Innovations in Cost Effective Multi-Tasking

The VC-500 AM (additive manufacturing) hybrid multi-tasking machine from Mazak Corporation (Florence, KY) combines full 5-axis capability and additive technology to revolutionize product design, reduce time to market and cut research and development costs. It builds part features to near-net-shape up to ten times faster than comparable systems and without wasting expensive material or losing time by subtracting large amounts of metal from a solid piece of material using conventional machining. This machine offers users geometric freedom via direct metal deposition, which allows for both additive and subtractive machining capabilities in a single setup. The laser cladding heads of the VC-500 AM reside side-by-side with the subtractive machining spindle.

During operation, the VC-500 AM uses fiber laser heat to melt the chosen metal powder that will be used to the grow near-net-shape 3D forms. The cladding head applies the molten material layer by layer, all of which solidify as the desired part surface or features grows. The laser cladding head can also be used to coat chosen sections of the part with metal, allowing the machine to repair worn or damaged high-value components. Constructed on a simple, compact 5-axis platform, the VC-500 AM is very cost effective and accommodates a wide range of part sizes and shapes up to 19.7 in diameter, 12 in tall and up to 440 lb. It is ideal for shops who require optimum part finish and high accuracy and is also well suited for educational institutions and research and development facilities.

Mazak also offers the Multiplex W200Y multi-tasking CNC turning center with the industry’s fastest Done In One part processing capabilities. The machine loads/unloads parts quicker, provides shorter chip-to-chip times and sports the Mazatrol SmoothG CNC with higher processing speeds for faster overall machine feed rates. Designed for single-setup, mid-to-high volume production and continuous operations, the Multiplex W200Y incorporates dual spindles, dual turrets with milling tools and Y-axis capability. The twin integral spindles each offer an 8 in (203 mm) chuck size and a bore size of 2.4 in (61 mm) diameter, and each delivers 30 hp (22 kW) and maximum speeds of 5,000 rpm. Since both spindles offer identical performance, part-processing flexibility is greatly increased, and full 360 deg circumferential clamping units are incorporated into the integral spindles to further increase C-axis indexing accuracy.

The twin VDI-type turrets hold 12 tools each and rotary tools can be mounted in any position. Y-axis travels of ± 2 in (± 50 mm) along with the 5,000 rpm (10,000 optional) milling spindles of the turrets further increase the machine’s single-set up part processing power. With the Mazatrol SmoothG control, the axes feed at speeds 14 percent to 50 percent faster than previously. The control makes it easy to generate programs for processing complex parts through off-centerline machining, as well as angled drilling, milling and tapping. The control incorporates a wide variety of advanced programming functions for ease of use that ensure high speed, high accuracy machining performance, including High Gain Feed Forward Control, Fast Rotary Axis Speeds, Variable Acceleration Control and Intelligent Pocket Milling.

To shorten part loading/unloading time by about 20 percent, the Multiplex W200Y has a rack-and-pinion type gantry loader, as opposed to a belt-driven one, and the motion of all the machine’s doors and partitions are synchronized to open precisely as the gantry approaches. As an automation option, a two-pallet changing conveyor system allows users to continuously feed parts into it without having to stop the gantry or the machine itself. And via part program macro, users can select when and which parts will exit the conveyor system for inspection. New turrets that feature clutch-less milling units significantly shorten chip-to-chip time on the Multiplex W200Y. The turret design is a two-motor type: one motor for indexing and the other for direct drive milling. Immediately after a turret indexes, the mill drive is instantaneously engaged to slash chip-to chip-time by over 50 percent in most instances.

The identical twin spindles and identical twin turrets with Y-axis travel allow for unique part machining. Long shaft parts can be held using both spindles and machined with synchronized spindle rotation. Or the first operations of parts can be done with the No. 1 spindle/turret, and then parts transfer to the No. 2 spindle/turret for completing remaining operations. Or two parts can be completed simultaneously and independently at both spindles/ turrets and using the machine’s center partition. Both left and right machine spindles can be equipped with a Tool Eye unit. When tool tips are brought into contact with these units, the Tool Eye data management system automatically registers tool position information to the machine’s CNC. The system can also be used for tool measurement and tool breakage inspection.

The Multiplex W200Y handles bar work diameters up to 2 in (50 mm), shaft work lengths to 21 in (533 mm) and chucked workpiece lengths to 7 in (178 mm). It provides a standard machining diameter of 10.24 in (260 mm) and a maximum swing of 12.6 in (320 mm) diameter.

For unequaled part processing opportunities and enhanced Done In One capabilities, Mazak also offers the Hyper Quadrex-250MY+Tailstock multi-tasking turning center for faster cycle times and more efficiency than other comparable machines thanks to its advanced Y-axis machining capability, twin-turrets, fully programmable tailstock and Mazatrol SmoothG CNC. For fast and reliable production, the Hyper Quadrex-250MY+Tailstock can completely machine parts from bar slug and/or bar material in single setups. Also, the balanced cutting of the machine’s upper and lower turrets, together with Y-axis machining, ensures high part throughput with simultaneous turning and milling operations on the same part.

Because the twin turrets operate independently or together on the same workpiece, the machine can process two different features on a workpiece simultaneously, or follow a balanced strategy where two tools work together on the same workpiece feature. In cases where the part configuration permits, balanced machining can potentially remove up to 25 percent of the cycle time. Both the upper and lower turrets accommodate 12 tools (16 tools optional) each and have 4 in (102 mm) Y-axis travel capability for off-centerline operations. And, unlike other comparable machines that offer only upper-turret live tooling, both turrets on the Hyper Quadrex-250MY+Tailstock accommodate rotary tools and at any tool position. Rotary tool spindles on each turret deliver 6,000 rpm and 7.5 hp for milling and drilling multi-tasking functionality.

For perfect part support, the MT#4 servo-driven tailstock with brake delivers a maximum thrust of 225 ft-lb to 1,574 ft-lb (1 kN to 7 kN) programmable in increments of 22.4 ft-lb (0.1 kN). Plus, the thrust amount can be adjusted while the tailstock is engaged. To help shorten non-cut time, the tailstock rapid traverses at speeds up to 315 ipm (8 m/min). Large diameter bearings support the machine’s spindle for high rigidity. The spindle features a 10 in (254 mm) chuck, 3.1 in (78.740 mm) bar capacity and 35 hp integral spindle motor that provides a maximum 4,000 rpm speed. With full CNC C-axis control, the spindle positions and contours with indexing increments of 0.0001 deg.

This machine also comes equipped with the Mazatrol SmoothG CNC that makes it fast and easy to generate programs for high speed multi-axis processing of complex parts through off-centerline machining as well as angled drilling, milling and tapping. For the Hyper Quadrex-250MY+Tailstock, the control also includes hobbing software. Through the Smooth Technology platform, the control offers programming with Mazatrol and/or EIA. There are also several other advanced programming functions. For continuous unmanned operations, the Hyper Quadrex-250MSY easily integrates with an optional bar feeder and unloader or robot loader/unloader.

Mazak Corporation, 8025 Production Drive, PO Box 970, Florence, KY 41042, 859-342-1700, Fax: 859-342-1865, www.mazakusa.com.