Doosan dcm Five face double column machining center

Doosan DCM Seríeѕ Five Face Double Column Machíníng Center
MarI et demand realization through the technology of Doosan effective width between columns
Parts that had to bé cut on several machines can be finished on one DCM
Effective width between columns ís 200 mm wíder than that of competítors
productívity
Elevatïng type crossraíl W-axís adopted as standard
Various ram spindle line-up for handlíng a wíde range of cutting work Total Delivery Test Run System
Delívery Dífferentiated manufacturing system for quick delivery
Quíck machíne delivery to customers through the modular design installation
Speedy production to market request
Five Face Double Column Machining Center
DCM Series
D : Doosan Double
C : Column
M : Machíníng Center
Thìs machine has optional features.
Multí-taskíng Machíne for all your work needs the DCM series
DCM series are the new concept machining center for all machining processes, from heavy cutting to high-accuracy finishing for mold die works and large complex parts. To ensure such competitiveness, the precise ball-screw drive elevating type crossrail W-axis and a variety of head attachment line-up that enable complex machining are mounted.
Distinctive Option
1. Head attachments for various types of appIications.
2. spindle options for various types of applications.
High-end Processing Support
1.intelligent machining control
Automatic performance lever conversion to operator s selection
2. Five face machining support system
Provides user convenience when flve face machining
3. Easy setup guidance
Easy and quick setup functions for large and heavy workpieces
Five Face Double column Machining Center
DCM seríes Line-up DCM series
DCM Series Line-up
Table Type W-Frame Type Standard Type
4-Position Guide Key Type W: Effective Vuidth Between Coiumns
4-Position Guide Key Method H: Table to Spindle Nose
APC Type Φ F-Frame Type High Column Type
2-Position Guíde Key +Curvjc Couplíng TypeW: Elfective Width Between Columns
2-Posìtion Guide Key +Curvic couplíng method H: Table to Spindle Nose L
Rígíd Bed and Coiumn Structure DCMseries
Stable bed and coiumn structure designed for high-speed, heavy-duty machining.
Key Features of the DCM Series
The DCM series are the professional equipments for heavy-duty machining developed based on Doosans know-how in machine design and production which ensure high accuracy and long life even under heavy machining loads.
Crossrail Structure
Bed Column Structure
The crossrail guide structure upholds the movìng loads of saddles, rams and
The structure of DCM series minimizes the impact of head attachments. 1t maintains high accuracy from heavy to finish cuiting.
vibration on workpieces under the loads of vertical and horizontal cuttings even when all fiue faces are being The wide guides are highly processed. Accurate compensation and thermal symmetric rigid rectanguiar sliding faces.
design to reduce thermal displacement are applied.
Bed Table Structure
The table moves on four guideways.
Numerous guideways can prevent local deformation through load distribution.
The accuracy is maintained by theroller bearing pack assembled under the table and the slide bearing which ;
has vibration absorption capability.
Five Face Double Column Machining Center
Various Ram Spindie line-up o
Heavy cutting option 
The ram section is bigger than that of competitors  
inch x inch which allows a superior heavy cutting 
aπy direction of horizontal machining loads. The spindle with 6000 r/min has been equipped as a standard.
Spindle power-torque diagram
Toryue : Nm Standard Specifications
Structure Design for Powerful Heavy Cutting
Built-In spindle : 6000 г/min
spIndle motor: 25/22 kW 34/30 нp The ram spindle unit is designed to maintain ideal conditions under any pressure through stress analysis.
spIndie torque : 600 N
Unit stress analysis of saddle Ram spindle Stress comparison of spindie sections
QUILLTYPE
High speed spindle BuIit-In : 12000 Γ/min
spindle motor : 30/25 kW 40/34 Hp
FEM analysis used to design a stable body. FEM : FInIte Element Method
spinále speeá μ/miφ The data is based on Doosan Machine Tools standards.
W-axis Machining Function Patent pending 0 Diverse Head Attachments for Assorted Processes Perfect parallelisim in between machine table and Y-axis movement along full stroke is maintained by this unique function composed of accurate proportional hydraulic Various head attachments caп be provided.
fine synchronous servo technology. ATC is applicable both vertical and horizontal  attachment.

