offers a cost-effective 5-axis small part production machining system by
The Leadwell V-40iT 5-Axis Machining Centre Features
the Leadwell V-40iT optimally concentrates the machining process for multi-face, intricately shaped work pieces and some difficult work piece positions where 3-axis machines cannot reach such as undercutting
for depth mould the Leadwell V-40iT can still keep high efficiency machining by setting a suitable angle of tool, thereby shortening the tool holding length
avoiding accumulative error from series machining procedure decreasing total cutting time while achieving required high speed high accuracy high efficiency
3-axis programs can still be run under constant position set-up for A/C axis without any cutting interference
high rigid cast iron construction with closed type design
stable machine design supported by big span saddle and foundation
without counter weight enhance the machine accuracy on mould making as well as avoid vibration
Z-axis transmission end fixed as well as ball screw pretension which enables to reduce operating temperature
The Benefits of Automatic Multi-Pallet Changing
lights-out manufacturing with multiple pallets automatically being changed without an operator
high spindle up-time with parts being loaded/offloaded on one pallet while machining a part on another pallet at the same time
Midaco Automatic Multi-Pallet Changer Features
aluminum pallets with cast iron receiver which mounts directly to the machine table (without requiring pneumatics or hydraulics)
automatically change up to 19 pallets without an operator
hardened and ground locating pins assure +/- 0.0001” (0.0025mm) repeatability
servo driven pallet movement on the pallet changer base
two (2) “drop-down door” loading stations
full CE enclosure - as a pallet change will not occur with open doors
Manufacturers around the world understand that a key to remaining competitive in a global economy is to decrease downtime and increase productivity. Midaco provides solutions that do just that. The Midaco Automatic Multi-Pallet Changer will improve efficiency on new and existing 5-Axis and standard Vertical Machining Centres. These pallet changers exceed international standards with optional CE guarding and are UL listed so they can be used anywhere in the world. Midaco Automatic Multi-Pallet Changers for Machining Centres The Midaco Automatic Multi-Pallet Changer is an ideal solution for 5-Axis and standard Vertical Machining Centres. The pallet changer is mounted on the front of the machining centre - aided by the included shuttle pivot system for front machine accessibility - and has 19 round aluminum pallets 10" in diameter, enabling the machine to run unattended. Because of its multiple pallets, this pallet changer is ideal for running parts in a "lights out situation". The operator can schedule 19 of the same parts or 19 separate jobs to run while unattended. Benefits of the Midaco Automatic Multi-Pallet Changer include:
heavy/large workpieces easily loaded outside the machine
increased machine and operator productivity
jobs can easily be interrupted for emergency jobs (JIT)
pallets easily interchange between machines or departments
exchange pallet in seconds with a +/- .0001" (.0025 mm) repeatability
Leadwell V-40iT 5-axis Machining Centre Specifications
Travel X-axis = 846mm (33”) Y-axis = 635mm (25”) Z-axis = 488mm (19.2”) A-axis = from 40° to -120° C-axis = 360° X/Y/Z axis feed motor = 4kW (5.4 hp) distance from table to spindle nose = from 50 to 538mm (1.9”-21”) distance from column front to spindle centre = 635mm (25”) axis guide ways = linear roller for high speed + high accuracy + high torque machining Table table diameter = 350mm (13.8”) table fixture plate = 400 x 600mm (15.75” x 19.68”) maximum load capacity = 200kg from 0 to 45 degrees / 100kg from 60 to 90 degrees t-slot width = 12mm height from floor to table top = 1220mm (48”) brake torque = 35kg/cm2
Spindle spindle nose = BT/CAT#40 spindle bearing inner diameter = 70mm (2.75”) spindle power S1-100% (S6-40%) = 15kW (20.1 hp) spindle torque = 70Nm (51.7 ft-lbs) maximum speed = 12000 rpm transmission = H.T.D. belt tool clamping force = 850kg (1870 lbs.) Feed Rate X/Y axis rapid feed rate = 36m per minute (1417” per minute) Z axis rapid feed rate = 20m per minute (792” per minute) X/Y/Z axis maximum cutting feed rate = 10m/minute (394” per minute) A/C-axis rapid feed rate = 25 rpm Automatic Tool Changer type = arm tool shank = BT/CAT#40 number of tool pockets = 30 maximum tool diameter with adjacent tool = 80mm (3.15”) maximum tool diameter with adjacent empty pockets = 110mm (4.3”) maximum tool length = 250mm (9.8”) maximum tool weight = 7kg (15.4 lbs.) tool-to-tool change time = 1.8 seconds General machine length x width x height = 3840 x 2200 x 2721mm (151.2” x 86.6” x 107”) machine weight = 7000kg (15432 lbs.) electrical requirements = 400 volt Midaco Automatic Multi-Pallet Changer Specifications number of pallets on shuttle = 19 pallet diameter = 254mm (10”) pallet thickness = 31.5mm (1.24”) locating pin repeatability accuracy = +/- 0.025mm (0.0001”) cast iron receiver base capacity - evenly distributed = 34kg (75 lbs.) pallet changer length x width x height = 2859 x 1456 x 1633mm (112.5” x 57.3” x 64.3”)
