TERMS OF USE

Users of this Product Guide shall be deemed to agree with the following Terms of Use.

1. USERS
This Product Guide is only for authorized persons with user ID and password issued by Roland DG
Corporation.

2. PURPOSE
Authorized persons can use this Product Guide only for the purposes of selling and providing to the
customers maintenance service of DWX-4W.

3. REUSE
Authorized persons shall not disclose, transfer, rent or distribute this Product Guide to, or allow this
Product Guide to be used in any manner by, any third party other than authorized persons.

4. REPRODUCTION
Authorized persons shall not copy, change or alter this Product Guide without permission of Roland DG
Corporation.

5. EFFECT OF VIOLATION
Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action.

Copyright © 2015 ROLAND DG CORPORATION

Confidential

Product Guide

DWX-4W

Version 1.1 2015.10.19

Roland DG Corporation
Version No. Date Description of Changes

1.0 Sep. 17, 2015 First Edition

P29, 30, 32, 36, 37, 41, 42, 45, 48, 49 :
1.1 Oct. 19, 2015
A description has been added.
1. Product Information

 DWX-4W
DWX-4W is the first bench-top wet mill from Roland DG.

DWX-4W
WET GRINDING
DWX-4
DRY MILLING
 1. Product Information

 Appearance

Flip-up front cover

Tilted work area for improved
visibility and workability

Fully-partitioned
work area
20 degrees
 1. Product Information

 Dimensions

unit : mm
 1. Product Information

 Easy Operation

Status light Ending sound Single button

 1. Product Information

 Easy Operation
All the connectors are placed on one side.
 1. Product Information

 Coordinate System and Origin

+Y

-X
+Z
Origin

Origin +Z

-X -Y
+A -X

Origin
X-axis always moves with negative value.
8/72
 1. Product Information

 Major Difference
DWX-4 DWX-4W

Cuttable material Zirconia, Wax, PMMA, Composite resin Glass ceramic, Composite resin

Types of material Block type and pin type (10mm / 6mm) Pin type (6mm)

Machining method Dry Wet

No. of axis 4 4

Spindle speed 6,000 to 30,000 rpm 15,000 to 60,000 rpm

Drive system Lead screw Ball screw

ATC Two-station Four-station

Bur Milling bur (dia. 4mm) Dedicated grinding bur (dia. 3mm)

Zirconia / Wax / Composite resin : 0.1 MPa

Air pressure setting 0.6 to 0.8 MPa
PMMA : 0.2 MPa

Interface USB USB

 1. Product Information

 Main Specifications

Cuttable material Glass ceramic, Composite resin

Loadable workpiece shape Pin type W x D x H : Maximum 40 x 20 x 20 mm
Operating speed XYZ : 6 to 1,800 mm/min
Spindle speed 15,000 to 60,000 rpm
Number of burs housed 4
Attachable burs Shank diameter : 3 mm, dedicated bur
Air pressure setting 0.6 to 0.8 MPa
Control command set RML-1, NC code
External dimensions W x D x H : 484 x 539 x 600 mm (19.1 x 21.2 x 23.6 in.)
Weight 53 kg (116.8 lbs.)
 1. Product Information

 Milling and Grinding

The way of cutting differs between the current DWX series and DWX-4W.
The current DWX series does milling but DWX-4W does “grinding”.

The difference between “milling” and

“grinding” is like the difference of cutting
with a carving knife and sanding with a file.

Milling Grinding
(Current DWX) (DWX-4W)

Current DWX DWX-4W

2. Mechanical Structure

 Drive System
Ball screw drive for X, Y and Z-axis.
Worm gear drive for A-axis.

DWX-4
Lead screw

DWX-4W
Ball screw
 2. Mechanical Structure

 Ball Screw Drive (X-/Y-/Z-axis)

Ball screw drive achieves long-term durability by reducing sliding friction.
Reducing sliding friction also keeps enough torque margin of motors.

X-axis

Ball nut

Ball

Y-axis Z-axis

Screw shaft
 2. Mechanical Structure

 Worm Gear Drive (A-axis)

A reliable worm gear drive system is adopted alike other DWX models.

