0 BOX H Beam End Face Milling Center 115

Wuxi JACK BOX H Beam End Face Milling Center

A. Purpose of Steel Structure Milling and Facing Center:

1. Business Background: This working center was developed and produced by Wuxi JACK, in second half of 2013 year, and delivered to Belarus in 2014 year. The central unit is 2 sets of CNC-DX1540 model BOX H Beam End Face Milling Machine with CNC;
2. Function: This machine group is used for BOX Beam and H Beam face milling at its both ends simultaneously, including cone H Beams with tilt angle of one flange up to 15°:
1) Design sketch on H Beam to be processed: (Fig.1)

Fig1 BOX H Beam End Face Milling Machine with CNC 000

2) The super long H Beam (24m length) being end face milled: (Fig.2)

Fig2 BOX H Beam End Face Milling Center 58

3) BOX Beam being end face milled: (Fig.3)

Fig3 BOX H Beam End Face Milling Machine with CNC 6

3. For this purpose, one set of CNC-DX1540 model BOX H Beam End Face Milling Machine with CNC in the Steel Structure Milling and Facing Center can make the linear movement, and the other set of CNC-DX1540 machine can turn around 0~ 60°;

4. Steel Structure Workpieces for BOX H Beam End Face Milling Machine with CNC:

1) Rolled and welded H Beam (I Beam), welded BOX Beam, length ranging in 6~ 24m;
2) Cross section size has scope of 250x250mm ~ 1500x 4000mm;
3) Cone angle of the workpiece (H Beam) flanges has degree range of 0~ 15°;
4) End face of the workpiece (H Beam) has inclination angle of 0~ 60°;
5) Guaranteed flatness of processed surface from the BOX H Beam End Face Milling Machine with CNC is 0.22mm/m²;
6) Roughness of processed surface is Ra12.5 after end face milling;

5. Work Videos of Wuxi JACK BOX H Beam End Face Milling Machine with CNC:

Due to the long elapsed time, we had only taken photos of the BOX H Beam End Face Milling Center, but not operating videos. As complement, please check videos of Wuxi JACK other CNC machines as below:

B. Formation of Steel Structure BOX H Beam End Face Milling Center:

1. General Design on Layout of CNC-DX1540 Steel Structure Milling and Facing Center:

This working group occupies total workshop land area of 29m length by 8m width, in the height of 4.5m:

2. Composition of Steel Structure Milling and Facing Center:

Shown in the above print and photos, this BOX H Beam End Face Milling Center is composed of several machines/ equipment and supporting systems, to meet on sophisticated demand of customer:
1) Two sets of CNC-DX1540 Steel Structure BOX H Beam End Face Milling Machine with CNC, of which one set is movable under motor drive along the 24m long rail, the other set is stationary, but has capability of 0~ 60° revolve scope, for the convenience of BOX Beam H Beam inclined end face milling;
2) Five sets of hydraulic drive workpiece fixation tables, for holding the workpiece processed with these two sets of CNC-DX1540 model machine;
3) One set of turning table with 0~ 60° range under motor drive, which is installed beneath the stationary set of CNC-DX1540 model machine;
4) 24m long double rails;
5) Electric control system;
6) Hydraulic system;

3. The Two Sets of CNC-DX1540 BOX H Beam End Face Milling Machine with CNC:

1) Both machines are installed in its foundation pit, at both ends of the Steel Structure Milling and Facing Center, with the sets of 5 main positioning tables in between;
2) Before work, both machines are reliably fixed by the hydraulic clamping devices;
3) Changes of the horizontal and vertical working speed of both the movable and turning CNC-DX1540 machines for its milling cutter feed are executed by vector frequency inverter. Adjustment and visual control of the feed rate is executed on the control panel of operator:
Operator works on H Beam in Wuxi JACK CNC-DX1540 BOX H Beam End Face Milling Center: (Fig.4)

Fig4 BOX H Beam End Face Milling Center 134

C. Specialty of Working Center BOX H Beam End Face Milling Machine with CNC:

And corresponding technical solutions:

