Multi-Tasking machine productively processes large, extremely complex parts
Florence, Kentucky, May 21, 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 INTEGREX i-630V that performs heavy-duty five-axis cutting via high-torque turning and milling spindles. This Multi-Tasking machine will be integrated with Mazak's pre-engineered PALLETECH manufacturing system to demonstrate complete Done-In-One unattended part production.
For fast, complete production of large, heavy workpieces typically requiring long set up times, the INTEGREX i-630V will operate in a fully automated manufacturing system that showcases the company's unique Multi-Tasking Automation Technology. The system will incorporate the INTEGREX i-630V and a Mazak ORBITEC 20 Large Part Machining Center linked together with the PALLETECH Manufacturing System. Both machines utilize a common pallet size, allowing parts to undergo various turning operations on the ORBITEC 20 then transfer to the INTEGREX i-630V for completion without ever having to re-fixture them. Such automated manufacturing systems also provide flexibility required for shorter product life cycles, reduce in-process inventory and allow for just-in-time production.
With the INTEGREX i-630V, shop's can select either square or round pallet shapes for the machine's standard two-pallet changer to handle workpieces up to 41.3" (1,050 mm) in diameter and 39.3" (1,000 mm) high. Square pallets measure 24.8" x 24.8" (630 mm x 630 mm), while round pallets 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.
The INTEGREX i-630V provides B-axis and C-axis capabilities for turning and milling. And for meeting all different material requirements, Mazak offers three versions of milling spindles for the machine - a standard 50-taper 10,000-rpm, a high-torque version with 5,000 rpm and 387 ft-lbs of torque and a 15,000-rpm high-speed version.
The rigid milling spindles are mounted in the machine's compact B-axis head that swings from -30 to +120 degrees in minimum increments of 0.0001 degree and is roller gear cam driven. A standard 43-tool automatic tool changer supplies milling spindles with tooling, and optional 80, 120 and 160-tool capacity versions are available.
Ample axis travels on the INTEGREX i-630V measure 58" (1,475 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). Machine axes incorporate Mazak's MX Hybrid Roller Guide System for high levels of 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.
The INTEGREX i-630V features Mazak's new MAZATROL MATRIX 2 CNC control designed specifically for optimized five-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 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-630V 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-630V at IMTS, Mazak will also feature advanced machining technologies for a wide variety of industry segments, including automotive, energy and medical. Additionally, IMTS attendees will get to experience a brand new Mazak booth as well as learn about the company's new 3-4-5 manufacturing solution for better tailoring Mazak machines to specific applications.