Among the many machines Mazak spotlighted at IMTS 2012, was the Integrex i-630V that performs heavy-duty five axis cutting via high-torque turning and milling spindles. This multi-tasking machine was 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 operated in a fully automated manufacturing system at IMTS to showcase the company’s unique multi-tasking automation technology. The system incorporated the Integrex i-630V and a Mazak Orbitec 20 large part machining centre 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 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 in. (1,050 mm) in diameter and 39.3 in. (1,000 mm) high. Square pallets measure 24.8 in. x 24.8 in. (630 mm x 630 mm), while round pallets are 31.5 in. (800 mm) in diameter. The pallet changer moves pallets in and onto the machine’s NC direct-drive motor table within 11 seconds.
The machine 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° in minimum increments of 0.0001° 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.
Axis travels measure 58 in. (1,475 mm) in X and 41.3 in. (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. This way system increases vibration dampening, extends tool life, handles higher load capacities and eliminates tramp oil in the coolant by utilizing a greener grease-based lubrication system.
The features Mazak’s new Matrix 2 CNC control designed 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 that provides full simultaneous five axis capability.