Single cycle unmanned machining for subcontractor with Mazak Integrex

Unicut Precision's specification for a 9-axis Mazak Integrex 100-IVST was created to provide maximum flexibility, resulting in a price tag of some £370,000. The machine incorporates an IEMCA Master 19 barfeed, identical 11 kW main and second spindles with automatic part transfer to enable the same level of turning, drilling and milling performance to both sides of the workpiece. The family of 46 components have been rationalised by Unicut to be produced from just three bar sizes with cycle times between four and seven minutes. Each part requires the milling of the outside profile and flats; a series of high tolerance deep holes between 2 and 3 mm having up to 15:1 length to diameter ratios; a number of compound angle features and holes; a range of cross holes and high tolerance sealing surfaces on undercuts; grooves and bore diameters. The geometrical relationship between certain features is very important and in single cycle with CNC positioning this never creates a problem whereas with normal production methods, involving separate operations with relocation of the parts, reject level would probably compromise the whole project. Joint managing director Charles Kenny commented: "Previously as the contract grew in the number of part types and volumes, we ran batches and stocked parts. But such were our levels of stock that we decided to investigate a strict made-to-order production capability and so successful has it been in practice that should we need 20 or so parts we key into the control. We can be back into production inside five minutes compared to at least half a shift with conventional machines."