Unique machine makes easy work of turned features on big, odd-shaped workpieces
FLORENCE, Ky., Oct. 8, 2013 – At DISCOVER 2013, Mazak demonstrated the wholly unique headstock design of the ORBITEC 20 and its ability to generate turned features on large valves and other such big, heavy odd-shaped parts with ease and accuracy. The large-part machining center can also integrate with Mazak’s PALLETECH system and other machines to form Multi-Tasking, Done-In-One® cells with unsurpassed productivity advantages. 
The ORBITEC 20’s patented headstock moves only the cutting tools to effectively perform multiple turning, boring, grooving, facing and threading operations while workpieces remain clamped and stationary. As an internally counter balanced system, the ORBITEC 20’s headstock, with 600-rpm, 40-hp integrated spindle motor, keeps tool tips facing either toward or away from the centerline of rotation while tools orbit around workpieces. This provides stable precision machining and less part interference because tools do not protrude beyond the rotating headstock when working on larger diameters.
The headstock design is a circle – as opposed to linear slides – within a circle for accurate linearly interpolated X-axis tool movement. For increased part accessibility, the machine’s X-axis stroke measures 11.02", (280 mm), while its U, V, and Z-axis strokes are 23.62" (600 mm), 23.62" (600 mm), and 48.43" (1,230 mm), respectively. The machine turns diameters up to 20" (508 mm), depending on the tools being used, on parts fitting into a work envelope of 41.34" (1,050 mm) in diameter and 51.18" (1,300 mm) high.
For further increased part processing versatility, the ORBITEC 20 generates phonographic finishes on flange surfaces, cuts tapered bores and does grooving in feed-out operations. The machine also performs trepanning, internal grooving, drilling and concave machining.
Equipped with a standard two-pallet changer, along with the availability of Mazak’s PMC-WEB cell controller software, the ORBITEC 20 easily pairs with the PALLETECH automation system. The ORBITEC 20 can then combine with Mazak HORIZONTAL CENTER NEXUS and INTEGREX machining centers to create aggressive, complete Done-In-One large part manufacturing cells for lights-out operation.
Because both the ORBITEC and INTEGREX machines utilize a common pallet size, parts can undergo various turning operations on the ORBITEC 20 and then transfer over to the INTEGREX via the PALLETECH for final processing without having to be re-fixtured. Workpieces – fixtured once on the machine’s 24.8” x 24.8” (630 mm x 630 mm) pallets – feed into the ORBITEC 20 for turning operations. Then, the PALLETECH system transports parts to the machining centers for secondary milling operations and, afterwards, on to any other subsequent operations. Pallets and part fixtures allow for the economical manufacturing of single-part lots, and tombstones with multi-part fixtures serve higher production needs.