1. Workpieces of Steel Structure BOX H Beam End Face Milling Center:

1) Varied cross section size of H Beam--- Flange height changes along its entire length into an oblique line. The corresponding oblique angle is 0°~ 15°;
2) Slant cross section --- The plane of one end cross section is not perpendicular with respect to longitudinal axis of the workpiece, but with an angle range of 0°~ 60°;
3) Correspondingly, for the CNC-DX1540 model machine of the Steel Structure Milling and Facing Center:
a) The max. cross section size at 0° is 1,500mm height x 4,000mm width;
b) While at 60°, it is 1,500mm height x 2,000mm width;
4) Long length --- Compared with the routine length of 15m, the H Beam machined here is 24m the longest length:
The long piece H Beam being milled in this CNC-DX1540 BOX H Beam End Face Milling Center: (Fig.5)

Fig5 BOX H Beam End Face Milling Machine with CNC 135

2. Wuxi JACK Design on BOX H Beam End Face Milling Center:

So, as supplier of this Steel Structure Milling and Facing Center, what proposal should Wuxi JACK propose to customer, to make the machine group have capability on machining such special workpieces?
In a nutshell, the key solutions should be:
1) One Machine Movement: For the two sets of CNC-DX1540 BOX H Beam End Face Milling Machine with CNC, one set should be able to move along 24m long parallel rails, to accommodate on changing length of workpiece. As an analogy, the movable machine is like a set of movable welding manipulator:
The set of movable CNC-DX1540 machine on parallel rails: (Fig.6)

Fig6 BOX H Beam End Face Milling Center 126

2) One Machine Turning: The other set of CNC-DX1540 model machine, although fixed, is installed on the 0°~ 60° turning table, for the ease of end face milling slant cross section of workpiece:
The set of stationary CNC-DX1540 BOX H Beam End Face Milling Machine with CNC, together with 0° ~ 60° turning table beneath it: (Fig.7)

Fig7 BOX H Beam End Face Milling Machine with CNC 124

3) BOX H Beam Clamp: Besides, there are 5 sets of hydraulic drive main positioning tables, which are movable along the double parallel rails also, serving as hold base for the long workpiece. The vertical stroke of oil cylinders of these positioning tables are different, so as to secure firmly the workpiece with oblique flange up to 15° inclination angle:
The 5 sets of hydraulic drive clamping table for firmly holding on common seen and special workpieces: (Fig.8)

Fig8 BOX H Beam End Face Milling Center 129

D. Technical View and Operation on BOX H Beam End Face Milling Center:

1. General Outline on Steel Structure Milling and Facing Center:

1) Type of processing equipment: 2 sets of CNC-DX1540 model BOX H Beam End Face Milling Machine with CNC. Its motion and movement are managed with CNC and servo motors; Operation is realized with touch screen on the CNC;
2) Main technological operations adopted: End face milling by means of high power (7.5kW) milling head, with its angle and rotating speed adjustable:
3) The Taiwan E-LONG brand MU-6S milling head, 7.5kW, into each set of CNC-DX1540 model BOX H Beam End Face Milling Machine with CNC: (Fig.9)

4) Operation: During work, the two sets of CNC-DX1540 machine have face milling operation at the both end faces of the workpiece at the same time. To cater for variable workpiece specification (Length and side face tilting angle), one set of BOX H Beam End Face Milling Machine moves along the rail, the other machine revolves within 2 segments of 0°~45° and 45° ~60°;

2. General Technical Specialty of BOX H Beam End Face Milling Machine with CNC:

1) Milling heads quantity in each set of the CNC-DX1540 machine is 1 piece, available for horizontal and vertical machining, with model of 7.5kW MU-9S, produced with Taiwan professional producer;
2) Milling cutter turning speed range is 65~ 715 rpm. There are 9 positions of turning speed to be changed, with manual adjustment on milling head front face;
3) Material of the milling blade is mark and type of used carbide blade SPCN1504ED;
4) Milling head boom size is 0~ Φ200 mm, and rotation angle is 0~ 45°;
5) Milling Adjustment: During work, adjustment on milling heads boom is performed by manual mechanical drive; And adjustment on milling heads rotation angle in the vertical plane is performed by manual mechanical drive.