Random angle Etfective machíning
W-axis machining of inclined surface
Y-axis
Table
Vertical machining
Performance Comparison between 3-axís and W-axis DCM
Narrow and
deep machining
Crossrail W-axis -vertical traverse
Protruded part of the ram spindle can be minimized as the crossrail
W-axis travels vertically. Therefore, cutting conditions remain stable from rough to finish cutting.
3-axís fixed top beam Curved contour machining
Excessive protrusion will cause vibration during heavy cutting. This will undermine the efficiency of rough cutting and the quality of finish Powerful cutting. horizontal cutting
Five Face Double Column Machining Center
Head Attachment Line-Up Patent pending 0
Provides numerous utilities to Untisliutyre Definition Dummy Extension 900 Angle
the same performance provided by Spindle Air Curtain Q the original ram spindle even after changing a Head Attachment. Flood Coolant/Air Blow
Head Attachment Too1 Unclamp - 
Head Attachment Spindle Air Purge 
TSC Through spindle Coolant  
Spindle Cooling  
Head Attachment Bearing Lubricant-
The provided ulility line could be ditferent as choosing the head attachment.
W-Frame
Head Attachment
Vertical spindle 10 ,15 , 30 , 45 
Manual index with multi-orientation -functions
Dummy Head Extension Head 90 Angle 
F-Frame Attachment
5-face machining
spindle with C-axis

Five Face Double Column Machining Center Overview

The Five Face Double Column Machining Center is a highly advanced and versatile CNC machine that incorporates automation and high precision, designed for handling complex machining tasks. Below are the key features and technical details:

Key Features:

Automatic Tool Changer (ATC) System

Linear Shuttle & AAC Automatic Head Attachment Changer:

A single arm performs tool changes for both horizontal and multi-face machining.

Different types of head attachments can be used depending on the machining requirement.

The tool change is controlled by the NC, ensuring automation and high precision during multi-face machining.

The spindle location is brought to a standby position during cutting, minimizing downtime.

The ATC system is designed to be highly reliable, minimizing troubles and operational downtime with its servo motor-driven tool magazine.

Chip Disposal System

Chip Disposal: Chips are rapidly and continuously discharged from the work area.

Options include a Lift-up chip conveyor, side chip conveyor, and coil conveyor.

The system is designed for horizontal ATC operation with a 90-degree head attachment mounted.

Automatic Pallet Changer (APC) is included, reducing workpiece setup time and improving productivity.

High Accuracy for Mold and Die

Model No. DCM 2740W / DCM 3250F:

Processing Material: KP4M (a high-performance material).

Material Size:

DCM 2740W: 1000 x 700 x 400 mm.

DCM 3250F: 1500 x 1000 x 500 mm.

Finish Cutting Time:

DCM 2740W: 10 hours.

DCM 3250F: 80 hours.

Heavy Cutting Performance

Face Milling – SM45C Carbon Steel:

Option 1 (Cutter: A18+SPM221):

Cutter Diameter: 60 mm

Cutting Width: 112 mm

Cutting Depth: 7 mm

Spindle Speed: 315 rpm

Feedrate: 665 mm/min

Removal Rate: 521 cm³/min

Option 2 (Cutter: A22+SPM3106):

Cutter Diameter: 140 mm

Cutting Width: 140 mm

Cutting Depth: 6 mm

Spindle Speed: 315 rpm

Feedrate: 1080 mm/min

Removal Rate: 907 cm³/min

Material: GC300 Cast Iron

Option 1 (Cutter: A18PM22):

Cutter Diameter: 60 mm

Cutting Width: 112 mm

Cutting Depth: 6 mm

Spindle Speed: 315 rpm

Feedrate: 1188 mm/min

Removal Rate: 798 cm³/min

Option 2 (Cutter: A22+SPM3106):

Cutter Diameter: 140 mm

Cutting Width: 140 mm

Cutting Depth: 8 mm

Spindle Speed: 315 rpm

Feedrate: 1404 mm/min

Removal Rate: 1572 cm³/min

End Milling Performance – SM45C Carbon Steel

Cutter Diameter: 63 mm:

DCM Series:

Cutting Width: 63 mm

Cutting Depth: 63 mm

Spindle Speed: 495 rpm

Feedrate: 312 mm/min

Removal Rate: 619 cm³/min

Ram Expansion: 24.37 mm

Material: GC300 Cast Iron:

Spindle Speed: 360 rpm

Feedrate: 200 mm/min

Removal Rate: 794 cm³/min

Five Face Machining Software Features:

Easy Pattern Cycle:

Reduces programming time by providing pre-programmed machining patterns suitable for part machining.

The software can be used directly on the shop floor for fast operations.

Work Coordinate System:

The system can be easily set by touching the tool or test bar against the workpiece.

