Publish Time: 2025-01-13 Origin: Site
1. Business Case: In Nov. 2024, Wuxi JACK signed contract and got advancement on a set of DX1535 Special Made End Face Milling Machine with a customer based in East Europe. It went through 5 months for Wuxi JACK engineering team to finalize on design and specification of the machine, which is concluded on the basis of customer concern and special demand. In the period of technical communication, numerous doubts were raised by customer, and timely responded by Wuxi JACK engineers, with great satisfaction and positive confirm from customer;
Some Details with Business Case of DX1535 Model Machine;
Technical Specialties with DX1535 Model Machine;
Project Progress with DX1535 Model Machine;
Technical Superiorities and Overall View on Wuxi JACK Steel Structure BOX H Beam End Face Milling Machine
1. Customer: The customer is a casting foundry located in East Europe. They have a machine used over 20 years, for end facing on their casting:
1) Photos of existing Casting End Face Milling Machine and casting for process at customer facility: (Fig.1)
2) Sketch draft on casting from customer: (Fig.2)
1) Overall Dimensions of Mechanical Main Frame: Compared with conventional models of BOX H Beam End Face Milling Machine, customer hopes on have bigger size of mechanical main assemblies: Horizontal bed/ upright column/ workpiece clamping brackets, although the conventional models mechanical main body already has sufficient strength and rigidity to sustain on end face milling operation on steel structure workpieces;
2) Dust Proof Capability: Because there will large amount of dust produced during end face milling operation on casting, which has negative impact on performance and service life of machine tool, so, customer has very strict demand on dust proof performance of the End Face Milling Machine;
3) Casting Fixation: Cast workpieces have large size/ heavy weight/ Irregular shape (Octahedral cross section, as shown in the above sketch). So, its firm and reliable clamp should be specifically cared on;
4) Milling Head Power: Also, because casting belongs to heavy duty working parts, which should be milled with heavy duty milling head, with power higher than ordinary types;
5) Cutterhead Size: Accordingly, the specification of cutterhead to be applied in this Special Made End Face Milling Machine should also fairly above average level, so as to guarantee sufficient cutting depth of each stroke;
6) Automation: Customer expect the machine tool to be high automatic, removing human intervention to the least level. This can not only greatly reduce variable cost, but also reduce operation error rate to minimum;
7) Consumables: Customer hope one year use consumable to be supplied together with the DX1535 Casting End Face Milling Machine. In this case, not only the additional sourcing cost on daily running can be greatly reduced, but also fully make sure non-stop of the machine caused from short of service parts.
General Idea: Excellence comes from exceeding customer expectations. To eliminate customer doubts, Wuxi JACK engineering team develops the machine with delicate design. Below are several examples:
First, below are several photos on DX1535 after assembly for testing, at Wuxi JACK workshop:
1) Taken at running side (Main frame) and hydraulic pump station: (Fig.3)
2) Taken at back side: Workpiece laying table and stainless steel sliding cover: (Fig.4)
3) Taken at operating side: Milling head/ operating platform and panel/ Workpiece clamp frame racks: (Fig.5)
Technical Feature: As can be observed from the above photos, the dimension of horizontal bed and upright column of DX1535 are 30% larger than conventional models. Besides, the traditional workpiece clamp brackets are replaced with tailor made solid ground platform, which we will introduce next;
In blog << Three Critical Issues on Put into Use Beam End Face Milling Machine >>, we give introduction on measures taken by Wuxi JACK to have satisfactory dust proof performance of the machine. In a nutshell:
1) Heavy duty precise linear guiderail on horizontal bed and upright column, for guiding movement of milling head: Select dust proof model: (Fig.6)
2) Illustration on proof model guiderail: (Fig.7)
3) Guiderails Guard: Accordion style guards on upright column, made of fire proof cloth (Marked as 1 in below photo); And laminated guide rail guards on horizontal bed, made of stainless steel (Marked as 2 in below photo): (Fig.8)
4) Hydraulic Pump Station: Individual type, put alongside main frame of the Beam End Face Milling Machine. Operating buttons are sealed with translucent cover: (Fig.9)
5) Electric Motor: Adopt with dust proof model;
6) Control Board and Operating Buttons: Adopt with dust proof design, with all buttons covered with translucent cover: (Fig.10)
1) Special Design Platform: Unlike conventional models of BOX H Beam End Face Milling Machine, which has 2 ~ 3 sets of grounding fixed brackets, for supporting workpieces, here in this special design DX1535, a piece of solid special designed and produced platform: Of 4300 length x 2200mm width x 600mm height has been manufactured. This is for best accommodating on size of 40GP container for stuff and transportation;
