High-torque turning and milling spindles productively process large complex parts
FLORENCE, Ky., Oct. 8, 2013 – At DISCOVER 2013, Mazak showcased the INTEGREX i-630V Multi-Tasking machine that performs heavy-duty full simultaneous 5-axis cutting on large complex parts via high-torque turning and milling spindles. 
The INTEGREX i-630V provides B-axis and C-axis capabilities for turning and milling. The machine’s powerful turning capability comes from a robust 50-hp, 550-rpm turning spindle. An optional 32” chuck is available for securing large parts. To meet a variety of material requirements, the machine comes with a powerful and rigid CAT-50 taper, 10,000-rpm milling spindle but has options that include high-torque 5,000-rpm and high-speed 15,000-rpm spindles.
The milling spindle mounts in the machine’s compact B-axis head that swings from -30 to +120 degrees in minimum 0.0001-degree increments and is roller gear cam driven. A standard 43-tool automatic tool changer supplies the milling spindle with tooling, and optional 80, 120 and 160-tool capacity versions are available.
Square or round pallets are available for use with the INTEGREX i-630V’s standard two-pallet changer to handle workpieces up to 41.3" (1,050) in diameter and 39.3" (1,000 mm) high. The square pallets measure 24.8" x 24.8" (630 mm x 630 mm), while the round are 31.5" (800 mm) in diameter. The pallet changer moves pallets in and onto the machine’s NC direct-drive motor table within 11 seconds.
Axis travels on the INTEGREX i-630V measure 56.10" (1,425 mm) in X and 41.3" (1,050 mm) in both Y and Z, and all three axes rapid traverse at 2,047 ipm (52 m/min). The axes incorporate Mazak’s MX Hybrid Roller Guide System to achieve high levels of durability and reliability that result in long-term accuracy. The innovative way system increases vibration dampening, extends tool life, handles higher load capacities and eliminates tramp oil in the coolant by utilizing a greener grease-based lubrication system.
The INTEGREX i-630V features the Mazak MATRIX 2 CNC control designed specifically for optimized 5-axis machining. The control incorporates both advanced hardware and software functionalities that make it easy to use while also delivering high accuracy and increased productivity for the machine. The control’s hardware performance is much faster with higher processing speeds for small increment operation, and a 5-axis spline interpolation function included in the control’s software provides smooth toolpaths from long block-by-block programs, easy tool vector control and shorter cycle times as well as superior 5-axis surface finishes.
For increased machining flexibility and unsurpassed productivity advantages, the INTEGREX i-630V will operate in a fully automated manufacturing cell that includes a Mazak HORIZONTAL CENTER NEXUS 6800 horizontal machining center linked together with a PALLETECH System. Such a combination makes for shorter product life cycles, reduced in-process inventory and just-in-time production.