This feature can be used with an automatic measuring probe to further streamline the setup process.

Tool End Point Shift within Work Coordinate System

M-Code Control: Enables head attachment position control and precise shifting of the tool endpoint to ensure accuracy during multi-face machining.

Head Attachment Compatibility: Various head attachments are supported for flexible and customized machining, controlled through the ATC system.

Summary:

The Five Face Double Column Machining Center provides an advanced, flexible, and automated solution for high-precision machining of complex parts. The combination of features such as automatic tool changing, chip disposal, and easy pattern cycles ensures high productivity and reduced downtime. The machine’s high-accuracy capabilities, especially in mold and die production, make it a versatile choice for heavy cutting and precise machining operations. With its advanced software and automation features, this machine optimizes workflow and enhances overall machining efficiency.

Five Face Double Column Machining Center - Advanced Features Overview

The Five Face Double Column Machining Center is equipped with several advanced features designed to enhance machining efficiency, precision, and automation. Below are the detailed features, emphasizing weight balancing, process monitoring, tool management, and installation processes.

Key Features:

Weight Balancer (W/B)

Patent Pending Technology: The weight balancer automatically controls load balancing to maintain stable motion and minimize material failure during processing.

Process Monitoring: Continuous tracking of cutting loads ensures consistent process efficiency, even when material weight fluctuates significantly during rough cutting.

Tool Monitoring:

Automatic Tool Detection: The system tracks worn-out or broken tools by monitoring abnormal cutting loads, ensuring tools are replaced when necessary.

Data Storage: Process data is stored for each workpiece, assisting with tracking and process optimization.

Tool Maintenance Function

Tool Life Alarm: The system triggers an alarm when a tool reaches the end of its useful life, reducing downtime and ensuring accurate machining.

Tool Group Management: Tools can be grouped for management and can be replaced with alternative tools if needed.

Cutting Load Reduction: With the Weight Balancer, the cutting load rate is reduced by up to 41%, optimizing overall machine efficiency.

Intelligent Machining Control

Differentiated Operation Parameters: M-Code functionality offers differentiated operation parameters tailored to each spindle motor, ensuring superior dynamic characteristics and improved processing performance.

Multiple Processing Modes:

M320 (High-speed Processing): Designed for faster operations with a focus on speed.

M321 (Precision Processing): Optimized for precise operations, ensuring high-quality results.

M322 (High Precision Finish Cutting): Used for finish cutting where the highest accuracy is needed.

Advanced Control Systems

NANO Level Control: Offers fine-grained control for high-precision machining tasks.

CAM Software Linkage: Seamless integration with CAM systems for efficient machining process management.

NURBS Function: High-level curve interpolation capability for smooth and efficient machining paths.

Machine Features & Ease of Operation

User-Friendly Interface

FANUC-31i CNC System: The machine uses the FANUC-31i system, known for its advanced capabilities and user-friendly interface.

Easy Operation Guidance: The guidance system offers easy-to-follow instructions, improving operator efficiency.

Control Interface: The main control panel is equipped with mono lever jog switches and manual handle (MPG) for convenient axis adjustments.

Tool Setting: Automatic tool position setting (with ATC and APC control) is available for easier machine setup and maintenance.

Installation and Setup

Hydraulic System Installation: Precautions for hydraulic system installation include testing soil bearing capacity and ensuring proper foundation strength, as per Doosan's standards.

Installation Timeframe: Installation typically takes around 6 weeks depending on site conditions and optional features. The process includes:

Foundation Test: Initial testing of the soil bearing capacity and foundation preparation.

Machine Setup: The machine is installed, calibrated, and precision-checked.

Training: Operator training on the system and its operations.

Work Area and Tooling

Maximum Tool Length: The machine supports a variety of tool lengths for versatility in different machining operations.

Work Area Dimensions:

Table Shape: The work table is designed for large workpieces, offering ample space for complex machining tasks.

Tooling with ATC: The Automatic Tool Changer (ATC) system supports multiple tools for varied machining tasks, optimizing workflow by reducing tool change times and ensuring seamless operations.

The Five Face Double Column Machining Center is equipped with advanced automation features that optimize machining processes, including weight balancing, load monitoring, and tool maintenance. With its precise and intelligent machining control system, the machine is suitable for a variety of tasks, from rough cutting to high-precision finish cutting. The easy-to-use control system and advanced CNC features ensure that operators can efficiently manage and program the machine. Additionally, its reliable installation and training support make it a highly efficient and valuable tool for industries requiring high-level machining precision.

