Yasda direct drive spindle

YASDA CNC JIG BORER
YBM 640V
YBM 950V
“We create the best
machines and services”
ver.III
ver.III

Note : This Power Point presentation is only for Yasda
dealers to show to customers, for the purpose of sales
promotion. It is not allowed to use copies to
advertisement, nor to pass copies to customers without
consent from Yasda beforehand.
YBM 640V ver.III Out view
YBM 950V ver.III Out view
YBM 640V/950V Concept
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Reliable and versatile machine for die and mold
customers with Hardmilling technology
Total profitability obtained from its mechanical rigidity
and the highest accuracy in market
Minimum thermal distortion, outstandingly stable for
long time running or automation
YBM 640V/950V Concept
Versatility created from one Yasda spindle
How Hardmilling is profitable?
in total process time
HRC60 cold forging die for bevel gear
How Hardmilling is profitable?
in total production cost
HRC60 cold forging die for bevel gear
How Hardmilling is better than EDM?
accuracy of gear forging die
Conventional Process
(Electric Discharge
Machining)
Hard Milling Process
SIDE1
SIDE2
SIDE1
SIDE2
Cumulative Pitch Error
ACC. PIT. VAR. (Fp)
0.0110
0.0108
0.0045
0.0050
Tooth Space Runout
CALC. RUNOUT (Fr)
0.0109
0.0105
0.0040
0.0040
Single Pitch Error
MAX. PIT. VAR. (fp)
0.0061
0.0058
0.0024
0.0030
Pitch Variation Error
MAX. SPAC. VAR. (fu)
0.0066
0.0065
0.0037
0.0044
HRC60 cold forging die for bevel gear
History of Hardmilling in Japan (1)
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Before 1993: Machining centers are used only for rough
milling of die steel or making copper electrodes
Since 1993: Customers started direct machining on after
hardened die steel to save total manufacturing cost
Hardmilling started in Japan, materials were NAK55, NAK80,
SKD61, up to HRC50 hardness, also sea level cutting has
developed cooperating with CAD/CAM supplier
At that time, accuracy of hardmilling was not enough, also
rigidity of machine was not enough
Yasda developed YBM 640V in 1994, getting cooperation
from a neighboring die making customer
they had 10sets of 3D CAD/CAM system
History of Hardmilling in Japan (2)
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-
-
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1994: Yasda exhibited YBM 640V at JIMTOF show
Osaka with iron die sample (NAK80) and surprised
many die & mold customers for its surface quality
In 4 to 5 years, most of die and mold customers
in Japan employed hardmilling solution
Nowadays, technology of hardmilling is separated:
Competitors: HSC (High Speed Cutting) due to less machine
rigidity with smaller cutting removal, in many cases only for
finishing
Competitors: Less accurate due to thinner construction
Yasda: High efficient hardmilling with larger cutting capability,
due to outstandingly rigid structure, in many cases from
roughing to finishing
Yasda: Outstandingly accurate and stable for automation due
to bigger construction with hand scraping process
Feeling “HRC”

