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December 2015

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Complete Process Platform for Multi-Axis Machines



Mazak's MAZATROL SmoothX and SmoothG are key elements of SMOOTH TECHNOLOGY, a process-performance platform for the company's multi-axis machines. "Spanning the entire part-production landscape, from programming to metal removal to data collection, SMOOTH TECHNOLOGY enhances productivity at every stage of the metalcutting process," said a company spokesperson.

MAZATROL SmoothX CNC is designed to reduce part cycle times, especially in fine increment programs for simultaneous 5-axis operations and free-form die/mold machining. MAZATROL SmoothG CNC is designed to simplify multitasking operations when processing parts through off-centerline machining as well as angled drilling, milling and tapping.

In addition to the advanced programming provided via the MAZATROL Smooth CNCs, SMOOTH TECHNOLOGY also factors in optimized machine design by way of intuitive hardware, high-speed servo systems, enhanced ergonomics and more. "Engineering support also complements the technology platform by factoring in automation integration and digital manufacturing–all of which will be key over the next decade as the Industrial Internet of Things (IIOT) transforms the manufacturing industry as we know it," said the spokesperson.

Advanced Programming and Support Functions

"The modern MAZATROL programming on the SmoothX and SmoothG CNCs quickly puts infinite part production possibilities at a Mazak machine operator's fingertips," said the spokesperson. "Both highly progressive designs, these CNCs share many of the same advanced features and functions; however, the MAZATROL SmoothG does not support simultaneous 5-axis operations."

MAZATROL allows operators to use either conversational or EIA/ISO programming to run their Mazak machines. The difference now is that should they prefer EIA, the patent-pending Quick EIA feature on the Smooth CNCs plots any toolpath prior to running a program to boost simulation speeds.

The View Surf function within the Quick EIA screen provides high-speed data analysis of the generated toolpath to identify and correct any errors. As such, manufacturers benefit from fewer test cuts and enhanced workpiece surface finishes. Furthermore, if machining should suddenly stop due to an unexpected interruption, such as a machine alarm or power failure, the Smooth Restart function allows the EIA program to pick up where it left off through stored blocks of G-code and modal commands.

The Quick MAZATROL programming screen allows for the direct importation of 3-D CAD models into the CNC. With that data, users can then view a part model and touch select a specific geometry or geometries for which they will develop a MAZATROL conversational program. The function then pulls the coordinates from the solid model to provide programming assistance. With the actual solid model imported into the machine's control, a single finger tap eliminates time-consuming steps when programming at the machine.

Voxel graphics technology, which is used to generate realistic graphics in gaming systems, is an important part of the 5-axis Virtual Machining function that provides 3-D simulation of real-life part programs so operators can check for errors and machine interferences. In fact, these realistic and accurate simulations for both conversational and EIA/ISO programming use the same machine movement parameters as the machine.

Increased Productivity Functions

Several CNC features and functions, including Orbit Machining, Position Controlled Hobbing, Real Time Tuning, Smooth Corner Control and Intelligent MAZATROL Pocket Milling, are designed to allow the MAZATROL SmoothX and SmoothG to further strengthen the performance of Mazak equipment as well as further decrease machining cycle times.

The Orbit Machining function uses circular interpolation and spindle rotation to mimic turning operations on Mazak machining centers. This allows manufacturers to turn features on large complex parts while they remain in a static position. The function also combines multiple processes in a single set-up. In terms of programming, operators no longer have to worry about the challenges involved when programming these same operations in EIA/ISO. Orbit Machining also allows operators to use the same programming as lathes, including nose-R compensation, constant surface feed and fixed cycles.

As gear cutting becomes more commonplace on multi-axis machines, the Position Controlled Hobbing function available through the controls brings high accuracy and convenience to hobbing and skiving operations. The function will synchronize the workpiece and cutter at any time, enabling operators to change the spindle override while cutting, adjust spindle speeds during roughing and finishing as well as check surface finish via manual interruption. Additionally, the CNCs allow for faster rotary axis speeds to further boost these gear production capabilities.

