DX1530 Welding Structure Member End Facing Machine for Long Parts

A. Scope and Wide Use of DX15xx and DX12xx Models Conventional Size Welding Structure Member H Beam End Face Milling Machine:

1. Conventional Models of Cross BOX I H Beam End Milling Machine:

In Steel Structure industry, end face milling height stroke of 1,500mm (DX15xx models, for example, DX1530) and 1,200mm (DX12xx models, for example, DX1215) are attributed as conventional, or standard models BOX H I Beam End Milling Machine, which suit on majority height of steel structure workpieces:

1) H Beam: (Fig.1)

2) BOX Beam: (Fig.2)

3) Cross Beam: (Fig.3)

As the best selling series Account for over 70% of practical machine use;

2. Usage of DX1530 and Other Standard Steel Structure BOX I H Beam End Facing Machine:

1) Function and Work Station: This machine tool is for performing end face machining on both ends of welding or rolling steel structure members, including H Beam/ I Beam/ BOX Beam. In a steel structure workshop, It is deployed at EOL (End of line) station of H Beam Production line/ BOX Beam Production Line;

2) Advantage: The machine has strong points of friendly operation and economical running. It is indispensable equipment for professional producers in steel structure industry;

3) Applied Industry: DX1530 and other conventional models are applied in industries of Steel Structure/ Chemical/ Pressure Vessel/ Shipbuilding/ Bridge Construction/ Machinery Manufacture;

3. Background of DX12xx and DX15xx Models Steel Structure H Beam End Face Milling Machine:

As the two most prominent standard models,

1) Same as DX15xx, DX1215 is another frequently selected small and middle size model, especially in the early years of machine evolvement, in those years DX1215 had the largest selling volume. The biggest height of workpiece available for end facing is 1,200mm;

2) In recent years, DX1520 gradually takes the place of DX1215, becoming the No.1 selling model. The reason is: 1,500mm height workpiece (H Beam/ I Beam) takes main stream in raw materials size of steel structure use;

3) Comparatively nowadays, DX1215 H I Beam End Milling Machine is mainly used for end facing on small and medium sized steel structure workpieces:

4) At Wuxi JACK assembly workshop, a set of DX1520 (Left) and a set of DX1215 (Right) model, with 300mm height difference: (Fig.4)

B. Structure and Work Principle of Conventional BOX I H Beam End Milling Machine:

1. Overall Structure of Standard BOX I H Beam End Facing Machine:

a) Rough design sketch on DX1520 model machine: (Fig.5)

b) A set of finish assembled Wuxi JACK DX1520 model machine: (Fig.6)

The complete configuration on one set of DX series has main units of:

1) Machining Unit: Milling head and milling cutter;

2) Mechanical main frame: Upright column and horizontal bed;

3) Workpiece clamp unit: Hydraulic drive clamping table and bracket;

4) Milling head carriage guide: HIWIN precise linear guiderail and safeguard unit;

5) Drive and transmission: Mechanical feeding system;

6) Electric control system;

7) Hydraulic pump station;

2.  Work Principle of Steel Structure H Beam End Face Milling Machine:

1) Milling head is execution mechanism in the machine, performing end face milling job in straight vertical plane of workpiece:

2) End face milling moment on steel structure workpiece, in Wuxi JACK DX1530 model BOX I H Beam End Milling Machine: (Fig.7)

3) Horizontal Direction Milling: During work, vertical column of machine moves leftward and rightward along horizontal base bed, in the valid stroke of 1500mm to 4000mm, fulfilling horizontal direction end milling operation, inverter speed control;

4) Vertical Direction Milling: When milling carriage moves up and down along upright column, in the valid stroke of 1200mm to 1500mm, milling head fulfills vertical direction end milling operation, also inverter speed control;

5) In regular control models, at any operation moment, only one direction milling, either horizontal or vertical, is carried out. This is different from CNC control BOX H I Beam End Milling Machine, the milling head can move along both direction simultaneously, acquiring on complicated trace milling job.