The Five Face Double Column Machining Center incorporates a wide range of advanced features for efficient and precise machining. Below is a breakdown of the key functionalities and programming options available, focusing on circular interpolation, tool management, and machine functions:

Key Features and Functions

Circular Interpolation (G02, G03)

G02 and G03 are used for circular interpolation in CNC programming. These commands control the movement of the machine along a circular arc.

G02: Clockwise circular interpolation.

G03: Counterclockwise circular interpolation.

M-Code Functions

M-codes are used for various machine control operations such as tool changes, spindle control, and other machine functions.

M00: Program stop.

M01: Optional stop.

M03: Spindle on clockwise.

M04: Spindle on counterclockwise.

M05: Spindle stop.

Tool and Work Offset Programming

G10: Tool offsets and work offsets are programmed using G10 for accurate part machining.

Tool Offset Management: Tool offsets are defined, allowing the machine to compensate for tool wear and ensure accurate machining.

Backlash Compensation

Backlash compensation helps in correcting any mechanical play in the machine's drive system, ensuring high precision and smooth movements during machining.

Advanced Machining Functions

G62: Automatic corner override, which adjusts cutting conditions at corners.

G68/G69: Coordinate system rotation, for flexible toolpath adjustments.

G40, G41, G42: Cutter compensation, used for maintaining tool positions relative to the part geometry.

G84, G74: Rigid tapping, used for synchronized tapping operations.

G76: Fine boring cycle.

Programming Features

Subprograms: Allows up to 4 nested subprograms, enabling complex operations to be broken into smaller, manageable sections.

Chopping Function: Provides efficient machining by dynamically controlling cutting operations.

Tool Life Management

Tool Life Management: Monitors the lifespan of tools and provides an alarm when tools are worn out, helping to prevent tool failure during operations.

Coordinate Systems

Supports multiple coordinate systems (G54 to G59), allowing flexibility in defining the workpiece origin and part setup.

G68/G69: For rotating the coordinate system, enabling operations on inclined or rotated surfaces.

Machining Control

HRV2 & HRV3: High-speed response control modes that enhance machine performance during fast movements or when working with complex geometries.

Cutter Compensation (G41, G42): Ensures that the tool is accurately aligned with the workpiece contours, compensating for tool radius.

Feed Functions

G00: Rapid traverse.

G01: Linear interpolation (for straight-line moves).

G02, G03: Circular interpolation.

Tool Path Management

Tool Path Drawing: Visual representation of tool movement during programming for better planning and optimization of machining operations.

Program Management

Program Storage: Capability to store up to 1000 programs, ensuring quick retrieval for repetitive tasks.

Graphical Program Display: Visualize toolpaths and machining progress in a graphical format for easier verification.

Safety and Monitoring

Emergency Stop: An emergency stop function that halts the machine immediately in case of a fault or safety issue.

Overtravel Protection: Prevents the machine from moving beyond its designated travel limits, ensuring mechanical safety.

Additional Programming Features

Feed Rate Override: Allows adjustment of the feed rate during machining, typically used to modify machining speed without stopping the program.

Spindle Speed Override: Allows fine-tuning of spindle speed during operation.

Custom Macro B: Enables the creation of custom macros to automate repetitive tasks or implement special functions.

System Functionality

Spindle Orientation: Allows for specific spindle positions, important for operations like tool changes or specialized cutting processes.

Coordinate System Rotation: Advanced support for rotating the coordinate system to handle parts with unusual geometries.

Pitch Error Compensation: Provides fine adjustments for pitch error during threading or other applications that require precision.

Optional Features

High-Speed HRV4: Further improvement in high-speed machining capabilities.

Tool Length Measurement: Automatic measurement of tool length to ensure consistent cutting performance.

Remote Control: Allows for remote operation, increasing flexibility during machine setup and operation.

Installation and Operational Support

Tool Management: Support for managing multiple tool types, ensuring that appropriate tools are used for each task, reducing setup time and improving productivity.

Installation Test Run: The installation process includes a full test run and precision check, ensuring that the machine is correctly calibrated before production starts.

The Five Face Double Column Machining Center provides a powerful, flexible, and precise solution for complex machining operations. With advanced features like circular interpolation, tool offset management, high-speed controls, and rigid tapping, this machine is designed to deliver top-notch performance across a wide range of applications. The integration of tool life management, programmable macro functions, and multiple coordinate system support enhances both productivity and precision, making it an excellent choice for industries that require versatile and reliable machining capabilities.