Sales Manual

Ver. HMC-MEGA100-EN-130308

HEAVY DUTY CNC LATHE

MEGA100 series

Hwacheon Machinery Co., Ltd. www.hwacheon.com

 MEGA100
1. Line-up

MEGA 100

Between centers x3000, x4000, x5000, x6000

Spindle through hole Dia. 155mm(S) Dia. 255mm(O) Dia. 320mm(O)

NC Controller SIEMENS-828D(S) SIEMENS-840D sl(O) FANUC 0iT-D(O) FANUC 32i(O)

Turret type 4 position curvic coupling toolpost(S)

4 position hydraulic auto turret(O)

12 position electric auto turret(O)

12 position turnmill turret(O)

(S) : Standard, (O) : Option

Sales Manual > MEGA100 2/60

 MEGA100
2. Main Features

1) High accuracy
Adoption of ball screw and servo motor
Easy checking for spindle speeds by attachment of spindle position encoder
Guarantee of repeatability 5 by adoption of curvic toolpost

2) Utmost convenience
Excellent operation & easy loading/ unloading work piece by convenient operation panel
Semiautomatic tailstock feeding device

3) Heavy duty cutting

Heavy duty cutting and precision turning by one piece fabricated bed & leg structure
High rigid headstock
-. Spindle through hole Dia.155mm : four point contacts with ball bearing, cylindrical roller bearing, angular bearing
-. Spindle through hole Dia.255mm : three point contacts with taper roller bearing
-. Spindle through hole Dia.320mm : three point contacts with taper roller bearing, double roller bearing
Ball screw
-. X-axis : Dia.32 x 6mm
-. Z-axis : Dia.50 x 12mm(3000T/4000T), Dia.62 x 12mm(5000T), Dia.80 x 12mm(6000T)
Guide way : Turcite

4) High stability
Maintaining high accuracy by turcite laminated on slide surfaces
Application of high pressure lubrication pump to guarantee perfect lubrication on slide surfaces
Prevention of operation error by lock type mono lever switch (Opt. Fixed MPG handle)

Sales Manual > MEGA100 3/60

 MEGA100
3. Machine Specification

MEGA100 MEGA100 MEGA100 MEGA100

Description Unit
x3000 x4000 x5000 x6000

Capacity
Swing over bed mm Dia.1,080
Swing over cross slide mm Dia.720
Max. cutting dia. over bed mm Dia.1,000
Max. turning dia. on cross slide mm Dia.700
Distance between centers mm 3,000 4,000 5,000 6,000

Spindle
Spindle nose KS A2-15 (Dia.155, 255) /

A2-20 (Dia.320)
Spindle through hole mm Dia.155 / 255 / 320
Spindle bore taper MT No.6
Spindle ranges step Auto 3 steps
Spindle speeds rpm 40~750 (Dia.155) /
30~650 (Dia.255) /
20~400 (Dia.320)

Axis travel
X-axis travel mm 520
Z-axis travel mm 3,000 4,000 5,000 6,000
X-axis rapid traverse mm/min 6,000
Z-axis rapid traverse mm/min 6,000 5,000

Toolpost
Type of turret - Curvic coupling
Max. No. of tools EA 4
Standard tool size mm 32

Sales Manual > MEGA100 4/60

 MEGA100
3. Machine Specification

MEGA100 MEGA100 MEGA100 MEGA100

Description Unit
x3000 x4000 x5000 x6000

Tail stock (Built-in)
Quill dia. mm Dia.200
Quill bore taper MT No.6
Quill travel mm 260

Bed
Bed length mm 5,370 6,370 7,370 8,370
Bed width mm 700
Bed way type - 1bed (2 slide way)

Motor
Main motor kW 23/18.5
X-axis servo motor kW 2.62 3.3
Z-axis servo motor kW 5.24 9.58
Coolant pump W 250
Bed lubrication pump W 53
Spindle lubrication pump W 200

Dimension
Height mm 2,150
Length x Width mm 6,200x2,350 7,200x2,350 8,200x2,350 9,200x2,350
Net weight kgf 11,500 13,000 14,500 16,000

Power (isolating) kVA 45

Coolant tank capacity 220 270 320 370

Controller - SIEMENS-828D

Sales Manual > MEGA100 5/60

 MEGA100
4. NC Specification SIEMENS-828D (Std.)
: Not available S: Standard O: Option
Item Specification Item Specification
 Controlled axis  Interpolation function
Control axies 2-axis S Thread cutting
Linear interpolation axes 2-axis S - with constant lead G32 S
- with variable lead G33, G34
0.001mm,
Least input increment 0.001deg, S Polar coordinates G110, G111, G112 S
0.0001inch Chamfer, rounding CHF, CHR, RND S
Working area limit S Approaching a fixed point G75 S
Software traverse limit 1,2 S Helical interpolation S
Measuring system error compensation S
Backlash compensation S  Feed function
 Operation Rapid traverse override 0-120% S
-with feed-rate override
Number of channels 1 Channels S Feed per minute (mm/min) G94 S
Number of mode-groups 1 Mode-groups S Feed per revolution (mm/rev) G95 S
Inch/metric conversion G70, G71 S Feed-rate for positioning axis FA,FPR S
Reference point approach G74 S Jog feed velocity 0-2000 mm/min S
Dry run, single block S Rapid velocity 0-6000 mm/min S
Block search with/without calculation S Separate override control 2 Channels S
Repositioning on the contour
- With operator command REPOS, S  Program input
- Program-controlled REPOSA
Program execution from RS232C interface S G-code system Siemens G-code (DIN66025) S
Program execution from Network drive Network Manager S ISO-dialect mode ISO-A S
Separate operating mode 2 Channels S
 Interpolation function Absolute/Incremental
dimension G90, G91 S
Positioning G00 S
Linear interpolation G01 Working area limitation G25, G26 S
- straight line with angle ANG S
Exact stop G60, G9 S
Circular interpolation G02, G03 Programmable rotation ROT, AROT S
- polar coordinates AP, RP S
- tangential transition CT Programmable scale factor SCALE, ASCALE S
Dwell (Per seconds) G04 S Programmable mirroring MIRROR, AMIRROR S

