The Whitney 4400MAX Combination Machine Tool uses the fastest technologies to make parts – Punching and Plasma Cutting.

The Whitney 4400MAX Combination Machine Tool uses the fastest technologies to make parts – Punching and Plasma Cutting.

• Punched holes provide accurate internal features.
• It is faster to punch holes than to pierce and contour holes with plasma or laser.
• External features are plasma cut. Advanced plasma-cutting technology provides highly productive contouring (much faster than laser) with high quality.
  • Small kerf angle (vertical cuts)
  • Dross-free cutting

• Additional features such as forming (countersinks, tread plate, louvers), drilling and tapping can be added to eliminate additional downstream operations, allowing parts to be completed in a single operation.

Manufacturing costs are lower using the combination machine technology.

• Labor costs are lower because it takes significantly less time to manufacture the parts.
• Operating costs are lower.
• Amortization of capital costs is significantly lower since
• Lower initial capital cost than laser
• Faster cycle time – Cost of capital per fabricated part is lower because capital costs are amortized over more fabricated parts.

The PROFIT-DOUBLER

• Higher profit per part —lower overall cost per piece gives a higher profit margin per piece.
• More parts generating profit—more parts are produced (in the same amount of time) on a combination machine, so there are more parts generating profit than on the other technologies.

SPECIFICATIONS OF MODEL 4400MAX

	INCH	METRIC
PUNCHING FORCE	100 Tons	900 kN
MATERIAL THICKNESS
Minimum	.074″ (14 GA)	2.0 mm
Maximum	1.000″	25.0 mm
MAXIMUM PUNCH DIAMETER	3.000″	76 mm
PUNCHING CAPACITY A36 (60ksi / 410 MPa Shear Strength)
.375″ (10 mm)	2.828″	71.8 mm
.500″ (12 mm)	2.109″	53.5 mm
.750″ (19 mm)	1.406″	35.7 mm
1.000″ (25 mm)	1.047″	26.6 mm
PUNCHING HIT RATE	125 HPM
10 gage (3 mm) material punched on 1″ (25.4 mm) centers
MAXIMUM POSITIONING AREA
X-axis	170″	4325 mm
Y-axis	96″	2450 mm
NOMINAL BLANK SIZE
Without Auxiliary Tables	96″ X 160″	2450mm x 4000mm
The 4400MAX can punch and plasma cut a full 8′ x 10′ 2450 x 3000 mm) sheet of material without repositioning.
EXTENDED BLANK SIZE
With Auxiliary Tables and Repositioning	96″ x 320″	2450mm x 4000mm
The 4400MAX can punch and plasma cut a full 8′ x 10′ 2450 x 3000 mm) sheet of material without repositioning.
POSITIONING SPEED PER AXIS	1,200 IPM	30,000 mm/min
POSITIONING ACCURACY	±0.005″	±0.13 mm
MINIMUM PROGRAMMED INCREMENT	0.001″	0.01 mm
MAXIMUM MATERIAL WEIGHT	4,900 #	2,250 kg
MAXIMUM BLANK SIZE
Standard X-Axis Without Auxiliary Tables	96″ x 160″	2450 x 4000 mm
Extended X-Axis Without Auxiliary Tables	96″ x 320″	2450 x 8000 mm
Longer plates may be accommodated in certain applications using automated repositioning. These applications must be reviewed by W. A. Whitney.
FOUNDATION REQUIREMENT
An 13″ / 330 mm reinforced concrete foundation is required beneath the press frame.
ELECTRICAL REQUIREMENTS
460/3/60	175 KVA
Contact W. A. Whitney for voltages other than 460/3/60.
APPROXIMATE FLOOR SPACE
Front – Back	268″	11420mm
Left – Right	370″	9400mm
Height – Machine	120″	2953mm
Height (w/ dust collector)	173″	4395mm

NOTE: Specifications are subject to change without notice.

