Mazak recently debuted its compact INTEGREX i-100 BARTAC-ST Multi-Tasking machine that features two turning spindles, a milling spindle and lower turret for full 5-axis machining and DONE IN ONE® processing of small high-precision parts. The machine also features a large 4.4" spindle bore that brings unsurpassed efficiency to the machining of bar material up to 4" in diameter.
With the capability to handle all processes from raw material input through final machining, the INTEGREX i-100 BARTAC-ST provides dramatic reductions in lead-times and improves part accuracy through the elimination of multiple setups. Plus, its full 5-axis capability makes it possible to easily process fully prismatic parts from solid block or castings, round parts or highly contoured sculptured parts. The 5-axis software for this machine is available as optional equipment.
The main spindle on the INTEGREX i-100 BARTAC-ST employs a 15-hp integral motor spindle with maximum spindle speeds of 2,000 rpm. For high-precision C-axis contouring, the main spindle indexes in 0.0001-degree increments, while the 15-hp, 6,000-rpm second spindle provides increments of 0.001 degrees. The main spindle features an 8" chuck with a 4.4" bore size that can process bar stock up to 4" in diameter, while the second spindle has a 6" chuck and 2.4" bore size.
An Intelligent Bar Loader System automatically feeds out the material the required distance from the chuck and minimizes the bar remnant. Furthermore, an optional chuck pressure management system automatically changes by part program for a wide variety of workpieces. It maintains not only the set chuck pressure per workpiece, but also the same pressure when changing material.
The INTEGREX i-100 BARTAC-ST has a powerful 10-hp, 12,000-rpm milling spindle (optional 20,000 rpm) mounted in the rotating B-axis with a range of 240 degrees in 0.0001-degree indexing increments. And for high accuracy of motion, B-axis scale feedback comes standard on the machine.
The machine comes standard equipped with a 36-tool magazine that accommodates tools up to 5.1" in diameter by 9.84" long when neighboring stations are empty and up to 3.5" in diameter when stations are occupied. For further tooling versatility, the machine also has a 72-tool magazine option as well as an automatic tool changer (ATC) that can exchange both fixed and rotary turning tools.
For off-centerline operations, the INTEGREX i-100 BARTAC-ST provides expansive axes travels of 8.2" in Y, 17.7" with a below centerline capability of 1.96" in X and 35.5" in Z; thereby allowing the machine to process a wide range of part sizes and shapes. Furthermore, the machine’s three linear axes attain high-speed rapid traverse rates of 1,575 ipm.
The machine’s lower drum turret carries nine tools and can work at either the main or second spindle with the same tool, allowing the turret to perform balanced cutting operations on one part working in tandem with the machine’s vertical milling spindle. There is also the option for milling capability with the lower turret. All of which provides the flexibility to process a workpiece’s second operation in the machine’s second spindle or to perform first and second operations simultaneously on one workpiece.
The INTEGREX i-100 BARTAC-ST sports the new MAZATROL SmoothX CNC that is a key element – along with new machine hardware and servo systems – of Mazak’s SMOOTH TECHNOLOGY. As a dramatic evolution in the advancement of machine tools, SMOOTH TECHNOLOGY is a complete process-performance platform that spans the entire part-production landscape from programming and setup to metal removal operations and automation to monitoring and data collection/transfer.
Designed for convenient system installation, the INTEGREX i-100 BARTAC-ST requires minimal floor space when compared to conventional equipment with gantry loader or robot systems with a footprint of 127" x 98". Furthermore, for those manufacturers seeking lights-out operations, the machine pairs with an optional integrated work unloader and conveyor that cost effectively handles completed work pieces from the second spindle.