Versatile MEGA 5 five-axis HMC tames titanium and speeds through large aluminum parts

February 2010 — MAG's MEGA 5 five-axis horizontal machining center is built for power and speed, with two spindle options providing high-torque machining of tough materials such as titanium or high-speed processing of aluminum, for large-part applications. The MEGA 5 combines twin ballscrew-driven axes in X-Y-Z, an infinite contouring B-axis table, and a compact u-frame, A-axis tilt spindle with 180? sweep for full five-axis contouring of highly complex parts. With its combined features, the MEGA 5 delivers five-sided machining capability, eliminating re-fixturing to reach odd angles and surfaces, for improved part accuracy and the lowest cost-per-part manufacturing. 

The XT spindle configuration is designed for machining hard metals such as compacted titanium, graphite iron, steel and Inconel, and is offered in HSK100A and ANSI 50 versions. A dual-speed gearbox with rugged spindle headstock provides speeds up to 6000 rpm, with constant power availability at 375 rpm for machining a variety of metals. The high-performance 45 kW (60 hp) AC drive motor and 1146 Nm (845 ft lb) of torque for hard metal machining give the XT spindle an S6-60 duty rating. The AP spindle package, specially-designed for machining aluminum, features a choice of two high-speed spindles – one rated for continuous operation at 50 kW (67 hp) and the other rated at 30 kW (40 hp). Both have HSK63A tooling interface, 61 Nm (45 ft lb) of torque and are capable of 24,000 rpm.

The MEGA 5 is built on one-piece nodular cast iron bed using a symmetrical design for high thermal and geometric stability. The machine's T-layout moves the part to and from the spindle in a straight line for optimum boring position. Digital scales provide linear accuracy of 9 µm (0.00035in) and repeatability of 6 µm (0.00024in), A and B rotary axes are accurate to 8 arc seconds and repeatable to 6 arc seconds.

The MEGA 5 features high dynamic stiffness for hard-metal processing, as well as a high feed rate of 60 m/min (2362 ipm) and 0.8G (7.8 m/s2) (310 in/s2) acceleration rate for high-speed processing. With 1425 mm (56.1 in) of X-axis travel, 1350 mm (53.1 in) of Y-axis travel and 1265 mm (49.8 in) of Z-axis travel, the MEGA 5 can handle parts up to 1300 mm (51.2 in) diameter and 2000 mm (78.7 in) high. A robust two-pallet automatic workchanger accommodates loads weighing up to 2200 kg (4840 lbs), and can swap square 800 mm x 800 mm (31.5 in x 31.5 in) or rectangle 800 mm x 1000 mm (31.5 in x 39.4 in) pallets in a best-in-class14.5 seconds, unclamp-to-clamp. A rotary table with pallet registration system ensures alignment each time a new pallet is shuttled into the machining zone.

An automatic tool changer handles 40-, 80- or 120-tool chains and can accommodate tools up to 540 mm (21.3 in) long, weighing up to 30 kg (60 lbs), and tool diameters up to 125 mm (4.9 in) with all pockets loaded – 335 mm (13.2 in) with adjacent pockets empty. The servo-driven, continuous motion tool changer features a tool-to-tool interchange time of just 2.4 seconds, utilizing tool queuing to minimize next-tool wait time. Metal-to-metal interchange time is 5.7 seconds to mid-travel.

The MEGA 5 features extra-large coolant capacity for thermal stability and improved part accuracy. High-pressure, 15 bar (220 psi) thru-spindle coolant is standard, with an option for 55 bar (800 psi) or 103 bar (1500 psi) for the HSK100A spindle. High-volume chip evacuation is handled via an extra-large center trough in the machine base.

About MAG

MAG is a leading machine tool and systems company serving the durable-goods industry worldwide with complete manufacturing solutions. The company offers a comprehensive line of equipment and technologies including process development, automated assembly, turning, milling, automotive powertrain production, composites processing, maintenance, automation and controls, and core components. Key industrial markets served by these technologies include aerospace, automotive and truck, heavy equipment, oil and gas, rail, solar energy, wind turbine production and general machining. 

With manufacturing and support operations strategically located worldwide, MAG ranks as a leader in the capital equipment market. A growing number of leading international companies are relying on the impressive innovation power of MAG to assure their technological leadership and prepare for future challenges.

For more information about MAG, please visit: www.mag-ias.com

Caption 

MAG’s MEGA 5 five-axis horizontal machining center with A-axis tilt spindle and B-axis position contouring table is the perfect machine for high-torque machining of titanium and hard metals or high-speed processing of aluminum applicatio