Sales Manual > MEGA100 6/60

 MEGA100
4. NC Specification SIEMENS-828D (Std.)
: Not available S: Standard O: Option

Item Specification Item Specification

 Program input  Editing operation
Number of zero offset 100 EA (G54..) S Part program storage size CNC User memory 3MB S
Manual measurement of Text editor with editing functions : Select, copy, delete S
Scratch function S Dual editor S
zero offset
Subroutine call 11 levels S Write protection for lines S
Custom macro S Suppression of lines in the display S
User parameter R-parameters (300) S Screen saver S
Turning cycle Cycle93 ~ 97 S Cyclical alarm display S
Timer & Counter function S
Drilling cycle Cycle81 ~ 82 S
Graphic simulation S
Contour programming S
Pocket calculator mode S
Compare and logic operations S
Easy program selection S
Arithmetic and trigonometric
S Multi-language display
functions
(English, German, French, Italian, Chinese, Japanese, S
 Spindle speed function Korean, Hungarian, Polish, Portuguese, Swedish.)

Constant surface speed control G96/G97 S  Data input/output

Spindle override 50-120% S Interface devices USB, CF Card S
Spindle orientation M19 S
Memory card O
Digital load meter S
Ethernet connection S
Spindle synchronous control

 Tool function / compensation  Others

Tool function T-number S Machine step programming SHOP TURN O
No. of tool/cutting edges 128/256 ea. S Extended operation S
Tool nose radius compensation S Shopmill HMI functions S
Tool geometry/wear compensation S Service Planner Maintenance scheduler S
Manual tool offset calculator S Easy Extend Managing machine unit S
Tool data backup S Display unit 10.4" color TFT S

Sales Manual > MEGA100 7/60

 MEGA100
4. NC Specification SIEMENS-840D sl(Opt.)
: Not available S: Standard O: Option

Item Specification Item Specification

 Controlled axis  Interpolation function
Controlled axes 2-axes S Thread cutting
Linear interpolation axes 2-axes S - with constant lead G32 S
- with variable lead G33, G34
Least input increment 0.001mm, 0.001deg, S
0.0001inch Polar coordinates G110, G111, G112 S
Working area limit S Chamfer, rounding CHF, CHR, RND S
Software traverse limit 1,2 S Approaching a fixed point G75 S
Measuring system error compensation S Helical interpolation S
Involute interpolation O
Backlash compensation S
 Operation  Feed function
Number of channels 1 Channels S Rapid traverse override 0-120% S
-with feed-rate override
Number of mode-groups 1 Mode-groups S
Feed per minute (mm/min) G94 S
Inch/metric conversion G70, G71 S
Feed per revolution (mm/rev) G95 S
Reference point approach G74 S
Feed-rate for positioning axis FA,FPR S
Dry run, single block S
Jog feed velocity 0-2000 mm/min S
Block search with/without
calculation S Rapid velocity 0-4000,6000 mm/min S
Repositioning on the contour Separate override control 2 Channels S
- With operator command REPOS, REPOSA S
- Program-controlled  Program input
Program execution from S
RS 232C interface G-code system Siemens G-code (DIN66025) S
Program execution from Network Manager S ISO-dialect mode ISO-A S
Network drive
Separate operating mode 2 Channels S
 Interpolation function Absolute/Incremental
dimension G90, G91 S
Positioning G00 S
Linear interpolation G01 Working area limitation G25, G26 S
S
- straight line with angle ANG Exact stop G60, G9 S
Circular interpolation G02, G03 Programmable rotation ROT, AROT S
- polar coordinates AP, RP S
- tangential transition CT Programmable scale factor SCALE, ASCALE S
Dwell (Per seconds) G04 S Programmable mirroring MIRROR, AMIRROR S

Sales Manual > MEGA100 8/60

 MEGA100
4. NC Specification SIEMENS-840D sl(Opt.)
: Not available S: Standard O: Option

Item Specification Item Specification

 Program input  Editing operation
Number of zero offset 100 EA (G54..) S Part program storage size CNC User memory 3MB S
Text editor with editing functions : Select, copy, delete S
Manual measurement of
Scratch function S Dual editor S
zero offset
Subroutine call 16 levels S Write protection for lines S
Custom macro S Suppression of lines in the display S

User parameter R-parameters (300) S Screen saver S

Cyclical alarm display S
Turning cycle Cycle93 ~ 97 S
Timer & Counter function S
Drilling cycle Cycle81 ~ 82 S
Graphic simulation S
Contour programming S
Pocket calculator mode S
Compare and logic
S Easy program selection S
operations
Multi-language display
Arithmetic and trigonometric (English, German, French, Italian, Chinese, Japanese,
S S
functions Korean, Hungarian, Polish, Portuguese, Swedish.)

