Enst+t EWsOENG'NES OF PRODUCTION

ENSHU (USA) Gorporation1380 Hamilton Parkway

Itasca, lL 60143(630) 773-6805

(630) 773-6827 Faxwww.enshuusa.com

The Enshu EV650 is a heavy frame, severe-duty vertical machin-ing center. Specially designed box ways on all axes together witha high-torque, dual range CAT #50 taper spindle are more than amatch for tough aerospace alloys or hardened tool steels com-mon in the die and mold industry. In fact, given its technologicaland engineering advancements, there are few machines in theworld as capable in hard materials as the EV65O; it is truly in aclass by itself.

. Severe-duty vertical maching center.o Fixed column design.. Four-way bed. Hardended and gound box ways throughout.. Integral dual-range spindle motor.. 20-hp peak, attained at just 300 rpm.. CAT #50 taper.. Choice of 6,000 rpm or 10,000 rpm spindle speed range.. Ceramic spindle bearings.. 30 tool ATC (40 tool optional) changes tools in 2.5 seconds.. Choice of two sizes:"4" - 41.3" x 25.6" x 26.0" travels"C' - 63.0" x 25.6" x 26.0" travels. Choice of Fanuc or Yasnac CNC

Ensru EV650

A masrlue tock-rolid machine.Precision bedded in iron.

The Enshu EV650 is a state-ofthe-art metalcutting machine tool. As advanced as it is, however,Enshu engineers could find no substitute betterfitted to handling super hard materials than micro-grained cast iron for the major bed and columnelements. And, they used a lot of it: 11.3 tons of it,to be precise.

Starting with the highest levels of finite elementanalysis (FEA) techniques, Enshu engineersdeveloped these primary structures with super-heavy ribbing and deflection absorbing geometry.Any vibration is transferred through the heavyribbing into the base where it is completely absorbed.The components were modeled using a 300% servoload for stiffness and again beefed up until less than1pm (0.000040") of deflection was achieved.

Equal scrutiny was given to thermal stability,essential to high accuracy and repeatability, and amajor concern during high machining loads that canliterally "pou/' hot chips onto the machining tableand into the bed. Countering this, of course, are theheavy castings themselves that dissipate the heat,

but Enshu engineersfurther designed a workarea that sheds chipsand coolant to a unique"double trough" systemwhich isolates chipsfrom the main bedcasting prior to rapiddischarge via an auger-type chip conveyor.

This attention to themetal cutting platformitself enables the EV650to easily handle high-temperature refractoryalloys, 57 Rc "D2" diesteel, titanium, and even

armor-grade aluminum. And while these severeapplications are common to the aerospace anddieimold industries, the EV650 performancecapabilities provide an incredible bonus whenmachining more conventional materials.

The high-performancemotion system: an elephantthat moves like a cat.

The design target of the EV650 project was amachine that can position loads of up to 3,300 lbs inall axes at speeds to 787 ipm within 0.0002", delivercutting feed rates to 394 ipm, and consistentrepeatabilities of r0.00006".

These reouirements demanded a motionsystem based on box ways, but even these requiredspecial engineering. The oversize box ways of theEV650 are integrally cast and induction hardened.To support the heavy work loads and high machin-ing stresses, the X axis travels on a pair of waysspaced at full table width, while the Y axis is basedon double ways (four) to minimize overhang. Thisheavy duty way design is carried forward by widelyspaced Z-axis box ways complimented by a ruggedsoindle carrier.

A novel airloil compensation system on theX and Y axes maximizes way contact area whileminimizing friction and virtually eliminating "stick-

slip." This unique and highly responsive designcombines air bearings with metered-flow waylubrication. A thin layer of injected air "floats" thetable, while way lubrication flows through a patternof channels to damper pots in the mating surface.This approach ensures a uniform oil film by displac-ing any build up that could occur during dynamictable moves.

Machine moves are powered by 3.9 hp digitalseruo motors equipped with absolute positionencoders teamed with control software for a state-of{he art positioning system that "remembers" workpiece origin position and part program location,even when power is turned off. This provides twosignificant advantages: it eliminates operator acci-dents related to restarting the machine while elimi-nating the maintenance and troublesome adjust-ment of stroke-end limit and/or proximity switches.

The drives are directly coupled to doublepretensioned ball screws, fully supported at bothends and "stretched" a few ten-thousandths of aninch when cold to cancel out the ball screw growththat typically might occur under heavy work load.In the event of a major accident, the large 1.969"ball screws are protected by flexible slip clutchesthat release at a Dreset torque.

Ersnt EV650

A highly elftcientmetal cutting platfolm.

As precise as the EV650 is, it must also be aprofitable piece of equipment, and that means speed.In the cut. And between cuts.