Try filed off the material of different
hardness…
HRC60
steel
nearly
impossible
HRC50
steel
difficult
HRC40
steel
possible
Copper
easy
Construction of competitors (1)
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Box guide ways: Only surface of
cast iron is hardened, together
with machine body. Difficult to
repair accuracy in case of hard
collision.
Spindle is held by smaller area,
leads to less rigidity.
There is no temperature
controlled oil in the spindle head,
that Yasda 640V/950V have.
Spindle torque 32N at 3,300rpm,
12N at 12,000rpm.
(640V&950V: 118N at 1,500rpm,
21N at 10,000rpm)
Construction of competitors (2)
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Spindle life is much shorter than
Yasda, purchased spindle is
employed.
36,000rpm to 40,000rpm spindle
with fixed preload, not suitable
for heavy duty cutting.
Thin LM guide ways, not rigid
enough for hardmilling, leads to
shorter cutter life and shorter
machine life.
Z-axis stroke is 500 to 600mm
(YBM640V&950V: 350mm),
easier to cause thermal
deformation when running long
hours.
YBM 640V/950V Structures
① Balance cylinder is eliminated
and contributes to smooth control
of Z-axis
② Direct drive spindle
with preload self-adjusting
system
Separated spindle and
spindle motor for accuracy
③ Through hardened
(HRC60) box guide ways
for X/Y/Z axis ideal for hard
milling of die and mold
④ Symmetrical bridge
constructure assures
high rigidity and thermal
stability
⑤ 3 point support for
machine base, easy to
adjust machine level
⑥ Temperature controlled oil is
Circulated through
-Spindle head
-Saddle unit
-Top beam of bridge
as standard
(through column bridge
as option)
YBM 640V/950V Specifications
YBM 640V/950V Spindle technology
Spindle motor
Spindle head
thermal distortion
control system
Direct drive
system
Finish process of
spindle taper
Preload selfadjusting system
Rotating radial error
0.80 µm / 20000min-1
Yasda Direct drive spindle
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-
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-
-
Others’ built-in motor spindle:
Damping capacity (that reduce
motor
the cutting vibration) is low.
Not favorable for heavy duty
cutting and fine grade finishing.
Spindle life less than 10,000hours. Driving force is transmitted
Yasda direct drive spindle:
Electric vibration from the drive
motor is isolated.
Rotation accuracy is outstanding
since the spindle’s
driving force does not work in the
radial direction.
Spindle life minimum 20,000hours.
In radial direction
Driving force is transmitted
straight to the spindle
* 20,000hours is indication, not guaranteed.
Yasda Preload self-adjusting system
Φ12-10mm square end mill
on HRC60 steel
R5-R3 ball end mill
on HRC60 steel
R1.5-R0.15 ball end mill
on HRC60 steel
Preload: High → Low
Spindle speed Low → High
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Unique mechanical design inside the spindle enables
self-adjustment of preload.
It gives high preload when using bigger cutters at
lower speed, and low preload when using smaller
cutters at high speed.
Versatile cutting applications with one spindle.
Yasda Spindle technology
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The taper and end face of
assembled spindle are
ground by rotating the
spindle, that ensures
highest accuracy
achievable in each spindle
unit.
Run out at the spindle taper
0.8μm at 20,000rpm
rotation (measured value).
Run out of spindle:
0.003mm in Z: 200mm
(measured value).
YBM 640V/950V 24,000rpm spindle
118N at 1500rpm
21N at 10000rpm
Selectable : HSK-A63 or BT40 BIG Plus taper
YBM 640V/950V 30,000rpm spindle
Only BT30 BIG Plus taper available
Recommended when using small ball end mills only
Cutting forces comparison
direct drive spindle and built-in motor spindle
Cutting forces measurement by vibration sensor
placed under work piece
Cutting Conditions:
 Ø10 ball end mill (6 teeth)
 Cutting depth: 5mm
 Cutting radius:1mm
(0.1mm/tooth)
 Spindle speed: 5000 min-1
 Feed rate: 3000mm/min
 Material: SKD11 (HRC60)
YASDA Direct drive spindle BT40
Bigger vibrations lead to
worse surface quality and
shorter tool life
Built-in spindle motor BT50
Importance of guide ways
If the guide ways are not straight…
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The movement of the machine reproduces the
accuracy of the guide ways. Therefore the guide ways
determine the inherent accuracy of the machine tool.
The most importance measure of accuracy in the
guide ways is the straightness.
If the straightness of guide ways are not enough, it is
not possible to compensate it accurately.
Competitors’
Guide ways finished by machining
Straightness of guide ways
≠Grinding machine’s inbuilt accuracy
Guide Way
Machining Center Bed
Clamping stress
might be induced