 Spindle speed function  Data input/output

Constant surface speed control G96/G97 S
Interface devices USB S
Spindle override 50-120% S
Memory card O
Spindle orientation M19 S
Ethernet connection S
Digital load meter S
Spindle synchronous control -  Others
 Tool function / compensation Machine step programming Shopturn O

Tool function T-number S Extended operation S

Tools/ Cutting edges in tool list 600/1500 S Shopturn HMI functions S
Tool nose radius compensation S Service Planner Maintenance scheduler S
Tool geometry/wear compensation S Easy Extend Managing machine unit S
Manual tool offset calculator S Display unit 10.4" color TFT S

Sales Manual > MEGA100 9/60

 MEGA100
4. NC Specification FANUC 0iT-D (Opt.)
: Not available S: Standard O: Option U: Export Standard

Item Specification Item Specification

 Controlled axis  Interpolation function
Controlled axis 2-axis(X, Z) S Positioning G00 S
Simultaneously controlled axis 2-axis(X, Z) S Exact stop G09 S
Least input increment 0.001mm, 0.0001inch S Linear interpolation G01 S
Absolute or Incremental command X,Z or U,W S Circular interpolation G02, G03 S
Interlock All axis S Dwell G04 S
Machine lock All axis S Thread cutting G32 S
Emergency stop S Thread cutting retract S
Over travel S Continuous threading S
Stored stroke check 1 S Variable lead threading S
Inch/metric conversion G20/G21 S Skip G31 S
 Operation Reference position return G28 S
Reference position return check G27 S
Automatic & MDI operation S
DNC operation with PCMCIA card Remote mode S  Feed function
Program number search S Rapid traverse override F0, F25, F50, F100% S
Sequence number search S Feed per minute (mm/min) G98 S
Program restart O
Feed per revolution (mm/rev) G99 S
Wrong operation prevention S
Automatic acceleration / deceleration S
Dry run S
Single block S Cutting feedrate clamp S
Manual continuous feed JOG mode S Feedrate override 0 - 200% S
Manual reference position return S Jog override 0 - 200% S
Manual handle feed 2unit S Manual per revolution feed S
Manual handle feed rate X1, x10, x100 S
Linear acc/dec after cutting feed interpolation S
Handle interruption O

Sales Manual > MEGA100 10/60

 MEGA100
4. NC Specification FANUC 0iT-D (Opt.)
: Not available S: Standard O: Option U: Export Standard

Item Specification Item Specification

 Program input  Auxiliary / Spindle speed function
Tape code EIA/ISO S
Auxiliary function M2 digit S
Optional block skip 1ea S
Spindle speed function S3 digit S
Program number O4 digit S
Constant surface speed control G96/G97 S
Sequence number N8 digit S
Actual spindle speed output S
Decimal point programming S
Coordinate system setting Spindle orientation M19 O
G50 S
Automatic coordinate system setting S Spindle override 50 - 150% S
Workpiece coordinate system G54 - G59 S  Tool function / Tool compensation
Manual absolute on S Tool function T4 digit S
G-code system A S Tool offset pairs 99 pairs S
G-code system B/C O
Tool offset pairs 200 pairs O
Chamfering/Corner R S
Tool nose radius compensation S
Programmable data input G10 S
Tool geometry/wear compensation S
Programmable parameter input S
Sub program call S  Accuracy compensation function
Custom macro S Backlash compensation Rapid & cutting feed S
Addition of custom macro variables #500 - #999 S Stored pitch error compensation S
Canned Cycles S Interpolation type pitch error compensation -
Multiple repetitive cycle S  Editing operation
Multiple repetitive cycle II Pocket profile S Part program storage size 512Kbyte S
Canned cycles for drilling S Part program storage size 1M byte O
Circular interpolation by R program R,I,J,K S Number of register programs 400ea S
Direct drawing dimension programming S Number of register programs 1000 / 2000ea -

Sales Manual > MEGA100 11/60

 MEGA100
4. NC Specification FANUC 0iT-D (Opt.)
: Not available S: Standard O: Option U: Export Standard

Item Specification Item Specification

 Editing operation  Setting and display
Help function S
Program protect S
Graphic display function S
Background editing S
Language display Korea, English S
Playback O
Dynamic graphic function S
Extended part program editing S
 Data input/output
Machining time stamp -
Reader/puncher interface RS-232C S
 Setting and display External message S
PCMCIA card
Clock function S Memory card input/output S
(Compact Flash 2GB)
Status display S USB memory input/output USB memory S
Current position display S Screen hard copy S
Ethernet Embedded Ethernet S
Program comment display S
 Others
Parameter setting and display S
NC ready, Servo ready
Alarm display S Status output signal S
Feed hold, NC alarm
Alarm history display S PMC ladder function 24000 steps S
Operation history display S Display unit 10.4 color LCD
Run hour and parts count display S Separate MDI
MDI unit S
Actual cutting feedrate display S (ONG horizontal type)

Display of spindle speed and T code at all screens S Operator manual

Fanuc manual 1set Maintenance manual S
Operating monitor screen (Load meter) S
Parameter manual
Servo setting screen S
Spindle setting screen
 Programming guidance function
S
for LATHE
Self-diagnosis function S Manual guide i (included manual )
O

Sales Manual > MEGA100 12/60

 MEGA100
4. NC Specification FANUC 32i (Opt.)