INCLUDED EQUIPMENT

This proposal describes the Model 4400MAX CNC Punch/Plasma Fabricating Center, 100 ton (900 kN) punching capacity, 96″ x 170″ (2450 mm x 4325 mm) positioning area per attached specifications, for 460/3/60 volt incoming power. (NOTE: Material blank sizes greater than 160” can be processed by utilizing the Programmable Repositioning Assembly.)

Siemens 840DSL CNC 3-Axis Positioning / Contouring Control including:

• Pendant mounted operator’s station,
• Windows 10 Operating System,
• Alpha/Numeric panel and Windows keyboard with trackball,
• 5 MB part program and system shared memory
• USB Interface
• 15″ High Resolution Color LCD Monitor.

Network Card, installed in the CNC Control, including:

• 10/100 Mb RJ45 Ethernet
• Ready for connection to customer’s existing Network, and
• Suitable for downloading Part Programs

Automatic Tool Changer – including storage magazine with (16) sixteen tool storage locations. The Tooling System uses Whitney 44TC Style Tools, and includes one (1) Alignment Tool Set.

Programmable Small Parts Drop Door – 24″ x 96″, (600 mm x 2450 mm), located immediately next to the plasma torch, used for automatically unloading small parts and cut-outs.

Hypertherm MAXPRO200®, LongLife® air and oxygen plasma cutting system with impressive cutting speeds, consistent cut quality, and exceptional consumable life.

Integrated Dust Collection System, including the dust collector, spark trap, duct, wiring, and interconnections are provided.

NOTE: The supplied dust collection system is designed for plasma cutting steel and stainless steel. Plasma cutting aluminum requires an optional additional aluminum dust collector.

Integrated Plasma System Support Equipment:

• Air intensifier for increasing shop air pressure as required for plasma cutting
• Slag Chamber lined with refractory materials

Whitney Halo, plasma torch collision detection device.

Retractable Hydraulic Work Clamp Assembly – including (3) hydraulic work clamps for up to 1.0″ (25 mm) thick material. Clamps require no adjustment for changes in material thickness.

NOTE: Retractable work clamps allow the rear edge of the raw material to be processed (punched and plasma cut) without repositioning, effectively eliminating work clamp avoidance zones.

Programmable Repositioning Assembly is designed to relocate the work clamps on the material in order to process areas of the material that are within the work clamp safety zones. Automatic repositioning allows the repositioning of material blanks which are longer that the X-axis.

NOTE :If  the machine will be making finished parts longer than the X-axis length, please contact Whitney to review the specific application.

Hydraulic Pressure Switch Circuit – selectable through part program, for ram reversal upon pressure. This allows forming work such as center punch marks, number stamps, countersinks, louvers, and embossing to be done.

Programmable Repositioning Assembly is designed to relocate the work clamps on the material in order to process areas of the material that are within the work clamp safety zones. Automatic repositioning allows the repositioning of material blanks which are longer that the X-axis.

NOTE :If  the machine will be making finished parts longer than the X-axis length, please contact Whitney to review the specific application.

Material Support Roller Tables are supplied for the left and right side of the machine.

NOTE: The material support roller tables are designed to support the material during processing. For applications in which the material thickness is predominately 0.125” (3 mm) or less, ball transfer support tables are recommended in lieu of the roller tables.

Hydraulic Power Unit – with 60 H.P. (45kw) drip-proof motor and hydraulic oil.

Automatic Punch Lubrication – with reservoir.

Remote Diagnostics Package – allows many machine problems to be diagnosed via the Internet using TeamViewer. W. A. Whitney Service Technicians can log directly onto the CNC control for the purpose of diagnosing problems, reviewing NC programs, downloading new software, and changing parameters if required. Customer is responsible for providing a suitable Ethernet connection at the machine CNC control with Internet access. A telephone line or cell phone is recommended so that the technician can talk to the operator/maintenance person while diagnosing the problem.

Software License – for all software resident on the CNC Control. The software is proprietary, and the intellectual property of W. A. Whitney Co. Prior to the commissioning of the machine tool, the user must sign a software license agreement. This is a non-transferable license that must be renewed by any and all subsequent owners of the machine tool. The value of this software license is $1,500.00, and it is included in the price of the machine.

