Advanced machine processes large-diameter shaft-type workpieces in single setups
FLORENCE, Ky., Oct. 8, 2013 – At DISCOVER 2013, Mazak demonstrated more than 30 of its advanced machine tool solutions, including the INTEGREX e-420H Multi-Tasking machine. Aerospace part applications run on the machine showed attendees how to achieve precision part processing of heavy, large-diameter shaft-type workpieces in single setups. 
Ideal for a wide variety of industries, including construction machinery, marine and energy, the INTEGREX e-420H combines the abilities of a high-powered turning center and full-function machining center to productively turn, mill, bore and drill, while offering 5-axis simultaneous machining. The machine fits into Mazak’s Done-In-One® category for being able to incorporate all processes from raw material input through final machining, which reduces production lead times, improves machining accuracy and lowers operating expenses.
The INTEGREX e-420H employs a headstock with an 8", a 12" or a 15" chuck and 3.6” diameter bore mounted on a 40-hp, 4,000-rpm integrated spindle motor that brings high output and high torque to a wide range of applications. The C-axis, which indexes in 0.0001-degree increments, features a brake mechanism and direct magnetic detector to provide high positioning accuracy.
A strong 30-hp, 12,000-rpm integral motor milling spindle that rotates 240 degrees in the B-axis enables the INTEGREX e-420H to perform simultaneous 5-axis and high-feedrate milling operations. A variety of tool magazine capacities, from the standard 40 tools to the optional 80 or 120 tools, offer versatility in the shapes and sizes of tools that can be stored to further support Multi-Tasking part-processing operations. To ensure the safe and accurate machining of long workpieces, the INTEGREX e-420H easily pairs with an optional steady rest.
The INTEGREX e-420H provides a maximum swing of 26.38" and a 16.54" Y-axis, which is the largest stroke in this class of machine tools. Longer workpieces are also easily handled in the machine’s standard bed length of 60" or optional bed length of 120".
Axis travels on the INTEGREX e-420H incorporate Mazak’s MX Hybrid Roller Guide System that 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 INTEGREX e-420H features Mazak’s new MATRIX 2 CNC control designed specifically for optimized 5-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 processing speeds for small increment operation. Furthermore, a 5-axis spline interpolation function included in the control’s software provides smooth tool paths from long block-by-block programs, easy tool vector control and shorter cycle times as well as superior 5-axis surface finishes.
For increased machine utilization, the INTEGREX e-420H is compatible with several forms of automation, such as bar feeders, gantry loaders and articulating robots.