: Not available S: Standard O: Option U: Export Standard

Item Specification Item Specification

 Controlled axis  Interpolation function
Controlled axis 2-axis(X, Z) S Positioning G00 S
Simultaneously controlled axis 2-axis(X, Z) S Exact stop G09 S
0.001mm, Linear interpolation G01 S
Least input increment S
0.0001inch
Absolute or Incremental command X,Z or U,W S Circular interpolation G02, G03 S
Interlock All axis S Dwell G04 S
Machine lock All axis S Thread cutting G32 S
Emergency stop S Thread cutting retract S
Over travel S Continuous threading S
Stored stroke check 1 S Variable lead threading O
Inch/metric conversion G20/G21 U Skip G31 S
 Operation Reference position return G28 S
Reference position return check G27 S
Automatic & MDI operation S
DNC operation with PCMCIA card Remote mode S  Feed function
Program number search S Rapid traverse override F0, F25, F50, F100% S
Sequence number search S Feed per minute (mm/min) G98 S
Program restart O Feed per revolution (mm/rev) G99 S
Wrong operation prevention S
Automatic acceleration / deceleration S
Dry run S
Cutting feedrate clamp S
Single block S
Manual continuous feed JOG mode S Feedrate override 0 - 200% S
Manual reference position return S Jog override 0 - 200% S
Manual handle feed 2unit S Manual per revolution feed S
Manual handle feed rate X1, x10, x100 S
Linear acc/dec after cutting feed interpolation S
Handle interruption O

Sales Manual > MEGA100 13/60

 MEGA100
4. NC Specification FANUC 32i (Opt.)
: Not available S: Standard O: Option U: Export Standard
Item Specification Item Specification
 Program input  Auxiliary / Spindle speed function
Tape code EIA/ISO S
Auxiliary function M2 digit S
Optional block skip 1ea S
Spindle speed function S3 digit S
Program file name 32 characters S
Constant surface speed control G96/G97 S
Sequence number N8 digit S
Actual spindle speed output S
Decimal point programming S
Coordinate system setting Spindle orientation M19 O
G50 S
Automatic coordinate system setting S Spindle override 50 - 150% S
Workpiece coordinate system G54 - G59 S  Tool function / Tool compensation
Manual absolute on S Tool function T4 digit S
G-code system A S Tool offset pairs 32 pairs S
G-code system B/C O
Tool offset pairs 64 / 99 / 200 pairs O
Chamfering/Corner R S
Tool nose radius compensation S
Programmable data input G10 S
Tool geometry/wear compensation S
Programmable parameter input S
Sub program call S  Accuracy compensation function
Custom macro O Backlash compensation Rapid & cutting feed S
Addition of custom macro variables #500 - #999 O Stored pitch error compensation S
Canned Cycles S Interpolation type pitch error compensation O
Multiple repetitive cycle S  Editing operation
Multiple repetitive cycle II Pocket profile O Part program storage size 256Kbyte S
Canned cycles for drilling S Part program storage size 512K/1M/2M byte O
Circular interpolation by R program R,I,J,K S Number of register programs 63ea S
Direct drawing dimension programming S Number of register programs 1000 / 2000ea O

Sales Manual > MEGA100 14/60

 MEGA100
4. NC Specification FANUC 32i (Opt.)

: Not available S: Standard O: Option U: Export Standard

Item Specification Item Specification

 Editing operation  Setting and display
Help function S
Program protect S
Graphic display function S
Background editing S Language display Korea, English S
Playback O Dynamic graphic function O
Extended part program editing S  Data input/output
Machining time stamp O Reader/puncher interface RS-232C S
 Setting and display External message S

Clock function S Memory card input/output PCMCIA card S

Status display S USB memory input/output USB memory S

Current position display S Screen hard copy S
Ethernet Embedded Ethernet S
Program comment display S
 Others
Parameter setting and display S NC ready, Servo ready
Status output signal S
Alarm display S Feed hold, NC alarm
Alarm history display S PMC ladder function 24000 steps S
Operation history display S Display unit 10.4 color LCD
Run hour and parts count display S
Separate MDI
Actual cutting feedrate display MDI unit S
S (ONG horizontal type)
Display of spindle speed and T code at all screens S Operator manual
Operating monitor screen (Load meter) S Fanuc manual 1set Maintenance manual S
Parameter manual
Servo setting screen S
Spindle setting screen S
 Programming guidance function
for LATHE
Self-diagnosis function S Manual guide i (included manual )
O

Sales Manual > MEGA100 15/60

 MEGA100
5. Accessories

Standard Accessories Optional Accessories

1) CNC system : SIEMENS-828D 1) CNC system : SIEMENS-840D, FANUC 0iM-D, FANUC 32i
2) Spindle through hole : Dia. 155mm 2) Spindle through hole : Dia. 255mm, Dia.320mm
3) 4 position curvic coupling toolpost (Manual type) 3) 4 position hydraulic turret
4) 4 jaw Independent chuck : 18 4) 12 position electric turret
5) Portable MPG handle 5) 12 position turnmill turret
6) Built-in tailstock 6) C-axis indexing (0.001)
7) Coolant equipment 7) 4 jaw independent chuck : 24, 28, 32, 40
8) Flicker lamp (R/Y/G, 3 colors) 8) 3 jaw scroll chuck : 18, 20, 21, 24, 25
9) Work light 10) 3 jaw hyd. chuck(for Dia.155mm) : 15, 21, 32
10) Tool kits & box 11) Face plate : Dia. 950mm
11) Boring holder (I.D.) : 60mm 12) Steady rest : Dia.50~350mm(Roller), Dia.300~600mm(Roller)
12) Boring sleeve (I.D.) : 25, 32, 40, 50mm 13) Follow rest : Dia.60~240mm(Roller), Dia.60~250mm(Metal)
13) Live center : M.T. No.6 14) Boring Bar
14) Dead center : M.T. No.6 15) Boring Bar Holder & sleeve
15) Drill socket : M.T. No.3, 4, 5 16) Grinding unit
16) Operation manual & part list 17) Fixed MPG handle
18) Semi enclosed splash guard : 1door / 2 door
19) Chip conveyor (Hinge type)
20) Transformer (isolating) : 45kVA
21) NC cooler
22) Shop turn (for SIEMENS system)
23) PCU 50 (built-in hard disc for SIEMENS-840Dsl)
24) Manual guide i (for FANUC system)

