust Not applicable Air Supply 72-115 psi and 15.9 cfm (22.9 cfm with optional air blow) of DRY air supplied through a

minimum supply pipe of 3/4" diameter with no reducers or nozzles. NOTE: The base machine configuration, specifications and pricing may be changed without prior notice to

incorporate improvements resulting from ongoing R&D programs

The quoted accuracies are attained through proper application of environmental conditions, and suitable industrial floor for machine stability. This document is the confidential intellectual property of Makino Inc and must be surrendered upon demand.