Multi-tasking gear machining system
- October 10, 2018
Mazak Corporation has unveiled the Integrex i-200ST AG Hybrid multi-tasking machine.
Equipped with the Auto Gear (AG) package, the machine processes mid-size complex components with the added versatility of twin spindles, milling spindle (S) and a lower turret (T) as well as a full range of Smooth Technology solutions specifically aimed at the Done in One production of gears. Unlike conventional gear machining, which requires specialty tools, single-purpose machines and redundant workholding, Mazak’s AG package gives manufacturers the ability to perform complete part processing for a wide variety of gear types. The machine can produce datum features, chamfers, edges and other part features in a single set up, reducing the need for redundant workholding and work-in-progress (WIP) inventory.
The Smooth Gear Cutting software package included on the Integrex i-200ST’s Mazatrol SmoothX CNC includes Smooth Gear Skiving, Smooth Gear Hobbing and Smooth Gear Milling for the production of both external and internal spur, helical and spline-type gears. This assures complete geometric freedom without added complexity – operators can use Mazak’s HMI solution to create programs on the control. The AG package pairs well with the Integrex i-200ST platform, which features two turning spindles that provide equally high levels of performance thanks to 5,000 rpm speeds and C-axis turning control. Both spindles have a bore capacity measuring 3 in. (76 mm) in diameter.
For C-axis contouring versatility at either turning spindle, the Integrex i-200ST AG uses a vertically mounted milling spindle that provides 30 hp (22 kW), 12,000 rpm and a rotating B-axis range of +120 and -120 degrees for 240 degrees of motion. Mazak’s roller cam drive for the B axis ensures accuracy and rigidity while providing zero backlash. A 36-tool (72-tool optional) magazine allows for fast tool changes and provides ample tooling for continuous part processing.