Multi-Tasking machine processes raw material to finished workpieces in single setups
Florence, Kentucky, May 21, 2012 - Mazak will showcase 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 INTEGREX i-200S, which efficiently and accurately processes mid-size complex components through twin turning spindles and a milling spindle with the power of a vertical machining center spindle.
Fitting into most facilities with its space-saving footprint of 157.1" x 110.2", the INTEGREX i-200S Multi-Tasking machine productively turns, drills, taps and mills, while offering off-centerline and full simultaneous 5-axis contouring. The machine falls within Mazak's Done-In-One concept as it incorporates all processes from raw material input through final machining in a single setup. As such, the INTEGREX i-200S reduces production lead times, improves machining accuracy and lowers operating expenses.
Both turning spindles on the INTEGREX i-200S provide equal high performance with spindle speeds of 5,000 rpm and C-axis turning control. And both have a bore capacity measuring 3" (76 mm) in diameter. The main headstock features an integral spindle/motor design that can accommodate a wide range of applications, from heavy-duty cutting at low speed to high-speed cutting of aluminum and other nonferrous materials. The second spindle also features an integral spindle/motor to ensure high efficiency machining for secondary operations.
The INTEGREX i-200S vertically mounted milling spindle provides 30 hp (22 kW), 12,000 rpm and a rotating B-axis range of -30° to +240°. Mazak's unique roller cam drive for the B-axis ensures higher accuracy and rigidity, while providing zero backlash. A 36-tool (72-tool optional) magazine allows for fast tool changes and provides ample tooling for continuous part processing.
Mazak incorporates its MX Hybrid Roller Guide System into the INTEGREX i-200S for durability and reliability that result in long-term accuracy. The 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.
For a compact Multi-Tasking machine, the INTEGREX i-200S provides an ample Y-axis travel of 9.8" (249 mm) and vertical X-axis of 24.2" (615 mm), with 4.92" (125 mm) below centerline. The machine accommodates parts up to 25.9" (657.8 mm) in diameter. And because its tool magazine is located at the front, machine operators can do programming and tool setup with minimal required movement. Additionally, all machine lubrication points and gages are gathered into a single panel for ease of viewing and maintenance.
The INTEGREX i-200S features Mazak's new MAZATROL MATRIX 2 CNC control designed specifically for optimized 5-axis machining. 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 5-axis surface finishes.
As part of Mazak's Five Levels of Multi-Tasking, the INTEGREX i-200S is a Level 4 machine - those providing full simultaneous 5-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-200S at IMTS, Mazak will also feature advanced machining technologies for a wide variety of industry segments, including aerospace, automotive, energy and medical. Additionally, 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.