A-axis
 2. Mechanical Structure

 Air Line and Coolant Circulator

Compressor

Tank
Filter
Air

Pump Coolant
 2. Mechanical Structure

 Coolant Circulator
Cutting debris will be removed in two steps with two filters.

Filter #1 catches
big debris
Filter #2 catches
small debris
 2. Mechanical Structure

 Spindle
A new ATC spindle (manufactured by Alfred Jäger GmbH) is adopted.

Jäger spindle

Shank diameter 3 mm

Spindle speed 15,000 to 60,000 rpm

ATC control Compressed air

Air pressure setting 0.6 to 0.8 MPa

 2. Mechanical Structure

 Spindle

air

water
Dustproof air line
Coolant spray comes
prevents the cutting
out from two places to
dust from getting inside
keep a lubricant layer
the spindle
 2. Mechanical Structure

 Spindle

air
ATC unit

ATC operation is performed

by the compressed air

Spindle motor
is included

Milling bur is released when

the shaft is pushed down
 2. Mechanical Structure

 Clamp
Up to three pieces of pin type material can be installed.
 2. Mechanical Structure

 ATC magazine
Four burs can be set to the ATC magazine.

Stocker #D is a dedicated
place for the detection
pin.
 2. Mechanical Structure

 Tool sensor

Click!

Micro switch type

tool sensor
 2. Mechanical Structure

 Coolant leak monitoring

Coolant leakage is monitored at two places.

When leaked coolant makes a bridge between

the two terminals, DWX-4W stops showing an
error.
 2. Mechanical Structure

 Coolant flow monitoring

Coolant flow is monitored with a mechanical sensor.

When the turbine stops due to lack of

coolant, DWX-4W stops showing an error.
 2. Mechanical Structure

 Air pressure monitoring

Air pressure for ATC operation is monitored with an electric sensor.

The air pressure used for the

ATC operation must be between
0.6 to 0.8 MPa.

When the air pressure reaches

its out-of-range amount, DWX-
4W stops showing an error.

NOTE :

Dustproof air is not monitored.

3. Features

 Correction of Magazine Location and Rotary Axis

Position of the ATC magazine, origin and rotary axis center can be detected by
the automatic correction feature in VPanel.
The correction can be done by mounting a special jig bundled with the
machine.

Special jig for automatic Easy-mounting

correction
 3. Features

 Correction of Magazine Location and Rotary Axis

Two types of correction is available in VPanel.
Rotary axis Rotary axis + ATC magazine

+ [Ctrl] key

Click Click

Rotary axis correction will be Rotary axis + ATC magazine

executed. correction will be executed.
 3. Features

 Correction of Magazine Location and Rotary Axis Rev. 1.1

Two types of correction is available in VPanel.

Rotary axis Rotary axis + ATC magazine

Necessary when… Necessary when…

- the milling quality problem occurred - DWX-4W is installed

- DWX-4W is moved

Required goods Required goods

- Detection pin for correction (bundled) - Detection pin for correction (bundled)
- Automatic correction jig (bundled) - Automatic correction jig (bundled)
- 1000013306 PLATE,FIXING DWX-4W
(service part)

Rotary axis + ATC magazine correction needs to be done at the installation of

the machine.
 3. Features

 Failure Prevention Feature Rev. 1.1

An error shows up if you start milling under the offset values are deleted.

The offset values may

disappear when…
Click
- the automatic
correction fails
- the main board is
replaced without
transferring machine
parameters
- the firmware is
upgraded
 3. Features

 Coolant
Prepare the coolant using purified water with the additive.

Purified water Additive for coolant

Blend ratio 950 50

(mL)
1900 100
95% : 5% 2850 150

Replacement cycle : once a week / every 15 hours of work

Dispose of coolant properly, in accordance with the laws in effect in your locale.
 3. Features

 Coolant Rev. 1.1

Why is the additive necessary?

The purpose of the additive for coolant

1. Cools the tip of the bur

2. Keeps the sharpness of the bur
3. Reduces coolant deterioration

Using tap water as the coolant is

not recommended.
It may reduce the lifetime of the
bur.
 3. Features

 Loadable Material Size

40

3
3

18
18
14 4

16
2

2
20

18

18
20
1

1
20
unit : mm
If width is 14 mm or less : If width is 14 mm or more :
up to three pieces up to two pieces
 3. Features

 Multicast Control
Multiple units can be connected to one PC
(Max. 4 units).
A maximum of 4 different jobs can be
processed at the same time with a single PC.