the receiver with dimensional drawing and the multi-pallet changer dimensional drawing:
Standard & Included Leadwell / Midaco Package Equipment
Fagor 8065 5-axis simultaneous control with 3D graphics and fully conversational + standard EIA (G-code) programming*
linear + rotary scales for high accuracy
belt type chip conveyor with built-in auger type chip conveyor
auto counter for work piece
remote manual pulse generator (MPG = electronic hand wheel)
through tool air blast
surrounding coolant system (coolant ring)
20bar coolant through the spindle
wash down system
spindle oil cooler
spindle air purge
Renishaw TS-27 tool measuring probe
machine auto door for automatic pallet loading/unloading
free off-line programming software on the customer’s computer
Fagor remote support program (allowing Fagor to remotely connect to your machine through TeamViewer to assist in “machine-down” diagnostics, trouble shooting tooling problems and provide programming assistance - all at no charge during the warranty period)
A reference article posted by UK and Ireland Leadwell agent WH-Lead:
TAIWANESE MACHINES ACCURATE TO MICRONS AFTER 25 YEARS
In August 2020 a pair of BT40 vertical machining centres (VMCs) built-in Taiwan by Leadwell was supplied by UK and Ireland agent WH-Lead (www.wh-lead.co.uk) to the Holmfirth factory of HB Bearings (www.hb-bearings.com), which less than a year previously had increased its turnover by one third through the acquisition of Gamet Bearings.
Low-volume manufacture of both bearing ranges, which include precision radial, taper roller, deep groove ball, cylindrical roller and angular contact as well as many other types, is being consolidated in the Holmfirth factory, where a purpose-built extension has been added to house some of the production equipment from Gamet Bearings.
The new Leadwell machines - a 4-axis model with rotary table and a 5-axis trunnion-type machining centre - were bought to strengthen production capacity for manufacturing the high precision, bespoke bearings in metric and imperial sizes. A wide range of materials are involved, including stainless steel, tool steel, plastics, bronze, aluminium and exotic alloys. The bearings are often specials, new designs or obsolete types that may need to be reverse-engineered to keep old manufacturing plant, steel mills, mining equipment, oil rigs or classic cars in operation.
Graham Hirst, managing director of HB Bearings / Gamet Bearings commented: “We have prioritised the purchase of these Taiwanese machines ever since we bought our first one, a machining centre, more than 25 years ago. We sold it when the two new machines arrived, with a view to pre-empting its eventual failure. However, right to the end it still milled dowel holes in 62 Rockwell steel to within 10 microns. We now have five machining centres from Leadwell and three of their lathes, including two recent models installed in August 2017, which are just as well-built, accurate and reliable.”
The purchase of a second five-axis machining centre for the factory, a Leadwell V-40iT, was down to a desire to supply increasingly complex bearings, especially to the motorsport sector, in ever shorter lead-times.
Some products have complex flanges and profiles that need simultaneous interpolation of all five axes for their production. Others have angled holes that benefit from using the machine in 3+2-axis mode. By automatically repositioning the component using the rotary axes, production can be completed in, for example, two operations rather than the four that would be needed on a 4-axis machine, reducing the manufacturing cost.
The V-40iT was selected partly due to its competitive price for an 846 x 635 x 488mm capacity 5-axis machine having a 12,000 rpm / 18.5 kW (24.8 kW-30min) BBT spindle with through-coolant and a 40-tool magazine.
Additionally, the generous width between the trunnion bearings makes it possible to accommodate on the 350mm diameter table a 680mm fixture for holding a 636 mm diameter bearing cage.
It was the other new machining centre, a V-30iF four-axis VMC with 800 x 460 x 510mm working envelope, that replaced the similarly sized, 25-year-old machining centre. The latest model has a 12,000 rpm / 11kW (14.7kW-30 min) spindle with through-coolant and 24-tool ATC.
Nearly all programming is carried out either conversationally or by directly inputting G-code at the machine controls, the latest machine being fitted with the Fanuc Series 0i-MF Plus. Any particularly complex features are developed in Ansys SpaceClaim and imported.
Mr. Hirst concluded: “We continue to buy Leadwell machines because they maintain their accuracy over decades. The oldest model we currently operate is more than 20 years old. Our operators like them too, as the machines do not cause any trouble and the Fanuc control option is also popular."
“Over such a long period since we bought the first machine, it has been interesting for me to observe how Leadwell has progressed as a machine tool manufacturer on the international stage. Their mills and lathes were always good, but they are even better now.”