Compact i-100ST with dual turning spindles, milling spindle and lower turret debuting at IMTS
Florence, Kentucky, July 3, 2012 - Mazak will spotlight more than 20 high-performance machine tools in booth S-8300 at IMTS 2012, taking place Sept. 10 - 15 in Chicago, Ill. Among those machines is the new INTEGREX i-100ST, a Multi-Tasking horizontal machining center that brings the high accuracy and productivity of the company's popular INTEGREX i Series into a smaller footprint that measures 119.2" (3,030 mm) x 98.2" (2,495 mm).
Ideal for small high-precision part applications such as those in the medical industry, the INTEGREX i-100ST employs two turning spindles, a milling spindle and lower turret for processing first and second operations simultaneously or performing required sequential operations on a single workpiece. The machine also executes full, simultaneous 5-axis machining for handling all processes from raw material input through final machining in just one machine; thereby, reducing production lead times, improving machining accuracy and lowering operating expenses.
In addition to the i-100ST model, Mazak also has the INTEGREX i-100 with a tailstock and i-100S with a second spindle from which to choose.
The turning spindles on the INTEGREX i-100ST share high performance capabilities as they both employ a 15 hp (11 kW) integral motor spindle with maximum spindle speeds of 6,000 rpm. For high precision C-axis contouring, the main spindle indexes in 0.0001-degree increments, while the second spindle provides increments of 0.001 degrees. Each spindle features a 6" chuck with a 2.4" (61 mm) bore size that can accommodate bar stock of up to 2" (51 mm) in diameter.
The INTEGREX i-100ST has a powerful 10 hp (7 kW), 12,000-rpm milling spindle mounted in the rotating B-axis with a range of 240 degrees in 0.0001-degree indexing increments. And for high accuracy of motion, B-axis scale feedback comes standard on the machine. The machine's 36-tool magazine accommodates tools up to 5.1" in diameter when neighboring stations are empty and up to 3.5" in diameter when stations are occupied.
For off-centerline operations, the INTEGREX i-100ST, while compact in size, provides ample axes travels of 8.2" (210 mm) in Y, 17.7" (450 mm) with a below centerline capability of 1.96" in X and 35.5" (904 mm) in Z; thereby allowing the machine to process a wide range of part sizes and shapes. Furthermore, the machine's three linear axes attain high-speed rapid traverse rates of 1,575 ipm (40 m/min).
The machine's lower drum turret has nine tool positions and indexes per step in just 0.14 seconds. The turret can work at either the main or second turning spindles with the same tool, which allows it to perform balanced cutting operations on one part working in tandem with the machine's vertical milling spindle. There is also the option for milling capability with the lower turret. All of which provides the flexibility to process a workpiece's second operation in the machine's second spindle or to perform first and second operations simultaneously on one workpiece.
The INTEGREX i-100ST features Mazak's new MAZATROL MATRIX 2 CNC control. Within the control are both enhanced hardware and software functionalities that make the control easy to use while also delivering high accuracy and increased productivity. Control hardware performance is much faster with higher processing speeds for small increment operation. Furthermore, 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 surface finishes.
As part of Mazak's Five Levels of Multi-Tasking, the INTEGREX i-100ST is a Level 4 machine because it provides full simultaneous five-axis capability. Mazak's Five Levels of Multi-Tasking allow manufacturers to precisely match machine capabilities to part processing requirements. Machine features and functionalities within the other four levels range from Level 1 with single spindle and rotating tool capabilities and Level 2 with Y-axis off-center machining to Level 3 machines featuring independent milling spindle headstocks with B-axis indexing, as well as full Y-axis travels and tool storage, and Level 5 Ultra-Tasking machines with additional specialized machining functions and Multi-Tasking automation.
In addition to running real-world application cutting demonstrations on the INTEGREX i-100ST, IMTS attendees will get to experience a brand new Mazak booth as well as learn about a new 3-4-5 manufacturing solution for better tailoring Mazak machines to specific applications.