"Machine tool computer numerical control (CNC) has just experienced a dramatic evolution - one that expands the concept far beyond what a machine's control typically represents," said a Mazak spokesperson. "At the heart of this evolution is a new complete process-performance technology platform that spans the entire part production landscape from programming and set-up to actual metal removal operations to automation to monitoring/data collection and transfer."
Called SMOOTH TECHNOLOGY, and developed by Mazak, the all-encompassing concept is designed to combine the advanced capabilities of today's machine tools and leading-edge CNC processing and software technologies with that of Mazak's process engineering expertise.
"With manufacturing technologies continuously growing more complex, SMOOTH TECHNOLOGY embraces and incorporates those latest advancements and presents them in an easy to use and understand, intuitive and highly dynamic platform that continues to evolve and expand," said the spokesperson. "As such, it always fulfills the process control needs of each specific industry sector while providing today's manufacturers with the tools they need to increase productivity."
For its SMOOTH TECHNOLOGY, Mazak engineered a new CNC called MAZATROL SmoothX as well as new machine hardware and servo systems. Mazak developed every function of the MAZATROL SmoothX CNC in direct response to real-world issues and customer input. "Its functionality and ergonomics make it the industry's most progressive machine tool control," said the spokesperson.
Mazak reported that it has essentially quadrupled the new CNC's interpolation speed over previous generation controls. The new control interpolates code and sends it to the machine tool servos in the shortest time possible. With such high performance, Mazak said that shops can eliminate two of the most common CNC bottlenecks - sluggish hardware and slow processing speeds - to dramatically shorten machining times and enhance such operations as full simultaneous 5-axis machining and complex mold machining.
To further strengthen performance and reduce machining cycle times, MAZATROL SmoothX CNC technology is designed to deliver innovative new functions such as Intelligent Pocket Milling, Seamless Corner Control and Real-Time Tuning.
Intelligent 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 ensure optimum machining conditions," said the spokesperson. "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."
MAZATROL SmoothX CNC's Seamless Corner Control is designed to reduce vibrations and help shorten part machining cycle times through cutter path adjustments made when machining into corners. Rather than moving the cutter directly into a 90° corner, the function inserts a preset radial tolerance. "This tolerance eliminates any dwell resulting from a rapid deceleration in the axial movement often associated with conventional corner machining," said the spokesperson. "Thus, corner surfaces are smoother, the risk of cutter gouging is reduced and cutters can feed much faster."
With the Real-Time Tuning function of the MAZATROL SmoothX CNC, turning machine tool turrets index quicker to help shorten machine tool non-cut times. Whether turrets are fully loaded, partially loaded or have heavier tools on one side as opposed to the other, Real-Time Tuning detects turret loads and automatically adjusts the acceleration and deceleration of the turret indexing speed to maintain an optimum balance.
Besides its performance functions, the MAZATROL SmoothX CNC provides up to six user control security settings. Shops can set data editing/overwriting permission for every input box on every screen per particular user. Users can access screens and view program data, but depending on their preset security level, they may be limited as to what they can and cannot change. A screen may have 24 inputs, and a security level could be set so that certain users can edit or overwrite only one input, other users only 10 and a select few users all of them. This helps prevent errors and ensures that only those who are qualified can make changes.
On the part programming side, MAZATROL SmoothX CNC offers several innovative functions designed to streamline and simplify the process. These include Quick MAZATROL, Quick EIA, full 5-axis 3D simulation and soon to be added View Surf, to name a few.
Quick MAZATROL allows for the direct importation of 3D CAD models into the MAZATROL SmoothX CNC. And with that data, users can then view a part model and click on 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.
"Prior to such technology, shops had to physically look at a blueprint, make calculations and then enter the necessary values to create the program," said the spokesperson. "With the actual solid model imported into the machine's control, a single mouse click eliminates all those time-consuming steps when programming at the machine on the shop floor."
The Quick MAZATROL function reduces the number of keystrokes needed to generate a program. "Machine idle time thus drops significantly, and operators can quickly perform real-time checking/comparing of the model form to that of how it will be machined in the part," said the spokesperson.
"Think of it as a hybrid born from the marriage of a CAM system and conversational programming," said Neil Desrosiers, Applications Engineer/Developer at Mazak. "Shops are now able to use a solid model to obtain part geometries, but still program conversationally. This means that with SMOOTH TECHNOLOGY users do not have to know how to use a CAM system to work from a solid CAD model to create programs."
