Multi-Tasking machine performs heavy-duty 5-axis cutting with new high-torque turning and milling spindles
Florence, Kentucky, October 25, 2011 – At T3 – Tomorrow's Technology Today, a Discover Mazak 2011 event, Mazak demonstrated its INTEGREX i-630V Multi-Tasking machine featuring turning and milling for heavy and large parts. Together with B-axis and C-axis capabilities, the turning and milling spindles allow for powerful and accurate full simultaneous 5-axis machining for large, extremely complex parts.
The new 50-taper milling spindle has a standard maximum speed of 10,000 rpm and a torque rating of 248 Nm, with optional high-torque 5,000-rpm (525 Nm) and high-speed 15,000-rpm (118 Nm) versions available. Whether workpieces require heavy-duty milling, involute gear machining, or large-diameter drilling, the INTEGREX i-630V provides a selection of spindle speeds and torque ratings for reducing cycle times and completing parts in single setups.
The milling spindle gets speed and rigidity being mounted in the machine's compact B-axis head that swings from -30 to +120 degrees in minimum increments of 1 degree, rapid traverses at 1,181 ipm (30 m/min) and is roller gear cam driven. A standard 43-tool automatic tool changer supplies the milling spindle with tooling, and optional 80, 120 and 160-tool capacity versions are available.
Within Mazak's Five Levels of Multi-Tasking, the INTEGREX i-630V is a Level 4 machine. The five levels were developed as an effective way for manufacturers to determine the best multi-tasking technology for meeting their specific application and process needs.
Level 1 machines in the Five Levels of Multi-Tasking typically offer a single turning spindle and drum-style turret with rotating tool capability for processing minimally complex workpieces. Level 2 machines add Y-axis functionality to machine drum turrets for off-center operations and Done-In-One machining together with either a twin spindle and milling turret or twin spindle/twin turret machine configuration. Level 3 Multi-Tasking machines feature independent milling spindle headstocks with B-axis indexing, as well as Y-axis travels and tool storage magazines. Level 4 machines emphasize automation and processing large or highly complex workpieces using full, simultaneous 5-axis machining. Level 5 is the addition of specialized machining tasks, such as gear cutting, honing and grinding, that transform Level 4 machines into Level 5 Ultra-Tasking machines that process even the most demanding and complex parts complete in single setups.
For accommodating workpieces up to 41.3" (1,050 mm) in diameter and 39.3" (1,000 mm) high, the INTEGREX i-630V's standard two-pallet changer features pallets measuring 24.8" x 24.8" (630 mm x 630 mm) that, within 11 seconds, move in and onto the machine's NC direct-drive motor table. With turning functionality, the machine's 31.5" (800 mm) table turns in a full 360-degree range at a maximum speed of 550 rpm and generates 2,944 Nm of torque for machining even the toughest materials.
Ample axis travels on the INTEGREX i-630V measure 58" (1,475 mm) in X and 41.3" (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. The MX Hybrid Roller Guide System dampens vibration to extend tool life, handles higher load capacities, accelerates and decelerates quicker to shorten cycle times, consumes less oil for "Greener" operations, and lasts longer with less required maintenance.