One of the largest-capacity machines on show was a preproduction Variaxis i-1050T machining centre, Mazak’s largest vertical-spindle gantry-format unit in a range of five, accommodating workpieces up to 1,250 mm in diameter. Series production begins in Japan next year. Cross-travel (X-axis) is 1,200 mm; long travel (Y-axis) is 1,385 mm; and the 10,000 rpm spindle extends 900 mm (in Z). It offers 5-axis simultaneous machining thanks to a beefy A-axis trunnion and C-axis rotary table. The former is tandem-driven with motor and roller gear cam drives mounted on both sides; the latter by a 37 kW, 3,000 Nm direct-drive motor to reach speeds up to 500 rpm. This provides the means for the ‘T’ in the model name: turning, in particular vertical turning. A static turning tool is inserted into the 50-taper spindle and locked in place with a hirth coupling. Turning is possible vertically with the workpiece at 0° inclination, or horizontally, with the trunnion tipped up to 90°.
At the other end of the showroom was the Integrex i-400AM Hybrid Multi-tasking machining centre, also launched at EMO. This millturn-type machine combines 5-axis additive and subtractive manufacturing in a single machine thanks to three elements that work together: horizontal (X-axis) turning spindle, rotating B-axis with an integrated milling spindle that can be fitted with AM technology and a trunnion-mounted rotating (A and C-axis) table. The latter makes up the additional degrees of freedom required for 5-axis simultaneous movement, because the vertical AM head, when connected to powder, laser and gas supply mounted in a protected cabinet behind the spindle, cannot swivel. There are in fact two different laser metal deposition heads, both of which can be automatically toolchanged, offered by supplier Hybrid Manufacturing Technologies: a high-speed cladding head produces a 3 mm by 1.5 mm bead, while the fine cladding head produces a 1 mm by 0.5 mm bead, and can also be used for laser marking.
A major presence at the event was Mazak’s new Smooth technology for machine tool controls, on machines, on simulators and in displays. A split-screen video demonstrated how much faster machining of a 5-axis part on an Integrex i400 (without AM functionality) was compared to the previous-generation control, Matrix 2. Using the same program, same tooling, same cutting conditions and same workholding, cycle time on the Integrex with SmoothX control was 29% faster.
Two thirds of that speed advantage comes from SmoothX’s new motion control technology and high-speed block processing (0.1 millisec); the other third comes from proprietary 5-axis software, including smooth corner control, variable acceleration control and SmoothX machine configuration, reports Mazak product manager Mark Hall.
SmoothX is the full-featured version of the control offering simultaneous 5-axis machining for both milling and turning. Also shown here, and launched at EMO, is SmoothG, offering a similar interface, controlling up to 16 axes, but only for 4-axis simultaneous machining. Rounding out the controls trio is SmoothC, a version of the control that retains the classic Mazatrol keyboard. It is intended for mass-production operations in which there is limited need for conversational programming.
Having recently benefitted from new investment in sales and service staff, Mazak laser sheet metal cutting equipment also had a presence at the event. Two of the brand’s 2D machines were on show, one each from the entry-level Optiplex 3015and OptiPlex 3015 Fiber II flagship range. A proprietary Zeta 9 cutting head beams lasers generated either by an IPG fibre laser or CO2 source. Formerly sold by a separate business Mazak Optonics, these machines were collapsed into Mazak’s general range of machine tools in 2012.
Behind the scenes of the glitzy showroom, the factory that makes 40 models of machine tools, up to the VTC-800 in size (3,000 mm travel in X), is being expanded. Phase 1 of this project covers extending the large machining department. One of the two machines that trims castings (which are made elsewhere) is being replaced by two new units, scheduled to be installed in the January-February 2016 timeframe. Decisions about further factory expansions will be made later in spring and depend on market conditions.
ARTICLE UPDATED 16 December to fix a number of errors: clarified operating mechanism of i-1050T trunnion; changed descriptions of axes of i-400AM, and its AM heads; altered SmoothX comparative speed improvement claim; corrected name of project manager and laser profiler brand name; increased maximum X-axis travel of VTC range; made minor word changes.