Grinding Machine
It is not possible to produce perfectly straight slide
ways which are better than the slide ways of the
grinding machine on which they are ground.
Competitors’ LM Guide ways
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Low vibration dampening capacity because contact is
lines of rollers inside.
Shorter operational life and requires replacement in
case of wear.
Weak against impact resulting in damage to the rolling
surface in case of a collision.
Width of LM guide ways’ base: 45-50mm
Yasda box guide ways: 85-100mm, surface contact.
Yasda Hand scraping (1)
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First introduced in England
during the industrial revolution.
A highly skilled operator uses a
scrapper to achieve absolute
flatness on a sliding or a datum
surface.
As the long process demands,
hand scrapping was gradually
replaced by machining and only
a few companies still continue
with it.
There is no other reliable
technique yet other than hand
scrapping to achieve highest
accuracy.
Yasda Hand scraping (2)
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A red compound is applied evenly
on the surface, and a master flat
is pressed and slid on it.
Where the master flat touches will
become lighter, and compound
remains where the master flat
does not touch.
The lighter points are scrapped
off. A skilled scrapper can tell how
many microns he had removed.
The process are repeated, till the
applied marking compound
appears to be evenly distributed.
Red compound
Yasda Guide ways (1)

Individually ground all 4
sides of the guide ways to
minimize the affect of the
inherent pitch and roll
inaccuracy of the surface
grinder.
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Hand lapped with a special
compound for fine finishing
and minimizing wear and
resistance.
Yasda Guide ways (2)
roller pack

Optimized guide way system for high precision
machining: Hybrid guide ways (roller pack and through
hardened (HRC60) box guide way) in X / Y / Z axis
Yasda Guide ways (3)
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The mating surfaces are
repeatedly and meticulously
hand scraped.
Straightness is measured
by an auto collimator by
bolting the guide ways.
These processes are
repeated until the
straightness specification is
0.25μm
achieved.
Straightness of YBM 640V
Y-axis guide ways:
0.37μm (measured value). - 0.12μm
Which way is right?
* American Machinist July 1998
Feeling “μm”

Thickness of copy paper : 90μm

Thickness of human hair : 70μm
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Size of microbe (bacteria) : 1 ～ 5μm
Yasda bed constrcution (1)
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Competitors:
The internal stress
induced during
assembly slowly get
relieved, resulting in a
deterioration of the builtin accuracy of the
machine.
YASDA: Joining surface
achieved by hand
scraping matches with
the counter mating part
evenly, no distortion
even after bolting the
parts together.
Machine
bed
Machine
bed
Machine
bed
Yasda bed constrcution (2)
Ball screw bracket and nut bracket
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The ball screw bracket and
the nut bracket are hand
scraped in order to align the
guide ways and ball screw in
the highest parallelism
Special test bar to measure
the variance between the test
bar and the ways
The result of these leads to;
1) high feed rigidity and high
positioning accuracy
2) high accurate and fine
finish machining and longer
machine tool life
Ball screw bracket 1
YBM 640V/950V Axis drive

Small lead (8mm pitch) and
large size ball screws to
increase the rigidity of feed
drive and response:
X/Z:Ø50mm Y: Ø45mm

Cooling in ball screw nuts
and support bearings in all
axes for protection of the
machine geometry from
thermal distortion.
YBM 640V/950V ATC
(Automatic Tool Changer)
Standard 30 ATC
Additional 60 ATC (option)
Standard 30 tools
 Option 40, 90 tools (30+60), 100 tools (40+60)

YBM 640V/950V PC / PLS
(Pallet Changer / PreLoad Stand)
Yasda HAS-3
(Highly Accurate and Speedy machining)
system (option)
CNC with high speed processing
CPU and highly rigid feed drive unit
 Improve configuration error in high
speed machining with nano-interporation
 Look ahead 600 blocks

YBM 640V/950V CNC control
Screen of Tool management
FANUC 31i-A5
 Leading-edge hardware technologies with
highly precise nano interpolation
 Tool management (option): totally manages
tool information including tool offset and tool life

