machine interference protection; Mazak Voice Advisor
for verbal messages; Intelligent Performance Spindle for
improved spindle operation; Intelligent Balance
Analyser for applications where large components are
being rotated; and Intelligent Maintenance Support to
provide real-time maintenance updates to improve
machine up-time.
The Mazak Integrex i-150 is the first machine to feature
six Intelligent Functions. This compact solution for high
precision complex components has a 65mm bar and up to
200mm diameter billet capacity. The travelling column
construction gives very large X and Y axis travels for such
a small footprint machine. The new Mazak work
handling and support system enables second operation
machining and work support without the need for a
second spindle or lower turret. It also enables controlled
automatic unloading of parts to an integrated conveyor.
Other innovations include a new B-axis generating
higher accuracy; new Intelligent Functions for safety and
reliability; and enhanced conversational programming.
The innovative work handling system can be indexed
in 90 o increments, allowing workpieces normally
processed by machining centres to be completed in just
one machine setup utilising Yamazaki Mazak’s ‘Done in
One’ concept. The result is a significant improvement in
the productivity of small workpiece machining.
The conventional method would be to process the
second stage of operations using a second spindle. The
downside of this is that it creates a greater requirement for
floorspace, irrespective of the component size. Using
Mazak’s ground-breaking work handling system, which
can clamp components up to 65mm diameter, the
component is simply indexed and machining continues
uninterrupted. As a result, the Integrex i-150 requires
only 2200 mm x 2420 mm of floorspace.
Other key features of the Integrex i-150 include a
high-performance, high-accuracy, milling spindle with
B-axis. The integral 12,000 rev/min, 7.5 kW (10 hp)
spindle motor can effectively be used for machining a
wide range of materials, and in applications from heavyduty
roughing to high-speed cutting of aluminium and
other non-ferrous materials. The versatility of the
Integrex i-150 is enhanced by the long Y-axis stroke. At
+/- 100mm it is the longest in this class of multi-tasking
machine tools. The machine’s B-axis is driven by a roller
gear cam and can be indexed in 0.0001 degree
increments. Thanks to the use, as standard, of a scale
feedback system, high accuracy positioning is
guaranteed over extended periods of operation. Also
assisting in maintaining high-accuracy over extended
periods of operation is the use of heat countermeasures
for both spindles. Temperature-controlled oil circulates
through the spindle and motor housing to remove heat
in order to ensure high accuracy machining.
Yamazaki Mazak’s ‘Done in One’ concept
incorporates every aspect of the machining process
from raw material input through to final machining in
just one machine. As a result of using this concept,
customers are able to reduce production lead time,
improve machining accuracy, reduce floor space and
initial cost, lower operating expenses, reduce operator
requirements and improve the work environment. The
concept not only streamlines production, it also
improves overall management.
www.mazak.co
april 2008
mwp awards 2008 sponsor
High spec & cost effective
Another new machine to benefit from Mazak’s development principles is the
Horizontal Centre Nexus 8800-II (HCN 8800-II). This versatile horizontal machining
centre is combines advanced technology, productivity and value to create a costeffective,
yet highly specified, class-leading 800 mm 2 pallet size machine.
Innovative design has delivered the largest machining area, workpiece size and
component weight capacity in this sector, making it ideal for machining larger
prismatic parts.
The benefits to the user are increased capability and improved productivity
assisted by a 50% increase in axis (X,Y and Z) traverse rates, up from 40m/min to
60m/min, and a 25% increase in acceleration rates, which make the HCN 8800-II a
much more agile machine than its predecessor. It also has a much larger machining
capacity with a maximum component size of 1450 mm diameter by 1450 mm high
and a maximum weight capacity of 2200 kg, all within a smaller footprint. The
high-torque integral spindle motor with 50 hp and 1218 Nm of torque provides the
capacity for heavy stable metal removal rates when combined with the highly-rigid
machine structure.
The HCN 8800-II also features several innovations, key among which are the
roller gear cam mechanism for the C-axis; a novel design for the slideway covers;
the Intelligent Functions of the Mazatrol Matrix control; a new toolchange
mechanism; and a greatly increased tool capacity. In developing these features,
and the machine as a whole, Mazak has reduced the number of mechanical parts
by 15-20%, depending on the options taken.
The move to a roller gear cam mechanism from the traditional worm and worm
gear system for positioning the C-axis (rotary table) eliminates backlash from the
system, allowing precise, controlled movement in any direction and is a major step
forward in technology, similar to switching from leadscrews to ballscrews.
Slideway covers tend to be a weak link in machine reliability, particularly where
traverse rates are high. To overcome this, Mazak has developed a novel
‘pantograph system’ that supports the covers and ensures that they move in a
synchronised fashion. This eliminates the possibility of the covers 'sticking' and
causing the machine to stop.
The new Intelligent Functions improve the machine’s performance and
productivity and supplement the operator/programmer's knowledge. Of particular
interest is the Intelligent Safety Shield system, which includes a comprehensive 3D
virtual machining function. This uses 3D models of the machine, fixturing and
tooling to allow safe prove-out of machine programs by simulating machine
movement and warning of potential collisions before they happen. The system can
also be used in manual mode, whereby the operator moves the machine elements
using the handwheel. When the Matrix control identifies a potential problem it
safely stops the machine and issues a warning either on-screen or verbally through
the Mazak Voice Advisor system.
The HCN 8800-II features an electronic toolchange system, which gives a significant
reduction in components, enhancing reliability; and toolchange time is reduced by 9%
(chip-to-chip). A significant saving in the context of number of toolchanges per day.
Changes have also been made to the machine’s tool capacity. The maximum length
and diameter of individual tools has been increased. The standard diameter tool is 125
mm assuming all tool pockets are filled. If adjacent pockets are empty this rises to 260
mm and, if specific tool pockets are chosen a limited number of tools up to 320 mm
diameter can be used.
Tools of this size are useful in
certain industries, such as
automotive, for machining
cylinder heads, where multiple
passes with a smaller diameter
tool are not acceptable due to
the witness mark that may be
left. The oil industry is another
sector that benefits from the
ability to store longer cutting
tools.
MWP
97
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