Operating and Service Manual – consisting of (1) print copy and (1) CD copy W. A. Whitney Documentation and (1) print copy of Vendor Documentation including Fanuc CNC and Drives.

Electrical Standards – The machine conforms to W. A. Whitney electrical design standards which are based on N. E. C., NFPA-79, and UL Standards with deviations. Components are NEMA and IEC rated where possible.

100 TON PUNCHING CAPACITY

IMPORTANT NOTE: Punching of high tensile material is a special application for Whitney Combination Machine Tools, and may void the machine warranty and cause premature tooling wear. High tensile strength material is defined as any material whose tensile strength is greater than 60ksi (413 MPa). Materials often referred to as “remnants” or “seconds” will often randomly exhibit tensile strength greater than 60ksi (413 MPa) and thus will void the machine’s warranty. WHITNEY reserves the right to have a representative sample of customer supplied material mechanically and/or chemically tested. If processing high tensile material, please consult the factory for a review of your specific requirements. In some cases, a larger Whitney Combination Machine model could be recommended.

The 100 TON PUNCHING CAPACITY allows the 4400MAX to:

• Punch larger hole sizes in a given material type and thickness
• Punch holes in higher tensile strength materials
• Punch thicker materials

4400MAX INCLUDED TOOLING CARTRIDGE AND ADAPTERS

Each Punch and Die Tooling station requires (1) Tooling Cartridge and (1) Tooling Adapter Assembly. Each complete tooling station assembly includes following components:

• (1) Tooling Cartridge
• (1) Punch Alignment Ring
• (1) Stripper Plate
• (1) Die Adapter Max. 3″ I.D. Dies.

A total of (16) punching stations can reside in machine at one time. The following components are included with the 4400MAX:

(16) Tooling Cartridge and Adapter Assemblies

• (8) 1-1/4″ (32 mm) O. D. Tooling Adapter Assembly
• (4) 2-1/8″ (54 mm) O. D. Tooling Adapter Assembly
• (2) 2-3/4″ (70 mm) O. D. Tooling Adapter Assembly
• (2) 3-3/4″ (95 mm) O. D. Tooling Adapter Assembly
• (16) Tooling Cartridges
• (16) Punch Alignment Ring

The final selection of Tooling Adapter Assemblies may vary with each application.

HALO TORCH COLLISION DETECTION DEVICE (STANDARD)

The HALO TORCH COLLISION DETECTION DEVICE detects part tip ups that collide with the plasma torch housing. If the halo detects a collision, an immediate emergency stop command is given to the CNC control to stop the machine axis motion and turn off the plasma cutting system, preventing torch replacement and down time cost.

MAXPRO200® PLASMA CUTTING SYSTEM (STANDARD)

The MAXPRO200® Plasma Cutting System, standard on the 4400MAX, offers LongLife® air and oxygen plasma technology, giving high quality plasma cuts with excellent consumable life. The MAXPRO200® plasma system incorporates the superior cut quality of oxygen plasma cutting with increased cutting capability and reliability.

Advantages include:

• Little or no dross on plasma cut edges
• Narrow kerf width for fine detail cutting
• Long consumable life with high system reliability
• Faster cutting speeds with best edge quality

The MAXPRO200® system includes:

• MAXPRO200® Plasma Power Unit
• Quick Change plasma torch and positioning assembly for correct stand-off height
• Dust collector with filters and spark trap
• Slag collection system

Cutting Speeds

The published values for the MAXPRO200® Plasma Cutting System represent the speeds attainable under controlled conditions. The practical speeds for processing carbon steels are shown in the following chart and are the optimum production values for minimum set-up time and best quality cuts.