YBM 640V/950V Lost motion and repeatability
UNIT : mm
ITEM
X-AXIS
Y-AXIS
Z-AXIS
LOST MOTION
+0.0000
+0.0000
+0.0000
-0.0001
+0.0001
-0.0002
+0.0001
-0.0001
+0.0001
-0.0002
+0.0000
-0.0002
-0.0001
-0.0003
+0.0000
-0.0002
+0.0000
-0.0002
+0.0000
-0.0001
+0.0000
-0.0001
+0.0001
+0.0000
+0.0002
+0.0002
+0.0001
+0.0000
-0.0001
+0.0002
REPEATABILITY
+0.0000
+0.0000
+0.0001
-0.0001
-0.0002
-0.0001
-0.0001
+0.0000
+0.0001
+0.0000
+0.0000
+0.0000
+0.0001
+0.0001
+0.0000
+0.0000
+0.0000
+0.0001
+0.0002
+0.0001
+0.0001
YBM 640V/950V Unit feed
UNIT : mm
ITEM
X-AXIS
Y-AXIS
Z-AXIS
UNIT FEED
(1/100mm STEP)
+0.0000
+0.0099
+0.0199
+0.0298
+0.0399
+0.0500
+0.0601
+0.0700
+0.0800
+0.0900
+0.0999
+0.0000
+0.0101
+0.0200
+0.0300
+0.0400
+0.0500
+0.0600
+0.0700
+0.0800
+0.0899
+0.0999
+0.0000
+0.0100
+0.0200
+0.0300
+0.0401
+0.0501
+0.0600
+0.0700
+0.0800
+0.0901
+0.1000
+0.0899
+0.0799
+0.0699
+0.0599
+0.0500
+0.0399
+0.0298
+0.0198
+0.0098
-0.0002
+0.0899
+0.0799
+0.0699
+0.0599
+0.0499
+0.0399
+0.0299
+0.0199
+0.0099
-0.0001
+0.0901
+0.0802
+0.0701
+0.0601
+0.0501
+0.0402
+0.0302
+0.0202
+0.0102
+0.0002
YBM 640V/950V Positioning accuracy (X)
UNIT : mm
ITEM
POSITIONING
ACCURACY
X-AXIS
0 ～ 400
420 ～ 800
TARGET
ERROR
+0.0000
+20.0000
+40.0000
+60.0000
+80.0000
+100.0000
+120.0000
+140.0000
+160.0000
+180.0000
+200.0000
+220.0000
+240.0000
+260.0000
+280.0000
+300.0000
+320.0000
+340.0000
+360.0000
+380.0000
+400.0000
+0.0000
-0.0001
+0.0000
-0.0001
+0.0000
+0.0001
+0.0001
-0.0002
-0.0002
-0.0002
+0.0000
+0.0000
-0.0001
+0.0002
+0.0000
+0.0003
+0.0000
-0.0001
-0.0002
+0.0000
+0.0001
TARGET
ERROR
+420.0000
+440.0000
+460.0000
+480.0000
+500.0000
+520.0000
+540.0000
+560.0000
+580.0000
+600.0000
+0.0001
+0.0001
-0.0001
+0.0000
-0.0001
-0.0002
+0.0002
-0.0002
+0.0000
-0.0001
YBM 640V/950V Positioning accuracy (Y)
UNIT : mm
ITEM
POSITIONING
ACCURACY
Y-AXIS
0 ～ 400
400 ～ 800
TARGET
ERROR
+0.0000
+20.0000
+40.0000
+60.0000
+80.0000
+100.0000
+120.0000
+140.0000
+160.0000
+180.0000
+200.0000
+220.0000
+240.0000
+260.0000
+280.0000
+300.0000
+320.0000
+340.0000
+360.0000
+380.0000
+400.0000
+0.0000
+0.0000
+0.0001
+0.0000
+0.0003
+0.0001
-0.0002
-0.0003
-0.0002
+0.0000
-0.0002
-0.0003
-0.0001
-0.0003
+0.0003
-0.0002
+0.0000
-0.0003
-0.0005
-0.0002
+0.0001
TARGET
ERROR
YBM 640V/950V Positioning accuracy (Z)
UNIT : mm
ITEM
POSITIONING
ACCURACY
Z-AXIS
0 ～ 400
420 ～ 800
TARGET
ERROR
+0.0000
+20.0000
+40.0000
+60.0000
+80.0000
+100.0000
+120.0000
+140.0000
+160.0000
+180.0000
+200.0000
+220.0000
+240.0000
+260.0000
+280.0000
+300.0000
+320.0000
+340.0000
+0.0000
+0.0000
+0.0004
+0.0001
-0.0001
+0.0001
-0.0005
-0.0004
-0.0006
+0.0001
+0.0000
-0.0001
-0.0003
-0.0003
-0.0001
-0.0003
-0.0001
-0.0001
TARGET
ERROR
YBM 640V/950V ISO230-2 Accuracy (X)
A: 0.0013mm
(VDI3441 Pa: 0.0014mm)
YBM 640V/950V ISO230-2 Accuracy (Y)
A: 0.0017mm
(VDI3441 Pa: 0.0019mm)
YBM 640V/950V ISO230-2 Accuracy (Z)
A: 0.0012mm
(VDI3441 Pa: 0.0013mm)
YBM 640V/950V Circular cutting
(with HAS-3 activated)
Circularity: 1.46μm
 Contouring cutting
 Aluminum dia.186mm
 S8000 F2000