You can select a target machine.

You can set ID for each machine in “Settings”.

 3. Features

 Mail Function
You can receive an e-mail notifying that the cutting is completed or when an error
has occurred.

DWX-4W
wetmilling@rolanddwx4w.com
Sent: 30 July 2015 12:00

Job Complete

A free e-mail account such as Gmail, Hotmail etc. are usable.

You can input more than one address by separating with a comma.
 3. Features

 Packing Diagram Rev. 1.1

746 615

846

Total weight : 61kg (135lb)

Weight : 53kg (117lb)

Unit : mm
 3. Features

 Installation Guide Rev. 1.1

The following environment is required for operating the machine.

PC
(not bundled)
Burs
(bundled)
Material
(not bundled)
......
......

CAM software
(not bundled)
USB cable
(bundled)

Regulator Compressor
(bundled) (not bundled)
6mm tube for air line
(not bundled)

Additive for coolant Tray for discharged

Purified water ZAW-1000D fluid
(not bundled) (not bundled) (not bundled)
 3. Features

 Installation Guide
Connecting the machine with the bundled USB cable is recommended.
Using a USB hub and/or cable extension may cause unexpected communication
errors.

Bundled USB cable (3m)

HUB CABLE EXTENSION

 3. Features

 Items to Prepare Separately

 Compressed Air Supply Source (Compressor)
 Use a compressor that meets the following conditions.
 Air Pressure : 0.7 to 1.0 MPa
 Air Capacity : 114 L/min or more
 Tank Capacity : 33 L or more
 Contamination of the compressed air by foreign material is undesirable. Use an
oil-free compressor.
 Moist air may cause rust. Use a device equipped with a dryer.
 Stable pressure is required. Select a source that has an adequate tank
capacity.
 Use a hose that meets the following condition.
 Hose outer diameter : 6 mm (polyurethane tube)

6 mm
Compressed air is used for the ATC
operation.
4. Burs

 Burs 40

3.0
D
LC

Dia.
Dia.
ZGB-25D

R
40

3.0
D

LC

Dia.
Dia.

ZGB-50D
ZGB-125D
R

Bur R D LC Material

ZGB-25D 0.25 1.7 8.8 Glass ceramic, Composite resin

ZGB-50D 0.5 1.0 6.0 Glass ceramic, Composite resin

ZGB-125D 1.25 2.5 14.75 Glass ceramic, Composite resin

You can use dedicated grinding burs only.

 4. Burs

 Burs Rev. 1.1

Life expectancy of ZGB burs

Replacement time
Bur
(hour)

ZGB-25D 7

ZGB-50D 7

ZGB-125D 7
5. Software

 Bundled Software Rev. 1.1

Roland Software Package CD (RSP-085a)

- VPanel for DWX-4W

- Windows Driver

- Manual

RSP-085a
 5. Software

 VPanel for DWX-4W

Simple and easy-to-use VPanel.

Progress bar Machine status

Machine selector

Operation
status Output list

Milling bur status Opens the Tool Opens the

Starts/cancel management Settings
s a job window window
 5. Software

 VPanel for DWX-4W

Easy-to-understand instructions with illustrations

Collet
maintenance

Spindle
Automatic run-in
correction
 5. Software

 Report export Rev. 1.1

Following information can be exported from VPanel as a cabinet file.

It may be useful as a primary step to get the information of the machine when a
trouble occurs.

[DWX-4W Log.cab] includes…

- System report
- Error log
- Event log
- Milling bur registration info
- Parameters

Click [Save file] button to create

a cabinet file [DWX-4W Log]
 6. Maintenance

 Daily maintenance
Two kinds of daily maintenance work is required to keep the spindle in good
condition.

Collet Spindle run-in

maintenance (short)
Approx. 5 min. Approx. 2 min.