3.  Milling Working Speed Control and Display in Steel Beam End Face Milling Machine:

1) In conventional models machine with relay control, end face milling speed of both horizontal and vertical directions, is adjustable within the range of 100∼ 800mm/min, in the manner of variable frequency drive;

2) In Wuxi JACK DX models machines, there are 2 pieces of A.C. inverter and 2 sets of digital display meters, for indicating on real time end face milling speed in horizontal and vertical direction respectively. Comparatively, in many competitors’ machine, there is only 1 piece of A.C. inverter, to save manufacturing cost of machine:

a) Control cabinet of Wuxi JACK BOX I H Beam End Milling Machine, 2 pieces of A.C. inverters of different power, for driving milling head along horizontal and vertical direction respectively: (Fig.8)

b) Operating panel, with 2 pieces of digital display on end face milling velocity: (Fig.9)

C. Main Units of Conventional Models BOX I H Beam End Facing Machine:

1.  HIWIN Heavy duty Ball Bearing Precise Guiderail:

1) In this machine, milling head movement along both horizontal (workpiece width) and vertical (workpiece height) guiderails are heavy duty precise linear guiderail, featuring in strong loading capacity/ small clearance and high precision:

2) HIWIN Linear guiderails of Wuxi JACK DX model machine: (Fig.10)

2. Operating panel is in the manner of overhanging pendant, at the same height level as operating staff. Please check figure 9 as above. It can be turned 360°, easy for operator cutter setting and monitoring;

3. Protection on Guiderail in BOX H I Beam End Milling Machine:

1) Height Stroke: The guiderail in the vertical column is protected with black color organ shield, preventing metal filings from splashing onto it and doing harm;

2) Horizontal Stroke: The guiderail in the horizontal bed is protected with telescopic nested cover, which is made from stainless steel. This protection unit has good sealing, heat dissipation and long using life:

3) Wuxi JACK DX1520 model machine, black color organ shield on upright column, and stainless steel telescopic nested cover on horizontal bed: (Fig.11)

4. Mechanical main frame of machine: Horizontal bed and upright column are all of welding structure, which are integrally annealed after fabrication, of high accuracy, steadiness, and no deformation;

5.  Milling Head of Steel Cross BOX I H Beam End Face Milling Machine:

Adopted is produced with Chinese mainland professional Machine Tool Factory, HD750;

It has characteristic and strong points of:

1) High power and milling cut efficiency;

2) Reasonable structure and reliable performance;

3) Wide speed adaptable spindle revolutionary range;

4) User friend operation with convenient adjustment;

5) Good rigidity and low running noise;

6) High efficiency and convenient operation;

7) Revolution of its facer blade can be modulated by means of hand shank according to size of cutter head:

7.5kW high power high and stable performance milling head, equipped with Wuxi JACK DX models BOX I H Beam End Milling Machine: (Fig.12)

8) Milling head can be revolved integrally 0°~ 45° along the its vertical installation board, so, groove can be cut out during work of the BOX I H Beam End Milling Machine. This is the unique feature of Wuxi JACK products;

6.  Lubrication: The horizonal bed is equipped with manual lubricating pump, making good lubrication on the guiderails:

Lubrication pump manipulating mechanism: (Fig.13)

7. The milling cutter head and cutter blade is standard type, which can be conveniently purchased in international market. Material of facer blade is cemented carbide steel:

D200 specification milling cutter head, equipped with Wuxi JACK DX models conventional size Steel Structure H Beam End Face Milling Machine: (Fig.14)

D. Technical Parameters of DX12xx and DX15xx Standard Models Steel Structure H Beam End Face Milling Machine:

Models		DX12xx, such as DX1215 DX15xx, such  as DX1530
No.	Parameter
1	Suitable Workpiece Max. Cross Section Size Height × Width=	For example: DX1530: 1500 ×3000 mm
2	Horizontal and Vertical Way (Workpiece Width) End Face Milling Speed	150~ 800 mm/min	Stepless,  Variable Frequency Drive, inverter control
3	Face Milling Carriage Idle speed in Horizontal and Vertical Direction	1100 mm/min	Fixed speed
4	Horizontal and Vertical Direction End Face Milling Movement Guide	Heavy   duty Precise Linear guiderail, assembled onto Machine horizontal bed and upright column
5	Workpiece Horizontal Drive Motor	2.2 kW	Y series A.C. Asynchronous motor
6	Workpiece Vertical Drive Motor	3.0 kW	Y series A.C. Asynchronous motor
7	Milling Head Power	7.5 kW	Made by Professional Supplier
8	Milling Head Tilting Angle	0° ~45°	Adjusted by hand
9	Milling Head Spindle Revolution	75 ~ 420 rpm	6 grades Revolution adjustable
10	Diameter of Face Milling Cutter	Ø125­­~ 315 mm	Ø 200mm equipped with machine
11	Milling Head Spindle Z axis Stroke	L= 100 mm
12	Hydraulic Drive Workpiece Bracket	1 set	1 set of pump station; Quantiy/ Structure of bracket depends on workpiece type and   size
13	Hydraulic Specification	3kW pump station; 5MPa