YBM 640V/950V Automation
YBM950V with pallet changer
3 x YBM640V with Z&K Germany
YBM640V with Erowa
2 x YBM640V with System 3R
Yasda training and after service
Highly motivated engineers
and sales team supports
customers for satisfaction.
 After service by local dealers
and Yasda Service team,
working together for
customers’ highest productivity.

YBM V-series Reference customers
YBM 640V/950V Application (1)
Surface Ry: 1.5μm along cutter lines
Ry: 2.8μm across cutter lines
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Work piece: Bevel gear cold forging die
Material: DC53 (HRC60)
Size: 60 x 60 x 50 mm
Total cutting time from solid: 2h 28min.
Finished by R1 x 8 CBN ball end mill
YBM 640V/950V Application (2)
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Work piece: Cold forging die
Material: DRM2 (HRC62) Matrix HSS
Size: φ100 x 50 mm
Total cutting time from solid: 6h 32min.
Finished by R1 x 8 CBN ball end mill
YBM 640V/950V Application (3)
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Work piece: Die casting mold
Material: DAC equivalent to 1.2344 HRC50
R5 (L49) ball end mill, R0.4 pencil neck ball end
mill, R1.5x20 ball end mill, etc.
Work dimension: dia.50x50～150x150mm
YBM 640V/950V Application (4)
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Outstandingly accurate in controlling Z axis
Material: STAVAX (HRC52)
YBM 640V/950V Application (5)
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Hard plate sample 250x150x22mm
Material: ARK1 (HRC60) machined from solid
Dimensions within 3μm
“YASDA” logo depth 10～2μm
Circularity of holes 1.6～2.4μm
YBM 640V/950V Application (6)
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Vertical pin sample
Material: NAK80 (HRC40)
Height of pin 97mm, R5 ball end mill
Showing outstanding run out accuracy, rigidity
and high performance in actual milling
YBM 640V/950V Application (7)
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Plate for gear pump
Material: W-Nr1.4112 (HRC58) Sumitomo BNES1100
Position of holes: within ±3μm
Circularity of holes 1.4μm
Surface roughness of holes Ra0.135μm
Replacing with jig-grinding operation
YBM 640V/950V Application (8)
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

Highly accurate copper electrode for IC industry
Position of pins: within ±3μm in 2 pieces after
20hours machining
Showing outstanding stability of high accuracy in
automation
YBM 640V/950V Application (9)
BIG Daishowa Air turbine spindle


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Oil seal die, silicon die
R0.25x2 ball end mill using Air turbine spindle
Smoother axes movement of Yasda box guide
ways helps achieve tight accuracy in seal and
silicon molds
Reference customers of seal die in Japan
YBM 640V/950V Application (10)
①



②
Machining accuracy, not possible to feel from catalogs
① Inserting parts of different hardness, finished by flat
end mills – sealing air between the gap
② Smooth mating parts finished by different cutters:
φ10 flat end mill / R3 ball end mill / R1 ball end mill /
φ5x5°taper end mill
YBM 640V/950V Application (11)





Lens die
Material: STAVAX (HRC52)
R4 to R1 ball end mill
Cutting time: 4h 37min.
With 30,000rpm spindle
YBM 640V/950V Application (12)


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Finishing mold base replacing with jig-grinding
operation
Material: S50C, Size: 400x300x80mm
Dia10 carbide end mill and Dia17 CBM end mill
Dimension within 5μm, pitch within 3μm
Never look at machine price only!!
What is the profitable machine
for next 10 years?
Thank you very much.