FLORENCE, Ky. – Mazak Corp. held its February All Axes LIVE virtual event on February 23. Streaming from both its Florence, Ky., manufacturing campus and Midwest Technology Center in Schaumburg, Illinois, the event centered on advanced manufacturing solutions for supply chain disruptions, loss of experienced employees due to attrition and shortages of skilled labor that manufacturers are facing as the industry deals with a global pandemic.
During the event, Mazak introduced its new INTEGREX i-H Series of Multi-Tasking machines with a live demonstration from the Midwest Technology Center of the INTEGREX i-200H ST spotlighting the shorter cycle times and increased utilization benefits of multitasking. The company also introduced the new NEO models of some of its most popular machine tools, the VARIAXIS i-800 NEO Multi-Tasking Center and HCN-6800 NEO Horizontal Machining Center with PALLETECH automation. Additionally, the event featured live demonstrations of optimized gear machining on an INTEGREX i-630V AG HYBRID Multi-Tasking Machine with the SMOOTH Gear Cutting software suite and MAZATROL SmoothAi control.
Mazak says it designed its new INTEGREX i-H Series machines with the flexibility necessary to process a variety of part types without additional capital expenses. The new machines allow shops to add automation options – some of which are retrofittable in the field – as production levels dictate. The machines within the series have new, ergonomic enclosures with compact footprints that require less floor space. In addition, Mazak equipped the INTEGREX i-H Series with faster and more powerful turning spindles, space-saving milling spindles and a new parallel-type lower turret with optional live tooling capabilities. The company also expanded tool capacities for lower turrets and for tool storage magazines along with offering a wider range of chuck size options.
Mazak says its NEO models are redesigned machines with enhancements that further reduce cycle times, increase maximum part and tool capacities, reduce required floorspace, extend part processing versatility, and streamline automation. During the All Axes LIVE event, Mazak showcased the NEO models with a live demonstration of the VARIAXIS i-800 NEO, which features faster feed rates, a redesigned two-pallet changer, new servo-driven ATC shifter, extended axis strokes, more automation options and Mazak’s MAZATROL SmoothAi control.
The HCN-6800 NEO, introduced and demonstrated during the February 23 broadcast of All Axes LIVE, includes an upgraded, new standard 43-tool drum-type magazine that reduces tool exchange times. A redesigned ATC door is now servo-driven and faster; the new design will now also accommodate a longer tool. Likewise, for ease of maintenance, the machine incorporates hydraulic/motorized pallet changer mechanisms and an easier-to-access maintenance panel.
The HCN-6800 NEO can accommodate parts weighing up to 3,306.93 pounds and as part of the NEO configuration, the machine enclosure itself has been reduced in size; with a chip conveyor, the new model has a width of 134.06" and depth of 266.61".
The company also demonstrated its INTEGREX i-630V AG HYBRID Multi-Tasking machine, which performs gear manufacturing on a common machine tool platform with SMOOTH Gear Cutting. The software, in tandem with the machine’s turning and milling spindle scale feedback, ensures cutting synchronization and smooth machine motion for the high speeds of power gear skiving on parts such as the 35" diameter gear that will be cut during the All Axes LIVE demonstration.
Equipped with Mazak’s MAZATROL SmoothAi control, SMOOTH Gear Cutting software and additional rotary axis scale feedback, the INTEGREX i-630V AG optimizes gear cutting, particularly in terms of programming and the synchronization of turning/milling spindles at high rpm. According to Mazak, the results are a more refined cutting action and smoother gear teeth surface finishes.
Designed for heavy-duty five-axis machining and large, complex parts, the INTEGREX i-630V AG employs a turning spindle with C-axis control and a rigid milling spindle with B-axis tilt of -30/+120 degrees, both of which are monitored via rotary axis scale feedback. During the All Axes LIVE event demonstration, the machine power skived a 35” diameter gear made from 4140 steel.