The Real Time Tuning function on the Smooth CNCs helps maintain optimal balance during the machining process by automatically adjusting the rapid feedrates of the rotary table axes to correspond with the changing weight of the workpiece. After all, rapid feedrates are based on the weight of the workpiece so that the heavier the part, the slower the speeds. As the workpiece becomes lighter over the course of the metal removal process, the speeds should start to go faster. The Real Time Tuning function detects the change in inertia during the machining process and makes the appropriate rapid feed adjustments based on the workpiece weight in real-time.

Based on a preset radial tolerance, the Smooth Corner Control function reduces vibrations and shortens machining cycle times through cutter path adjustments made when machining into corners. This tolerance eliminates any dwell resulting from a rapid deceleration in the axial movement often associated with conventional corner machining. Thus, corner surfaces are smoother, the risk of cutter gouging is reduced and cutters can feed much faster.

Intelligent MAZATROL Pocket Milling engages a high-efficiency toolpath when milling out part cavities. As opposed to conventional offset milling, the function consistently maintains a constant angle of tool engagement and cutting loads to help ensure optimum machining conditions. This results in the full use of a machine tool's power capabilities and up to 35% faster and more efficient machining of even the most difficult-to-cut materials.

Intuitive Hardware and Enhanced Ergonomics

MAZATROL SmoothX and SmoothG CNCs both have an intuitive human-machine interface (HMI) for enhanced speed and convenience.

Large 19" displays present all of the critical machine data within a single-page view so operators can instantly jump from the home screens to any other area or section within the controls. And, with multi-touch screens that are similar to those on smartphones and tablets, operators benefit from a highly flexible user interface. For example, they can easily manipulate 3-D part renderings by simply using their fingertips to pan, rotate or zoom on the screen.

Ergonomics also play an important role in the functionality of the MAZATROL SmoothX and SmoothG in that operators can easily tilt the control panel to allow for optimum positioning based on his or her height. In terms of program storage capacity, both controls have a CFast card that offers high data-transfer speeds and can hold up to 32 GB of information.

Automation and Digital Manufacturing

In terms of automation, Mazak made its modular PALLETECH System key to the SMOOTH TECHNOLOGY platform. The technology has been integrated with the PALLETECH Manufacturing Cell (PMC) software and is called Smooth PMC.

Smooth PMC features a home screen that has the same look and feel as the MAZATROL Smooth CNC. This schedule operation software predicts the necessary tools and output according to the production schedule. A variety of graphs within the software also allows for utilization analysis. Furthermore, users can monitor a PALLETECH-based manufacturing cell from almost anywhere via a smartphone or tablet.

For digital manufacturing functionality, SMOOTH TECHNOLOGY supports the MTConnect open communications protocol and includes an NC Data Library–an Ethernet interface to a library of data-accessing functions for programmers if they wish to communicate with the machine via an Ethernet network. This also means machines with SMOOTH TECHNOLOGY can have an MTConnect adapter for collecting data from the MAZATROL CNCs.

MAZATROL SmoothX CNC works with:

  • INTEGREX i-Series
  • INTEGREX e-H Series
  • INTEGREX i-V Series
  • INTEGREX e-V Series
  • VORTEX i-V Series
  • VARIAXIS i-Series
  • VARIAXIS j-5X Series
  • VERSATECH Series.

MAZATROL SmoothG CNC works with:

  • INTEGREX j-Series
  • VARIAXIS j-Series
  • HYPER QUADREX Series
  • CYBERTECH TURN Series
  • MULTIPLEX Series
  • DUAL TURN Series
  • FJV Series (#50)
  • HCN Series (#50).

"As manufacturing technologies continue to advance, SMOOTH TECHNOLOGY has the means to evolve alongside them so Mazak machine owners can consistently combat any part production challenge that stands in their way," said the spokesperson.