Sales Manual > MEGA100 16/60

 MEGA100
6. Machine Size Non door (Std.)

unit : mm

7,882(8,882/9,882/10,882)

6,200(7,200/8,200/9,200) 2,350

3,000(4,000/5,000/6,000) 1,940

2,150

1,413

1,220
Front view
Side view

Sales Manual > MEGA100 17/60

 MEGA100
6. Machine Size 1 & 2 door (Opt.)

unit : mm
7,882(8,882/9,882/10,882)

6,200(7,200/8,200/9,200)

3,000(4,000/5,000/6,000) 2,350

1,400 1,400 2,075

(2nd door) (1st door)

2,150
1,290

1,220
Front view
Side view

Sales Manual > MEGA100 18/60

 MEGA100
7. Foundation MEGA100x3000

unit : mm

Sales Manual > MEGA100 19/60

 MEGA100
7. Foundation MEGA100x4000

unit : mm

Sales Manual > MEGA100 20/60

 MEGA100
7. Foundation MEGA100x5000

unit : mm

AIR LINE CONNECT POINT

SIZE : 3/8 (HOSE ID : 11mm)
MAIN POWER INLET
)
CABLE SIZE : 20SQ(
(CABLE INLET POINT : BOTTOM) ANTI-VIBRATION WALL(STYROFOAM or PAD)

Sales Manual > MEGA100 21/60

 MEGA100
7. Foundation MEGA100x6000

unit : mm

NON-SHIRINKAGE MORTAR

ANCHOR BOLT

NON-SHIRINKAGE MORTAR

E/L BOX

Sales Manual > MEGA100 22/60

 MEGA100
8. Turret Interference 4 position toolpost (Std.)

Maker : Hwacheon
Type : Curvic coupling
Swing over bed (Max. cutting) : Dia. 1,000mm
Swing over cross slide (Max. cutting) : Dia. 700mm
X-axis stroke from spindle center : 520 mm

Sales Manual > MEGA100 23/60

 MEGA100
8. Turret Interference 4 position hydraulic toolpost (Opt.)

Maker : Golden Sun

Type : Hydraulic
Swing over bed (Max. cutting) : Dia. 1,000mm
Swing over cross slide (Max. cutting) : Dia. 700mm
X-axis stroke from spindle center : 520 mm

Sales Manual > MEGA100 24/60

 MEGA100
8. Turret Interference 12 position electric turret (Opt.)

Maker : Duplomatic
Type : Electric
Swing over bed (Max. cutting) : Dia. 830mm
Swing over cross slide (Max. cutting) : Dia. 700mm
X-axis stroke from spindle center : 415mm

Sales Manual > MEGA100 25/60

 MEGA100
9. Tooling System 4 position toolpost (Std.)

Bite
32mm, 1

Boring bar
Boring holder

Boring sleeve
Boring bar
Metric : 25, 32, 40, 50mm
Inch : 1, 1 , 1 , 2

Drill socket
Drill
Metric : M.T. #3, 4, 5
Inch : M.T. #3, 4, 5

Sales Manual > MEGA100 26/60

 MEGA100
9. Tooling System 4 position hydraulic toolpost (Opt.)

Bite
40mm, 1

Boring bar
Boring holder

Boring sleeve
Boring bar
Metric : 25, 32, 40, 50mm
Inch : 1, 1 , 1 , 2

Drill socket
Drill
Metric : M.T. #3, 4, 5
Inch : M.T. #3, 4, 5

Sales Manual > MEGA100 27/60

 MEGA100
9. Tooling System 12 position electric turret (Opt.)

Bite
32mm, 1 Clamp piece

Extended O.D. Holder

Face & I.D. Holder

Boring bar
60, 2.36 Boring holder

Boring sleeve
Boring bar
Metric : 25, 32, 40, 50mm
Inch : 1, 1 , 1 , 2

Drill socket
Drill
Metric : M.T. #3, 4, 5
Inch : M.T. #3, 4, 5

Sales Manual > MEGA100 28/60

 MEGA100
9. Tooling System BORING BAR ASSY(Opt.)