Daily maintenance menu is

available in VPanel.
 6. Maintenance

 Calibration for Moving Distance

There is no function to calibrate the moving distance because of the following
reasons.
 Ball screw drive stabilizes the moving distance
 Work area is not big enough to have the moving distance error
LIMIT OFFSET: 673
BACK SIDE OFFSET (BASE): 93
BACK SIDE OFFSET (USER): 0
CORRECTION BASE POINT: 47226,41602,-35555
BASE TOOL LENGTH: 41047
DISTANCE CORRECTION
FACTORY: 100.000,100.000,100.000
USER: 100.000,100.000,100.000
AUTOMATIC TOOL CHANGER
CURRENT TOOL NUMBER: 5
CURRENT TOOL LENGTH: 41043 Manual correction is available from VPanel.
TOOL SENSOR POSITION OFFSET: -274,-220,1343

Correction value (FACTORY) on the system report is always 100.0%.

 6. Maintenance

 3D-PIT Rev. 1.1

Maintenance application software

Moves each axis and

rotates the spindle

Status of the
sensors

Necessary functions
Event log for maintenance are
collected
 6. Maintenance

 Milling of Check Block Rev. 1.1

Mill the check block to confirm that the machine meets the factory shipment
standard of DWX-4W after repair.

1 Install the bur. 2 Send the test pattern. 3 Measure the block.
Stocker #1: 2.8 mm square end mill
1000015093 TOOL,END MILL D2.8
L15 DWX-4W

Digital caliper
Required specification :

Measurement range 10 to 150 mm

Accuracy 0.01 mm

Wax
3000000224 WAX,BLOCK TEST DWX-4W
It mills the test pattern automatically.
Clamp
Required time : Approx. 17 min.
6702949020 ASSY,WAX CLAMP DWX-
4W
 6. Maintenance

 Spindle Repair
Spindle repair is not possible in the field, or at Roland DG Japan.
All the repairs can be done by Alfred Jäger GmbH only.

Needs to be
repaired…

Field
7. Consumables

 ZAW-1000D (Additive for coolant)

Capacity : 1000 mL
Storage life : 1 year When filling up the tank…

Purified water Additive

Blend
ratio 2850 150
(mL)

Replacement cycle of coolant :

once a week / every 15 hours of work
- Once a week : To keep the coolant from deteriorating
- Every 15 hours of work : To avoid the filter from clogging

ZAW-1000D is not bundled with the machine.

Prepare enough of the additive to meet the volume of work.
 7. Consumables

 ZAW-1000D Consumption
Consumption cycle changes depending on the usage of the machine

[CASE 1] Working time : 3 hours or less / 1 day

DAY 1 DAY 2 DAY 3 DAY 4 DAY 5 * 1 week = 5 working days

3 hrs 3 hrs 3 hrs 3 hrs 3 hrs

Dispose the coolant once a
week

Add 1L to fill Add 1L to fill

a shortage a shortage 150mL + 50mL + 50mL
Use 250mL of additive per week
1L 1L

3L 2L 2L 2L 2L
150mL 50mL 50mL
evaporated evaporated 250ml x 4 times (4 weeks) = 1000mL
A bottle of additive will be
consumed in 4 weeks
(20days)
 7. Consumables

 ZAW-1000D Consumption
[CASE 2] Working time : 24 hours / 1 day

DAY 1 DAY 2 DAY 3 DAY 4

12 12 12 12 12 12 12
9 3 15 hrs 9 3 15 hrs 9 3 15 hrs 9 3 15 hrs 9 3 15 hrs 9 3 15 hrs 9 3
6 6 6 6 6 6 6
0:00 15:00 6:00 21:00 12:00 3:00 18:00

3L 3L 3L 3L 3L 3L 2L
150mL 150mL 150mL 150mL 150mL 150mL 100mL

Dispose the coolant every 15 hours of work

A bottle of additive will be consumed in 4 days

 7. Consumables

 ZF-CLD (Filter for coolant tank)

Time for replacement : If the clogging of the filter cannot be recovered. (Use of 1
month)
 7. Consumables

 ZC-3JD (Collet)
The user can replace the collet by themselves.
Time for replacement : If any spindle operation problems occur, such as the collet
damage.

Since the spindle has a built-in collet, there is no need to order the collet
when replacing the spindle.
 7. Consumables

 Grease for collet

Time for replacement : When the grease has run out. (approx. 6 months)

Maintenance kit (bundled)

1000013791 GREASE,COLLET DWX-4W