2) 2 Pieces of V support are fixed onto the platform, for laying customer workpiece castings. The size and structure of the V supports are specifically designed based on casting drawing from customer;
3) 2 Pieces of Overhead Brackets, with downward acting pressing rod, of which downward movement are driven with hydraulic oil cylinder, forming a square shape clamping frame, to tightly clamp on workpiece casting, thus guarantee on its reliable fixation into the DX1535 BOX H Beam End Face Milling Machine:
4) Tailor made platform, 2 pieces of V brackets, and 2 hydraulic drive brackets, for firmly clamping castings: (Fig.11)
In this way, castings of 20~ 30 ton weight can be applicable for being end faced reliably in DX1535;
1) The milling head model of standard models of Wuxi JACK BOX H Beam End Face Milling Machine is 7.5kW (Other suppliers’ is 5.5kW), which can meet most majority customer requirement on steel structure machining. However, customer of DX1535 still has concern on sufficient power of its milling head;
2) For this reason, Wuxi JACK engineering team proposed Taiwan produced E-LONG brand milling head of 11kW, which delivers much more cutting depth and milling efficiency. Besides, because of larger cutting of each milling stroke, the finished end face milling has more gloss finished surface:
3) The 11kW high power Taiwan produced E-LONG milling head equipped with DX1535 Casting End Face Milling Machine, with illuminating lamp for easy operation: (Fig.12)
1) In conventional models of BOX H Beam End Face Milling Machine, cutterhead is D200. In this case of special design DX1535, customer expects larger ones to gain higher efficiency on end face milling productivity. Accordingly, Wuxi JACK engineers equip D320 for DX1535 model machine:
2) The D320 cutterhead on 11kW milling head of DX1535 End Face Milling Machine: (Fig.13)
1) Automation: Working in casting foundry surroundings, the DX1535 is expected by customer to be as automatic as possible, thus eliminating human operation to the least degree. In Wuxi JACK DX series End Face Milling Machine, operation is carried out already fully automatic. Here, we upgrade the DX1535 of its half automatic lubrication, to fully automatic type:
Automatic lubricating unit for horizontal and vertical linear guiderail of DX1535: (Fig.14)
2) Consumables: To make sure customer will not fret over sourcing on consumables of DX1535 Casting End Face Milling Machine, during its 1st year operation, Wuxi JACK engineers propose to customer one year use of consumables, covering mechanic/ hydraulic / electric components, and confirmed with customer in the form of detailed list on model and quantity of each component.
Below is general timeline on DX1535:
1. Initiate Communication: In middle June 2024, customer had first contact with Wuxi JACK, and gave requirement on DX1535. Wuxi JACK engineers gave custom made proposal on DX1535 accordingly;
2. Select Wuxi JACK as Supplier on DX1535: In July 2024, after numerous times e-mail on technical exchange, Wuxi JACK technical strength/ rich experience/ Sense of responsibility on customer were recognized, and we are selected as supplier on DX1535 from potential candidates;
3. Technical Communication on DX1535: From August to October 2024, customer had in-depth discussion on technical detail of the DX1535 Special Made Casting End Face Milling Machine, and concluded technical agreement accordingly;
4. Business Formalities with DX1535: In November 2024, both sides draft on contract of DX1535, signed it, and advancement payment are made accordingly;
5. Design and Production on DX1535: From end of November 2024 to early January 2025, Wuxi JACK kicked off development on DX1535 End Face Milling Machine, going through its Order to Delivery process;
6. Delivery on DX1535: By middle of January 2025, when closing up production on DX1535, Wuxi JACK takes photos and videos on DX1535 Special Made Casting End Face Milling Machine commissioning process, communicated with customer, and prepare on machine shipment.
1. Wuxi JACK Commitment on Customer: As can be found from this business case on DX1535, every set of our DX series Steel Structure BOX H Beam End Face Milling Machine involves and embodies Wuxi JACK staff’s hard work and dedication on customer, which distinguish our machine tools in industry and market. And with years of accumulation, our products have gained widespread client recognition;
2. The technical superiorities of our DX series Steel Structure BOX H Beam End Face Milling Machine not only excellent in special made models as introduced above on DX1535, but also exceeds as an integral machine family: That every set of our End Face Milling Machine delivers the best performance for customers. This includes but not limited to: Overall design/ Machine structure/ Key function units: Milling head, heavy duty precise linear guiderail, hydraulic system, electric control system (2 pieces of A.C. inverters in one machine/ Renowned brand of electric components)...