Boring Bar Holder Maker : Hwacheon

Long Boring Bar Maker : SANDVIK
Max. inner cutting dia. : 460mm

Sales Manual > MEGA100 29/60

 MEGA100
10. Torque Diagram SIEMENS system

Spindle Through Hole

[Dia. 155mm] [Dia. 255mm] [Dia. 320mm]

Torque(kgm) Torque(kgm) Torque(kgm)
Power (kW) Power (kW) Power (kW)
23kW(RATE30min) 23kW(RATE30min) 23kW(RATE30min)
23 23 23

SPINDLE TORQUE (kgf.m)

SPINDLE TORQUE (kgf.m)

18.5kW(CONST) 18.5kW(CONST) 18.5kW(CONST)

SPINDLE TORQUE (kgf.m)

18.5 18.5 18.5
482 548 897

OUTPUT (kW)
OUTPUT (kW)
OUTPUT (kW)

388 457 722

23kW(Rate30min) 23kW(Rate30min) 23kW(Rate30min)

178 182 373
MIDDLE HIGH 143 LOW MIDDLE HIGH 143 MIDDLE HIGH 300
LOW LOW
67 71 149
18.5kW(CONST) 54 18.5kW(CONST) 54 18.5kW(CONST) 120
30 35 56
24 24 45

0 40 126 325 750(rpm) 0 30 100 300 650(rpm) 0 20 60 150 400 (rpm)

23/18.5kW 23/18.5kW 23/18.5kW

40~750rpm 30~650rpm 20~400rpm

Sales Manual > MEGA100 30/60

 MEGA100
10. Torque Diagram FANUC system

Spindle Through Hole

[Dia. 155mm] [Dia. 255mm] [Dia. 320mm]

Torque(kgm) Torque(kgm) Torque(kgm)
Power (kW) Power (kW) Power (kW)
22kW(RATE30min) 22kW(RATE30min) 22kW(RATE30min)
22 22 22
18.5kW(CONST) 18.5kW(CONST) 18.5kW(CONST)

SPINDLE TORQUE (kgf.m)

SPINDLE TORQUE (kgf.m)

SPINDLE TORQUE (kgf.m)
18.5 18.5 18.5

OUTPUT (kW)

OUTPUT (kW)
OUTPUT (kW)

460 570 858

388 480 722

22kW(Rate30min) 22kW(Rate30min) 22kW(Rate30min)

170 214 357
LOW MIDDLE HIGH 143 LOW MIDDLE HIGH 180 LOW MIDDLE HIGH 300

66 71 143
18.5kW(CONST) 54 18.5kW(CONST) 60 18.5kW(CONST) 120
29 33 54
24 28 45

0 40 126 325 750 (rpm) 0 30 60 150 650 (rpm) 0 20 60 150 400 (rpm)

 18.5/22kW  18.5/22kW  18.5/22kW

 40~750rpm  30~650rpm  20~400rpm

Sales Manual > MEGA100 31/60

 MEGA100
11. Sales Point Structure

[Chuck cover]

One-piece high rigid flat bed structure

 Minimize thermal deformation
Precisely heat treated bed slide way and unique bed design
[Front door (1, 2door_opt.]
 Excellent vibration absorption
 Guarantee surface illumination and high accuracy during heavy duty cutting
Turcite type bed slide way (front side : dovetail / rear side : flat)
 Maintain the high rigidity and high precision even when operating for a long time
Excellent user accessibility and chip disposal
 Improving work performance and convenience
[Rear splash guard]

Sales Manual > MEGA100 32/60

 MEGA100
11. Sales Point Spindle construction

Spindle through hole Dia. 155mm (Std.)

Type of Spindle Nose A2-15

Spindle speed range 40 ~ 750rpm

23/18.5kW (SIEMENS)
Spindle Motor power
22/18.5kW (FANUC)

Spindle bearing , Cylindrical roller bearing

Angular roller bearing

Ball bearing
* Ultra-precision spindle bearings ensure excellent stabilities for heavy duty cutting

285
380
219
175
155

Sales Manual > MEGA100 33/60

 MEGA100
11. Sales Point Spindle construction

Spindle through hole Dia. 255mm (Opt.)

Type of Spindle Nose A2-15

Spindle speed range 30 ~ 650rpm

23/18.5kW (SIEMENS)
Spindle Motor power
22/18.5kW (FANUC)

Spindle bearing , , Taper roller bearing

* Ultra-precision spindle bearings ensure excellent stabilities for heavy duty cutting

285
380
339
293
255

Sales Manual > MEGA100 34/60

 MEGA100
11. Sales Point Spindle construction

Spindle through hole Dia. 320mm (Opt.)

Type of Spindle Nose A2-20

Spindle speed range 20 ~ 400rpm

23/18.5kW (SIEMENS)
Spindle Motor power
22/18.5kW (FANUC)

Spindle bearing , Taper roller bearing

Double roller bearing

* Ultra-precision spindle bearings ensure excellent stabilities for heavy duty cutting

412
520
420
370
320

Sales Manual > MEGA100 35/60

 MEGA100
11. Sales Point Transmission

Spindle speeds range (Auto 3 steps)

40 ~ 750 rpm (Spindle through hole : Dia. 155mm)
-. Low : 40 ~ 126 rpm
-. Middle : 127 ~ 325 rpm
-. High : 326 ~ 750 rpm
30 ~ 650 rpm (Spindle Through Hole : Dia. 255mm)
-. Low : 30 ~ 100 rpm
-. Middle : 101 ~ 300 rpm
-. High : 301 ~ 650 rpm
20 ~ 400 rpm (Spindle Through Hole : Dia. 320mm)
-. Low : 20 ~ 60 rpm
-. Middle : 61 ~ 150 rpm
-. High : 151 ~ 400 rpm

Possible to operate high speed process & low speed with high torque process by gear transmission
Possible to do stable operation by minimizing transmission of heat and vibration to main spindle
setting apart from gear box & main spindle motor
Power is delivered to the spindle through a three speed transmission allowing high spindle speed
as well as powerful low torque.