Cutting Speeds – MAXPRO200® – Mild Steel – O2 / Air

	.075″ 2.0 mm	.135″ 3.0 mm	.187″ 4.0 mm	.250″ 6.0 mm	.375″ 10.0 mm	.500″ 12.0 mm	.625″ 15.0 mm	.750″ 20.0 mm
50A	220 ipm 3050 mmpm	130 ipm 3650 mmpm	85 ipm 2800 mmpm	65 ipm 1750 mmpm
130A		240 ipm 5900 mmpm	190 ipm 5325 mmpm	150 ipm 3925 mmpm	110 ipm 2680 mmpm	80 ipm 2200 mmpm	60 ipm 1665 mmpm	50 ipm 1195 mmpm
200A				235 ipm 6210 mmpm	150 ipm 3735 mmpm	130 ipm 3415 mmpm	105 ipm 2845 mmpm	80 ipm 1920 mmpm

Available Cutting Processes:

	MAXPRO200® PROCESS SELECTION GUIDE (Plasma / Shield)
	100AMP		130AMP		200AMP
Steel	O2 / Air	Air / Air	O2 / Air	Air / Air	O2 / Air	Air / Air
Stainless	Air / Air	—-	Air / Air	N2 / N2	Air / Air	N2 / N2
Aluminum	Air / Air	—-	Air / Air	N2 / N2	Air / Air	N2 / N2
	Note: Typical preferred processes are indicated BOLD.

Gas Requirements:

		MAXPRO200®
GAS TYPE	REQ’D	QUALITY	SUPPLY
Air	✓	Clean, dry, oil-free (ISO 8573-1 class 1.4.2)	90 psi ±10 psi @ 400 scfh 6.2 bar ±0.7 bar @ 11330 l/h
Oxygen (O2)	✓	99.5% pure (liquid gas recommended)	90 psi ±10 psi @ 400 scfh 6.2 bar ±0.7 bar @ 11330 l/h
Nitrogen (N2)	✓	99.995% pure (liquid gas recommended)	90 psi ±10 psi @ 400 scfh 6.2 bar ±0.7 bar @ 11330 l/h

NOTE: Customer is to furnish suitable regulators for connections to included supply hoses.

MACHINE OPTIONS

HPR130XD PLASMA CUTTING SYSTEM (OPTIONAL)

The HyPerformance Plasma HPR130XD Oxygen Plasma Cutting System option is available in lieu of the standard MAXPRO200® plasma system.

The HPR130XD incorporates the superior cut quality of HyDefinition® technology with increased cutting capability and reliability of the standard MAXPRO200®. Patented LongLife® technology improves consumable life and reduces cutting costs.

Advantages include:

• Near vertical edge quality
• Little or no dross on plasma cut edges
• Narrow kerf width for fine detail cutting
• Long consumable life with high system reliability
• Improved Stainless Steel process reduces edge discoloration
• Faster cutting speeds with best edge quality

The Whitney HPR130XD Optional package includes:

• HPR130XD Plasma Power Unit
• Automatic Gas Console
• Quick Change plasma torch and positioning assembly for correct stand-off height
• Quick disconnect torch head
• Air Intensifier
• 8 Cartridge Dust Collector with filters and spark trap
• Robust Slag Collection System

XPR170 PLASMA CUTTING SYSTEM W/ CORE™ or OPTIMIX™ CONSOLE (OPTIONAL)

The Hypertherm XPR170™ Plasma Cutting System option is available in lieu of the standard MAXPRO200® plasma system.

The XPR170™ represents the most significant advance in mechanized plasma cutting technology, ever. This next generation system redefines what plasma can do by expanding its capabilities and opportunities in ways never before possible. With unmatched X-Definition™ cut quality on mild steel, stainless steel and aluminum, the newXPR170™ increases cut speed, dramatically improves productivity and slashes operating costs by over 50%. New ease-of-use features and engineered system optimization make the XPR170™ easier to run with minimal operator intervention, while also ensuring optimal performance and unmatched reliability.

Advantages include:

The XPR170 advances HyDefinition® cut quality by blending new technology with refined processes for next generation, X-Definition cutting on mild steel, stainless steel and aluminum.