E. Major Specifications of CNC-DX1540 Working Group BOX H Beam End Face Milling Machine with CNC:

1. BOX H Beam Positioning: Before official operation, the workpiece should be loaded into this BOX H Beam End Face Milling Center, and reliably fixed with hydraulic clamping devices;
2. Turning Angle Measure: Angle positioning adjustment of the turning machine, relative to the workpiece (H Beam) is 0~ 60˚ with accuracy of 2' (minutes). For the stationary tilting CNC-DX1540 machine, a circular ruler is used for rotation angle measurement and control;
3. Horizontal Quick Movement: The set of movable CNC-DX1540 machine can move along two linear guide rails, the related travel speed for workpiece length adjustment is 3000 mm/min., which is non-adjustable;
4. Horizontal and vertical speed of cutter working feed, of the two sets of CNC-DX1540 BOX H Beam End Face Milling Machine with CNC: 150~ 600 mm/min. This working speed should be gradual, stepless adjustment is performed by inverter;
5. Vertical Quick Movement: Vertical speed of cutter quick action feed of the two machines is 1500 mm/min. This speed is also non-adjustable;
6. Horizontal speed of cutter quick action feed of the two sets of CNC-DX1540 machine: 2000 mm/min., this speed is non-adjustable;
7. Milling Head Both Directions Servo Motors Power: Horizontal and vertical feeding motor power of the two sets of CNC-DX1540 machine: 3.0 kW for both directions. The servo motors are equipped with encoder and brake;
8. Longitudinal movement motor power of CNC-DX1540 model BOX H Beam End Face Milling Machine with CNC is 2.2 kW. The motor is also with encoder and brake.

F. Workpiece Fixation Operation with CNC-DX1540 BOX H Beam End Face Milling Center:

1. Work piece fixing on main tables is realized by vertical clamps and performed in view of clamping plate;
2. For the performance of the minimum boom of the work piece (H Beam and BOX Beam), for the purpose of its reliable fixation at a turning machine during end face milling operation, it is necessary to provide extra hold down clamps, specifically:
1) Provide a bed plate of the turning machine with the supporting table beam, with two installed hydraulic hold down clamps, in vertical and lateral side;
2) Vertical and lateral hold down clamps should have a sufficient longitudinal travel stroke for the beam fixation, into the 2 sets of CNC-DX1540 BOX H Beam End Face Milling Machine with CNC, depending on the machine angle of setting from 0 to 600mm;
3. To provide clamp turning device installed on all side hold down clamps for cone H Beam positioning and fixing, to eliminate the skew of rod of hydraulic cylinder;
4. Main tables positioning motor power is 0.75 ×3 kW;

5. Hydraulic System of Steel Structure Milling and Facing Center:

1) Hydraulic station power of 2 sets of CNC-DX1540 machines and turning table/ fixing table is 11.0 kW. This equals to: Two hydraulic stations: 5.5 kW x 2;
2) Working pressure in hydraulic system is up to 6.0 MPa;

6. Electric Wiring and Hose Deployment in BOX H Beam End Face Milling Center:

1) Laying of all movable parts/ electric cables and high pressure hoses to supply machine and on it shall provide in cable layers;
2) Wiring layout of all non-movable parts/ electric cables and high pressure hoses to on it shall provide in closed protective hoses or trays.

G. Technical Parameters of Working Group BOX H Beam End Face Milling Center:

Parameter	Value
Model of the 2 sets of BOX H Beam End Face Milling Machine with CNC	CNC-DX1540
Minimal size of the work piece (H Beam) flange for the movable and turning machine, H x W	250×250 mm
Maximum size of the work piece (H Beam) for the movable and turning machine, H x W	1500×4000 mm
Maximum size of the work piece (H Beam) for the turning machine at the rotation angle of 0°, H x W	1500×4000 mm
Maximum size of the work piece (H Beam) for the turning machine at the rotation angle of 60°, H x W	1500×2000 mm
Maximum size of the work piece (H Beam) flange for the turning machine at the rotation angle of 60˚, H x W	1500×4000 mm
Minimal length of the work piece according to its largest side (at simultaneous double side processing of ends) at the turning angle of the turning machine 45˚≤ α ≤ 60˚ degrees	6000 mm
Minimal length of the work piece (at simultaneous double side processing of ends) at the turning angle of the turning machine 0˚≤ α ≤ 45˚ degrees	5000 mm
Maximum length of the work piece under the condition of the simultaneous double side processing of ends in Steel Structure Milling and Facing Center	24000 mm
Cone angle of the work piece (H Beam) flanges	0°- 5°
Work piece BOX Beam H Beam material	St3sp5, 09G2S, 10KHSND, 15KHSND

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