Sales Manual > MEGA100 36/60

 MEGA100
11. Sales Point High precision ball screw & servo motor for X & Z axis

X-axis ball screw : Dia.32 x 6mm

Z-axis ball screw : Dia.50x12mm(3000T, 4000T), Dia.62x12mm(5000T), Dia.80x12mm(6000T)

Sales Manual > MEGA100 37/60

 MEGA100
11. Sales Point Double chuck system

Spindle through hole

Dia. 255mm(A2-15) /
Dia. 155mm(A2-15)
Dia.320mm(A2-20)

Adapter type

Direct mount type

MEGA100 machine has spindle through hole with 155mm(6) as a standard and 255mm(10), 320mm(12.5)
as a option. When working through spindle hole with long work piece, we can provide special double
chuck system to have stable clamping.

Sales Manual > MEGA100 38/60

 MEGA100
11. Sales Point Hyd. Chuck System

(15, 21, 32)

Hydraulic collet chuck

CYLINDER COLLET CHUCK Hyd. CHUCK

For operation of hydraulic turret, chuck cylinder, steady rest and tailstock.

Sales Manual > MEGA100 39/60

 MEGA100
11. Sales Point Toolpost / Turret

4 Posi. manual toolpost (Std.) 4 Posi. auto turret (Opt.) 12 Posi. auto turret (Opt.) 12 Posi. turnmill turret (Opt.)
- Curvic coupling - Hydraulic - Electric - Electric
- 250 x 250mm - 250 x 250mm

4 Posi. auto turret (Opt.) Double grinding unit (Opt.) Boring bar holder (Opt.)
- Electric + Hydraulic (V4)
- 250 x 250mm

Sales Manual > MEGA100 40/60

 MEGA100
11. Sales Point Steady rest & Follow rest

Steady rest Follow rest

1) Dia. 50~350mm (2~13.7), 1) Dia. 60~240mm (2.4~9.4),

Roller type Roller type

2) Dia. 350~600mm (11.9~23.6), 2) Dia. 60~250mm (2.4~9.8),

Roller type Metal type

Loading capacity
Description Chuck + Tailstock Steady Rest(1 EA) Steady Rest(2EA) Chucking

G
Working Method
250

Loading Cap. 5,000kgf 6,500kgf 8,000kgf 1,000kgf

Sales Manual > MEGA100 41/60

 MEGA100
11. Sales Point Built-in Tailstock (Std.)

Operating handle on the side

(low-noise & low torque by using spiral bevel gear)
200mm

NUT type center

(easy to attach/remove)
1) Quill Sleeve : Dia. 200mm x 646mm
-. Spinning sleeve
-. Manual clamp
2) Quill bore taper : No. 6

M30x170mm bolt 3) Quill travel : 260mm

4) Sub spindle : 692mm

[Built-in tailstock with hydraulic line(Opt.)] [Built-in tailstock with chuck(opt.)] [Tailstock load meter(opt.)]
-. Tailstock clamp/unclamp & Quill travel

Sales Manual > MEGA100 42/60

 MEGA100
11. Sales Point Lubrication system

Headstock lubrication pump Slide way lubrication

Automatic lubrication is provided to all guide ways and ball screws.

A low level alarm prevents the machine from restarting without lubricant.

Sales Manual > MEGA100 43/60

 MEGA100
11. Sales Point MPG Handle

Portable MPG handle (Std.)

Fixed MPG handle (Opt.)

Note 1) Shop Turn function can be operated with Portable MPG handle.
2) If Manual Guide i function is required, customer should purchase Fixed MPG handle.

Sales Manual > MEGA100 44/60

 MEGA100
11. Sales Point Door & Splash guard

Standard Option

Non door 1door 2 door

Front door

Non splash guard Rear full splash guard Rear full splash guard

Rear cover (refer to the above photo)

Sales Manual > MEGA100 45/60

 MEGA100
11. Sales Point Chip conveyor (opt.)

Hinge type (Apron type)

Superior ability to dispose the long-shaped magnetic and
non-magnetic chips
Avoid to dispose of small and powdered chips, especially
machined from FC, AL materials

Scraper type
Applicable for disposal of small, short and powdered chips
Superior ability to dispose the FC, FCD, AL chips machined
from endmill and broach process

Mesh drum type

Possible to dispose the floating chips on the cutting oil
in AL & FC process
Rotation filtering structure driven by chain gear inside of
scraper conveyor

Sales Manual > MEGA100 46/60

 MEGA100
11. Sales Point Chip conveyor

Index Steel Cast iron Non-ferrous metals

Shape of chip

Hinge type Available Not available Not available

Scraper type Not available Available Available, but no recommend

Drum filter type Not available Not available Available

Type Hinge type Scraper type Drum filter type

Outward appearance

Sales Manual > MEGA100 47/60

 MEGA100
11. Sales Point C-axis & Turnmill

Polar coordinate interpolation Cylindrical interpolation

Twist
Drilling Dia.32mm(Dia.1.25)
Cutting
Capacity
Tapping
M20

Driven tools for Milling, Tapping, Drilling

contribute to highly intensive process with
spindle indexing(0.001 ) by an AC Spindle
motor.
Machining is one process can be achieved

Sales Manual > MEGA100 48/60

 MEGA100
11. Sales Point Peripheral equipment

1. Hydraulic unit
-. for Tailstock clamp/unclamp
-. for Tailstock quill travel
2 3 -. for Hydraulic toolpost

1
2. Oil cooler
-. for Grinding unit (Opt.)