Industry Leading Cut Quality

• Consistent ISO range 2 results on thin mild steel
• Extended ISO range 3 cut quality results compared with earlier plasma technology

Optimized Productivity and Reduced Operating Costs

• Consumable life increases of over 40% compared with previous systems
• 20% thicker piercing capability on stainless steel and 30% thicker on mild steel
• Operating costs reduced by over 50%

The Whitney XPR170 package includes:

• XPR170 Plasma Power Unit
• Core™ Gas Console – for unmatched mild steel cutting performance and superior angularity and edge finish on stainless steel up to 12 mm (1/2″). This is delivered through a new N2 HDi™ process that prevents the mixing of air into the plasma gas, creating an improved, brighter edge finish.
• Optimix™ Gas Console (optional) – provides additional inputs and control for enhanced plasma processes in stainless steel and aluminum
• EasyConnect™ torch lead and one hand torch-to receptacle connection for fast and easy change-outs
• Whitney QuickChange positioning assembly for correct stand-off height
• Air Intensifier
• Dust Collector with filters and spark trap
• Robust Slag Collection System

XPR300 PLASMA CUTTING SYSTEM W/ CORE™ or OPTIMIX™ CONSOLE (OPTIONAL)

The Hypertherm XPR300™ Plasma Cutting System option is available in lieu of the standard MAXPRO200® plasma system.

The new XPR300™ represents the most significant advance in mechanized plasma cutting technology, ever. This next generation system redefines what plasma can do by expanding its capabilities and opportunities in ways never before possible. With unmatched X-Definition™ cut quality on mild steel, stainless steel and aluminum, the new XPR300 increases cut speed, dramatically improves productivity and slashes operating costs by over 50%. Newease-of-use features and engineered system optimization make the XPR300 easier to run with minimal operator intervention, while also ensuring optimal performance and unmatched reliability.

Advantages include:

The XPR advances HyDefinition® cut quality by blending new technology with refined processes for next generation, X-Definition cutting on mild steel, stainless steel and aluminum.

Industry Leading Cut Quality

• Consistent ISO range 2 results on thin mild steel
• Extended ISO range 3 cut quality results compared with earlier plasma technology

Optimized Productivity and Reduced Operating Costs

• 300 amps and 63 kW of output power deliver higher cut speeds; up to 15% on thicker materials
• Consumable life increases of over 40% compared with previous systems
• 20% thicker piercing capability on stainless steel and 30% thicker on mild steel
• Operating costs reduced by over 50%

The Whitney XPR300 package includes:

• XPR300 Plasma Power Unit
• Core™ Gas Console – for unmatched mild steel cutting performance and superior angularity and edge finish on stainless steel up to 12 mm (1/2″). This is delivered through a new N2 HDi™ process that prevents the mixing of air into the plasma gas, creating an improved, brighter edge finish.
• EasyConnect™ torch lead and one hand torch-to receptacle connection for fast and easy change-outs
• Whitney QuickChange positioning assembly for correct stand-off height
• Air Intensifier
• 12 Cartridge Dust Collector with filters and spark trap
• Robust Slag Collection System

HPR400XD PLASMA CUTTING SYSTEM (OPTIONAL)

The HyPerformance Plasma HPR400XD Oxygen Plasma Cutting System option is available in lieu of the standard MAXPRO200® plasma system.

The Whitney HPR400XD Optional package includes:

• HPR400XD Plasma Power Unit
• Automatic Gas Console
• Quick disconnect torch head

The HPR400XD incorporates the superior cut quality of HyDefinition® technology with increased cutting capability and reliability. Patented LongLife® technology improves consumable life and reduces cutting costs.

Advantages include:

• Near vertical edge quality
• Little or no dross on plasma cut edges
• Narrow kerf width for fine detail cutting
• Long consumable life with high system reliability
• Improved Stainless Steel process reduces edge discoloration
• Faster cutting speeds with best edge quality

The Whitney HPR400XD Optional package includes:

• HPR400XD Plasma Power Unit
• Automatic Gas Console
• Quick Change plasma torch and positioning assembly for correct stand-off height
• Quick disconnect torch head
• Air Intensifier
• 12 Cartridge Dust Collector with filters and spark trap
• Robust Slag Collection System

BEVEL CUTTING HEAD FOR PLASMA CUTTING (OPTIONAL)

3-axis bevel cutting head integrated with the CNC control. The bevel head is supplied in lieu of the standard plasma cutting head.