For more information contact:

Tasha Riddell

Mazak Corporation

P.O. Box 970

Florence, KY 41022-0970

859-342-1700

triddell@mazakcorp.com

www.mazakusa.com

Southwest

Dana R. Scott

Mazak SW Technology Center

10950 Greenbend Blvd.

Houston, TX 77667

281-931-7770

dscott@mazakcorp.com

www.mazakusa.com

LA

Richard Cahn

Dixie Mill Machine Tools Co.

901 Tchoupitoulass Street

New Orleans, LA 70152

504-525-6101

800-462-9519

rcahn@dixiemill.com

www.dixiemill.com

OK, AR

Butch Cumminsky

David James

Machinery Resources Inc.

5550 South 94th East Avenue

Tulsa, OK 74145

918-622-6495

800-448-1878

butch@mritul.com

www.mritul.com

N. TX

Chris Papke

Mazak Corporation

2000 East Lamar Blvd, Ste. 600

Arlington, TX 76006

800-642-6110

El Paso, TX

Felipe Arvizo

Magnum Precision Machines Inc.

12025 Rojas Dr. Suite A

El Paso, TX 79936

915-856-7900

farvizo@magnumep.com

www.magnumprecisionmachines.com

NM

Chris Edgar

Magnum Precision Machines, Inc.

8448 Washington Place NE

Albuquerque, NM 87113

505-345-8389

cedgar@magnumabq.com

www.magnumprecisionmachines.com

Southeast

Dave Kennedy

Mazak Southeast Technology Center

1075 Northbrook Parkway

Suwanee, GA 30024

678-985-4800

dkennedy@mazakcorp.com

www.mazakusa.com

TN

Dennis McCurry

Pinnacle Machine Tools, Inc.

5912-A Toole Drive

Knoxville, TN 37919

865-951-0260

mccurry@pinnaclemachine.net

AL

Jerry Edwards

Pinnacle Machine Tool Inc.

141 Nick Fitcheard Road

Huntsville, AL 35806

256-852-0900

edwards@pinnaclemachine.net

NC, VA

Rick Smith

MachineTech, Inc.

8100-J Arrowridge Blvd.

Charlotte, NC 28273

704-665-6301

rick@machinetechcnc.com

www.machinetechcnc.com

GA, SC

Tim Kramer

Premier Engineering Co.

1635 Lakes Pkwy. Ste. U

Lawrenceville, GA 30043-5858

678-442-8382

tim@premierengineering.com

www.premierengineering.com

MS

Richard Cahn

Dixie Mill Machine Tools Co.

901 Tchoupitoulass Street

New Orleans, LA 70152

504-525-6101

rcahn@dixiemill.com

www.dixiemill.com

FL

Mike HessneyJoe Selway

Unbridled Technologies

PO Box 344

Brooksville FL 34605

888-334-8402

info@utechcnc.com

www.utechcnc.com

Northeast

New England, E. NY, NJ

Steve Wilkins

Mazak Northeast Technology Center

700 Old County Cir.

Windsor Locks, CT 06096

800-436-8900 / 860-292-4400

SWilkins@mazakcorp.com

www.mazakusa.com

E. PA, MD, DE

Jim Rutan

Mazak Mid Atlantic Office

1275 Glenlivet Drive

Allentown, PA 18106

jrutan@mazakcorp.com

www.mazakusa.com

W. NY

Bill Miller

A.W. Miller Technical Sales

East Aurora, NY

716-652-8282

bmiller@awmiller.com

www.awmiller.com

W. PA

Russ Weis

A.W. Miller Technical Sales

3 Tara Drive

PO Box 220

Harmony, PA 16037

724-453-1690

rweis@awmiller.com

www.awmiller.com

Midwest

Kevin Bates

Mazak Midwest Technology Center

300 East Commerce Drive

Schaumburg, IL 60173

847-885-8311

kbates@mazakcorp.com

www.mazakusa.com

ND, SD, MN

Joel Lundin

Tony Bailey

Northwest Machine Technologies, Inc.