3. Water chiller
-. For Grinding unit (Opt.)

4. NC cooler
-. for Electric control box
4
5. Hydraulic unit
-. for Hydraulic chuck
5

Sales Manual > MEGA100 49/60

 MEGA100
11. Sales Point E/L Box

[SIEMENS] [FANUC]

Sales Manual > MEGA100 50/60

 MEGA100
11. Sales Point Controller panel (Std. SIEMENS system)

Various communication port

Ethernet (RJ45)

USB

CF memory card

User-friendly : 10,4 Color TFT Easy maintenance

-. Data save function without battery(NV-RAM)
-. Deletion of cooling fan by minimizing heat generation

Sales Manual > MEGA100 51/60

 MEGA100
11. Sales Point Communication Programming (SIEMENS : Shop Turn)

Flexible program input

Graphical programming
including tool, feed rate and cutting rate / spindle speed,
with chaining of machining steps
Highly flexible G-code programming with graphical contour
and cycle support

User-friendly operation
Graphical support for measuring tools and work-pieces
USB memory stick directly at the operator panel front
3D simulation with zoom to details and automatic calculation
of machining time

CAD/CAM
Intelligent functions for higher productivity
Input of the counter spindle functions by dialog screen
In-process measuring for tools and work-pieces
Programming and training software for PC

Sales Manual > MEGA100 52/60

 MEGA100
11. Sales Point Controller panel (Opt. FANUC system)

Ethernet

CF memory card

USB

Multi-axis / Multi-channel control, High functional CNC

High speed built-in PMC

Most advanced SERVO processor

Sales Manual > MEGA100 53/60

 MEGA100
11. Sales Point Communication Programming (FANUC : Manual Guide i)

Operation Guidance, which supports whole operations on an all-in-one screen .

All-in-one Screen
Only one screen concentrated all
operations
Machine status window
Easy programming
Machine status such as actual
Based on ISO-code program
position, feed rate and load meter
format, complex machining
are displayed always
motions can be created
easily by menu form

Realistic machining simulation

3-D solid model machining
simulation is available CAD/CAM

Intuitive menu selecting Good affinity with CAD/CAM

Menu can be selected easily and intuitively Most popular ISO-code program format on
by soft-key with icon CAD/CAM can be dealt as it is

Sales Manual > MEGA100 54/60

 MEGA100
12. Performance Cutting technical data

Model : Bush
Machine : MEGA100
Material : Copper
Work piece size : Dia.700XL1,400
Cutting Fluid : -

Process Tool N (min-1) F (mm/rev) Time

Side Face Boring Bar+CNMG 280 0.20 2m

O.D Rough Long Boring Bar+CNMG 280 0.25 29m

O.D Finish Long Boring Bar+CNMG 280 0.2 36m

I.D Rough Long Boring Bar+CNMG 280 0.25 29m

I.D Finish Long Boring Bar+CNMG 280 0.2 36m

Total 2h 12m

Sales Manual > MEGA100 55/60

 MEGA100
13. Work Sample

Oil & Gas Industry

Aerospace Industry
Power Plant
Ship Building
Pulp & Paper Industry
Maintenance
Steel pipe
Roller
Flange
Long shaft
Cylinder
Spindle
Belt pulley
Valve body
Turbine Blade

Sales Manual > MEGA100 56/60

 MEGA100
14. Reference Customer

6000 LONG BED : Std. 7000 LONG BED : Order Made

A company : Dia.255mm, Hydraulic 4 Position, Built-in Tailstock, Full Cover

B company : Dia.155mm, Electric 12 Position, 24 Hyd. Chuck, Built-in Tailstock, Full Cover
C company : Dia.255mm, Hydraulic 4 Position, Built-in Tailstock, Full Cover

Electric 12 Position, 24 Hyd. Chuck, Built-in Tailstock, Rear Boring Holder, Boring Bar (1600mm)

(P Company : Defense Industry)

Sales Manual > MEGA100 57/60

 MEGA100
14. Reference Customer

), Direct S/P Motor, Tailstock with Chuck

Prism Roll Machine : Linear Scale (0.1

(H Company and others : IT)

Special Roll Lathe : Double Grinding Unit, Dressing Unit, Built-in Tailstock

(P Company and others : Steel Mill)

Sales Manual > MEGA100 58/60

 MEGA100
15. Packing Dimension

Packing information
Machine Model Description
Length Width Height N/Weight G/Weight C.B.M.
Main body 6,700 2,300 2,640 11,500 13,000 40.682
Chip conveyor 6,550 1,230 2,170 1,150 1,800 17.483
MEGA100x3000
Oil pan 4,620 865 450 400 950 1.798
Hydraulic unit 555 695 1,032 100 210 0.398
Main body 7,700 2,300 2,640 13,000 14,500 46.754
Chip conveyor 7,550 1,230 2,170 1,200 1,850 20.152
MEGA100x4000
Oil pan 5,620 865 450 500 1,050 2.188
Hydraulic unit 555 695 1,032 100 210 0.398
Main body 8,700 2,300 2,640 14,500 16,000 52.826
Chip conveyor 8,550 1,230 2,170 1,250 1,900 22.821
MEGA100x5000
Oil pan 5,620 865 450 620 1,170 2.188
Hydraulic unit 555 695 1,032 100 210 0.398
Main body 9,700 2,300 2,640 15,500 17,000 58.898
Chip conveyor 9,550 1,230 2,170 1,300 1,950 25.490
MEGA100x6000
Oil pan 7,620 865 450 718 1,268 2.966
Hydraulic unit 555 695 1,032 100 210 0.398

Sales Manual > MEGA100 59/60

 MEGA100

Thank you for your attention!

Sales Manual > MEGA100