The bevel head includes:

• Innovative light weight bevel design
• 95^o Side-Side & 95^o Forward-Back motion and 360^o Full Rotation without twisting any cables or hoses!
• Eliminates the need for double handling. Cut steel and perform the weld preparation at the same time.
• Fixed tool center point eliminates translation adjustments
• Plasma torch movement is provided by digital drive amplifiers and servo motors for all axis – tilt, rotation and vertical height
• Arc voltage automatic height control to provide the most accurate bevel tolerance.
• Robust design for heavy industrial environment
• Consistent and reliable bevel quality for holes and edges

ADDITIONAL DUST COLLECTOR FOR PLASMA CUTTING ALUMINUM (OPTIONAL)

NOTE: ALUMINUM DUST CAN CAUSE FIRES OR EXPLOSIONS

The ADDITIONAL DUST COLLECTOR FOR PLASMA CUTTING ALUMINUM is a second dust collector that collects aluminum and steel in different dust collectors. The dust collector used for aluminum cutting must be located outside. Precautions must be taken when running aluminum. The chances for fires or explosions increase when running both steel and aluminum on the same machine. Hot steel slag (which has a higher melting point than aluminum) will ignite the aluminum dust particles.

The following items are included in the dust collector assembly:

• Dust collector and filters with silencer
• Explosion vent on dust collector (should there be an explosion, this will direct the force of an explosion in the appropriate direction, and minimize damage to the dust collector).
• Second slag pan, to be used for aluminum cutting only. This slag pan will be interlocked to make sure the appropriate slag pan is used (per part program).
• Manual damper vent to direct exhaust to the appropriate dust collector. This damper vent will be interlocked to make sure that the appropriate dust collector is selected per part program.
• Miscellaneous electrical components and software.
• Special ducting to prevent the settling of aluminum dust within the duct work.
• Documentation (manuals) and name plates

HIGH TEMPERATURE PACKAGE (OPTIONAL)

The HIGH TEMPERATURE PACKAGE includes extra cooling for the hydraulics and electrical when the standard environmental conditions cannot be met.

INK JET PART MARKING SYSTEM (OPTIONAL)

The INK JET PART MARKING SYSTEM provides a non-contact system to marks parts being produced on the machine. The system is mounted on the plasma positioning assembly and can mark on surfaces with rust and oil.

Equipment Description

• Black text non-contact printing
  • One (1) line of 1.25” tall characters
  • One (1) line of ½” tall characters
  • Two (2) lines of ½” tall characters
• Capability of providing a solid or dashed line for bend line marking
• Printing Head Positive Standoff
• 6 liters of black ink suitable for use with metal which has minimal dirt, scale and oil on surface 6 liters of cleaning solution

PNEUMATIC TAPPING SYSTEM (OPTIONAL)

Designed for occasional use, the PNEUMATIC TAPPING SYSTEM allows you to tap previously punched holes, adding features to your parts while minimizing the cost and time of additional downstream operations.

Approximate average cycle time of 30 seconds dependent upon application, material type, material thickness, and tap size.

Included in the system:

• (1) Pneumatic Tapping Head
• (1) Set of seven tap adapters – the follow tap sizes can be accommodated
  • Inch (fine or coarse) – #10, 1/4, 5/16, 3/8 1/2, 5/8, 3/4
  • Metric (fine or coarse) – M6, M8, M10, M12, M16

PNEUMATIC COMBINATION DRILL/TAP SYSTEM (OPTIONAL)

Adding to the versatility of the punch/plasma system, the PNUEMATIC DRILL/TAP SYSTEM allows you to add features to your parts while minimizing the cost and time of additional downstream operations.

Manually interchangeable heads provide drilling and tapping where punching is not practical. Approximate average cycle time of 30 seconds dependent upon application, material type, material thickness, and drill/tap size.

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