20851 Commerce Blvd.

Rogers, MN 55374

763-493-3660

tbailey@nwmtec.com

www.nwmtec.com

NE, W. IA

Duane Ohlrich

Industrial Systems & Supply Inc.

2760 E. 29th Avenue

Columbus, NE 68601

402-564-4445

ohlrich@industrial-systems-supply.com

www.industrial-systems-supply.com

E. IA

Kevin Bates

Mazak Midwest Technology Center

300 East Commerce Drive

Schaumburg, IL 60173

847-885-8311

kbates@mazakcorp.com

www.mazakusa.com

MO, S. IL

Bill Summers

Municipal Tool & Machinery Co.

2465 Rock Island Blvd.

Maryland Heights, MO 63043

314-994-9905

bsummers@municipaltool.com

www.municipaltool.com

KS, W. MO

Paul Domurat

Concept Machinery -

A Shelton Machinery Company

6319 W. 110th St.

Overland Park, KS 66211

913-647-5366

pdomurat@concepttechsales.com

www.concepttechsales.com

WI

Mike Cekanor

Machinery Systems North

3280 Gateway Rd.

Brookfield, WI 53045

262-781-4850

mikec@machsys.com

www.machsys.com

IL, N.W. IN

Eric Hilliard

Machinery Systems Inc.

614 East State Parkway

Schaumburg, IL 60173

847-882-8085

www.machsys.com

E. MI

Peter Addy

Addy Machinery Co.

36055 Groesbeck Highway

Clinton Township, MI 48035

586-741-3000

800-ADDY-NOW

peter@addymachinery.com

www.addymachinery.com

W. MI

Peter Addy

Addy Machinery Co.

3757 Broadmoor Ave SE, Ste. A & B

Grand Rapids, MI 49512

800-AddyNOW

peter@addymachinery.com

www.addymachinery.com

S. OH

Greg Papke

Mazak Corp.

8025 Production Drive

Florence, KY 41042

859-342-1700

gpapke@mazakcorp.com

www.mazakusa.com

IN, KY

Nick Shelton

Shelton Machinery, Inc.

9900 North by Northeast Blvd.

Fisher, IN 46037

317-845-5588

www.sheltonmachinery.com

N. OH

Frank Gibbons

Numerequip

4810 Briar Road

Cleveland, OH 44135

216-265-0400

fgibbons@numerequip.com

www.numerequip.com

West

CO, E. WY

Randy Breitenbach

Action Machinery International

4950 Oakland Street

Denver, CO 80239

303-532-2900

randy@action-machinery.com

www.action-machinery.com

WA, N. ID, OR

Mark Harris

CNC Machine Services, Inc.

7808 184th St. SE

Snohomish, WA 98296

425-788-4500

mharris@cncmachineservice.com

www.cncmachineservice.com

AZ

Chris Edgar

Magnum Precision Machines

3614 E. Southern Ave. #1

Phoenix, AZ 85040

602-431-8300

cedgar@magnumabq.com

www.magnumprecisionmachines.com

UT, S. ID, MT, W. WY

Clark Smith

Smith Machinery Company

41 W. Guest Avenue

Salt Lake City, UT 84115

80l-263-6403

csmith@smithmachinetools.com

www.smithmachinetools.com

S. CA

Richard McCauley

Mazak West Regional Headquarters and

Aerospace Technology Center

1333 West 190th Street

Gardena, CA 90248

310-327-7172

rmccauley@mazakcorp.com

www.mazakusa.com

N. CA

David Lindenmuth

Mazak San Francisco Sales and

Technical Center

1497 N. Milpitas Blvd.

Milpitas, CA 95035

408-941-2240

dlindenmuth@mazakcorp.com

www.mazakusa.com

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