The heart of the EV650 is its exceptional spindlepackage, a powerful 20 hp "wide response" integral driveunit that delivers up to 6,000 rpm, accelerating to thatspeed in just 3.4 seconds. With dual windings that areelectronically switched to the ideal motor characteristicsfor the selected rpm, the machine will provide a full 20 hpat 300 rpm for ferrous roughing, and continue this level ofpower all the way to 4,500 rpm for heavy high-speedcutting in non-ferrous materials. With its impressively flatpower curve, the rugged EV650 spindle will deliver a full15 hp at 6,000 rpm, and 10 hp continuously, all day long.And that's "wide response" in anybody's book.

lmportantly, Enshu engineers designed this high-performance spindle package to be virtually maintenancefree. The multiple sets of oversize 4.3" ceramic bearings,20!" more rigid than steel, are permanently sealed andlubricated. A chil ler unit delivers coolant around theintegral motor jacket, and air is used to cool the spindlebearings and the spindle shaft. This design approacheliminates thermal expansion, keeping the spindle preloadconstant. The resultant "steady state" spindle performanceassures reflective "mirror finish" capability in aluminum,consistently accurate Z-axis depth positioning, and rock-solid positioning for an entire shift, three-shifts per day.And, since cutting threads is so often required in hardenedmaterial work, the EV650 is equipped standard with a rigidtapping capability. Tapping cycles of up to 3,000 rpm canbe programmed, synchronized to one pitch per revolutionof the spindle. Simply mount the taps in solid, collet-typetool holders for quicker tapping cycles, better thread form,improved accuracy, superior depth control, and longer tooll ife. All while eliminating costly and inaccurate "floating"

tao drivers.The CAT #50 spindle taper permits the use of larger

cutters in higher metal removal rate situations with abso-lutely no fear of "belling out" at the nose. And at the nose,an air-curtain protects the bearings from chips and coolantcontamination.

Should the application require, Enshu can alsosupply the EV650 with a 10,000 rpm unitized spindle witha hybrid lubrication system and chiller unit to lubricate thespindle bearings and to cool the spindle shaft and motorjacket.

access-by-absolute address feature assures the shortestpath tool delivery. The ATC is virtually maintenancefree. The toolchanger accesses the magazine via an auto-matic door, completely segregating the tools from thework enclosure.

Tool-to-tool exchanges via the double-arm system are2.5 seconds, including spindle orientation. Chip-to-chippedormance is within 6.6 seconds. That's even moreimpressive when you take a look at the size of the toolsbeing handled: The double arm can hold and exchange apair of tools up to 4.9" in diameter x 15.7" long andweighing up to 33 lbs each. Even bigger tools, with dia-meters to 7.9", can be stored and exchanged whenadjacent magazine pockets are not used.

For even mone capabilffiEnshu can equip the EV650 with a broad range of

productive options from 256-psi through spindle coolant toa heavy-duty, chain-type automatic pallet changer (APC)capable of loads to 3,300 lbs per pallet. 01 for more com-plex pafis, the EV650 can be specified with a 4th-axisindex table or Sth axis tilVrotary table, both capable ofNC contouring.

An auger-style chip conveyor is standard. Optional isa high-rise, leaf-style chip conveyor for depositing the hugevolumes of chips to ss-gallon drums or other high-walledcontainers. For precise tool and/or work piece set up,Enshu can supply the EV650 witha magazine-based automatic toollength measurement that includesa broken tool detection system.And for the fullest range ofmeasurement requirements, theEV650 can be equipped withsystems from the broad family ofRenishaw@ Probing Solutions.

lmportantly, Enshu (USA)Corporation's highly skilled andexperienced applicationsengineers and technicians are there to get you startedthrough installation and training, and Enshu-trainedpersonnel are on hand to provide fast and dependableregional service. More specifically, Enshu (USA) can tailoran EV650 as a turn-key system, tooled, fixtured, andprogrammed to your most exacting requirement.

But no matter how you use the EV650, as an Enshu,it will continue to perform for years to come as the mostreliable machine in its class. Enshu designs its machinesfor maximum productive uptime, and proves out thosedesigns in its own Engine Division, as harsh anenvironment as exists anywhere. Machines in servicethere are constantly monitored, with the data transmittedback to machine engineering for "onthe-fly" upgrades.

There are few machines that receive this kind ofconsistent performance scrutiny. And there are fewmachines that can hold up to the kind of dependability builtinto every Enshu machine. Which means you'll be hoggingmetal for years to come on the EV650. Without fail.

The heavlr duU ATC.Every second the spindle is not in the work piece,

making chips, is simply not profitable time. So Enshuconcentrated on providing the EV650 with a tool changerthat would be fast, capable of handling large tools, provideproduction-proven reliability, and be easily loaded andserviced.

An absolute-position-encoder equipped servomotorpowers the side-mounted, 3o-tool magazine (40 toolsoptional). The ultra-smooth bi-directional rotation is devoidof the jerky moves that can set up vibration. The random-

EV650 Machine Specifications

EV650

Standard Equipment. 30 tool automatic tool changer. 1,050mm "X" axis travel - Type A

1,600mm "X" axis travel - Type C. Fourth axis prewire. Spindle air curtain. Spindle oil chil ler. Soindle load meter. Soindle flood coolant. Bed flush coolant system. Screw type chip augers. Manual pulse generator. Spindle speed, feedrate and rapid traverse overrides. Halogen work l ightr Three stage machine status stack light. Door interlock. One set "M" codes (one pair). Program memory: 23O-24O meters, depending upon controlr Helical interoolationo Inch/ metric switchable capabilityo Total enclosed splash guard with manually operated door. Automatic power breaker. Standard tools for machine. Leveling bolts and blocks

Options Available. 10,000 RPM spindleo Automatic pallet changer. 40 tool automatic tool changer. Coolant through spindle (256 psi). Lift up chip conveyor. Auto tool length measurement and tool breakage detectiono Custom macro "B" (Fanuc)o Part program storage - 320m, 640m or 1280m. Program restart. Tool length measurement. Tool life management. Tool offset addition - 64 to 1199 pairs, depending

uoon control. Work coordinate system - 48 to 300 pairs, depending

upon control. Coordinate system rotation

AXIS TBAVELSxaxistravel re

x 25.6"