Versatile Multi-Tasking machine offers several part processing options
Florence, Kentucky, October 25, 2011 – Mazak showcased the part processing versatility of the new INTEGREX i-400ST Multi-Tasking Center at T3 – Tomorrow's Technology Today, a Discover Mazak 2011 event. The machine's two turning spindles, milling spindle and lower turret allow shops to process first and second operations simultaneously or perform required sequential operations on a single workpiece.
The INTEGREX i-400ST features main and opposing horizontal turning spindles capable of indexing in 0.0001-degree increments. The main turning spindle is a 40 hp (30 kW) integral spindle motor that provides a 3,300 rpm maximum spindle speed, while the second, opposed headstock features a 35 hp (26 kW) integral spindle motor and 4,000 rpm top speed.
Additionally, a 35 hp (26 kW), 12,000-rpm integral motor milling spindle rotates in the B-axis throughout a range of +210 and –30 degrees from vertical. The milling spindle also travels a generous +/- 4.92" (125 mm) in the Y-axis and is supplied with tools from a 36-tool magazine. For increased versatility, the INTEGREX i-400ST accommodates workpieces up to 25.9" (658 mm) in diameter and 59.8" (1,519 mm) long.
The machine's lower drum turret carries 9 turning tools or 6 rotary tools, and can work at either the main or second spindle with the same tool. This makes it possible for the turret to perform balanced cutting operations on one part working in tandem with the machine's vertical milling spindle. Milling can also be done with the lower turret to provide the option of simultaneously processing a second operation in the machine's second spindle. Or first and second operations can be done simultaneously on one workpiece.
Additionally, Mazak integrates its MX Hybrid Roller Guide System into the INTEGREX i-400ST to deliver levels of durability and reliability that result in long-term accuracy. The Mazak MX Hybrid Roller Guide System dampens vibration to extend tool life, handles higher load capacities, accelerates and decelerates quicker to shorten cycle times, consumes less oil for "Greener" operations, and lasts longer with less required maintenance.
As a Mazak Multi-Tasking machine, the INTEGREX i-400 ST is a Level 4 machine in the company's Five Levels of Multi-Tasking, which were developed as an effective way for manufacturers to determine the best multi-tasking technology for meeting their specific application and process needs.
Within the Five Levels of Multi-Tasking, Level 1 machines typically offer a single turning spindle and drum-style turret with rotating tool capability for processing minimally complex workpieces. Level 2 machines add Y-axis functionality to machine drum turrets for off-center operations and Done-In-One machining together with either a twin spindle and milling turret or twin spindle/twin turret machine configuration. Level 3 Multi-Tasking machines feature independent milling spindle headstocks with B-axis indexing, as well as Y-axis travels and tool storage magazines.
Level 4 machines emphasize automation and processing large or highly complex workpieces using full, simultaneous 5-axis machining. Level 5 is the addition of specialized machining tasks, such as gear cutting, honing and grinding, that transform Level 4 machines into Level 5 Ultra-Tasking machines that process even the most demanding and complex parts complete in single setups.