With programming/set-up speed in mind, Mazak equipped its MAZATROL SmoothX CNC with Quick EIA, which allows users to generate any toolpath prior to running the program. "But most importantly, the function boosts toolpath simulation speed by as much as 99% and simplifies the process," said the spokesperson. "Plus, there is extremely accurate full 5-axis 3D machining simulation and interference checking capability."
According to Mazak, the secret behind the fast simulation speed of Quick EIA is that the MAZATROL SmoothX CNC incorporates the use of today's new advanced graphics technology. These are, according to Desrosiers, basically the same type used to generate the graphics for gaming systems.
Mazak also applied these advanced graphics to the 5-axis 3D simulation function of the MAZATROL SmoothX CNC. With such capability, users can run real life part programs in simulations to check for errors and machine interferences. According to the company, these extremely realistic and precise simulations use the exact same machine movement parameters as actual Mazak model machines.
Once a toolpath is generated, the upcoming View Surf function in the MAZATROL SmoothX CNC will provide toolpath data analysis. Users will indicate that they wish to check G-code, and the function will generate the whole toolpath on the screen and indicate all errors. Once users simply zoom in and click on those specific error locations, the function will automatically bring up the exact corresponding line in the actual program. This will eliminate the need of having to scroll through the entire program to find one exact point along the toolpath.
"The View Surf function means fewer test cuts will be required, and shops will get the first part faster," said the spokesperson. "Plus, workpiece surface finishes will be much smoother."
At the human machine interface (HMI) level, MAZATROL SmoothX CNC features an entirely multi-touch home screen that, within a single page view, presents all critical data to operators. This allows them to instantly jump from the home screen to any other area or section within the CNC. They can also use a fingertip to pan, rotate or zoom and otherwise manipulate a 3D part rendering of the component being machined. Or, they can flick an area of the screen to scroll through the displayed program G-code. All MAZATROL SmoothX CNC screen functions are similar to those of a smart tablet.
The control's streamlined navigating/dashboard-type screen displays typical data output such as machine rapid speeds, horsepower, axis positioning, machining loads, estimated time of part completion and more. There are location buttons and an EIA window that displays G-code lines of the program.
Additionally, the new control provides the capability to monitor up to five additional machines that may be together in a cell or near each other. Thus, operators responsible for multiple machines can easily track their status from one machine display to eliminate the need to physically go to each machine in the group.
Because of advanced screen technology, MAZATROL SmoothX CNC consoles are the same physical size on every machine. In the past and depending on the machine type, the number of buttons determined its size. "The new control, however, will never vary in size because Mazak has designed it to include the necessary information, options and features for every Mazak machine type," said the spokesperson. "Also, a common bank of buttons remains constant from one control panel to the next, which makes it even easier for operators to go from one type of Mazak machine to the next."
With its larger machines in mind, Mazak made the Manual Pulse Generator (MPG) for the MAZATROL SmoothX CNC wireless. This gives operators freedom to move around and inside the machine untethered for executing manual operations, such as touch probing.
For digital manufacturing functionality, SMOOTH TECHNOLOGY supports MTConnect and includes an NC Data Library - an Ethernet interface to a library of data-accessing functions for programmers if they wish to write software to communicate with the machine via an Ethernet network. This also means that machines can have an MTConnect adapter and that users can collect data from the CNC.
Mazak is also applying SMOOTH TECHNOLOGY to its PALLETECH Manufacturing Cell (PMC) software and will call it PMC Smooth. Additionally, the company's Cyber Production Monitoring software will transition to what will be known as Smooth Production Center. Both of these new systems will have the same graphical look and functionality as the SMOOTH TECHNOLOGY applied to Mazak's machine tool CNCs.
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
John Grabenau
Premier Machinery Inc.
990 Sunshine Lane
Altamonte Springs, FL 32714
407-786-2000
doc@premierequipment.com
www.premierequipment.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
Paul Domurat
Concept Technical Sales, Inc.
6240 W. 135th St.
Overland Park, KS 66223
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
Ron Mager
Machinery Systems Inc.
614 East State Parkway
Schaumburg, IL 60173
847-882-8085
ronm@machsys.com
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
Jim Shelton
Shelton Machinery, Inc.
9900 North by Northeast Blvd.
Fisher, IN 46037
317-845-5588
jshelton@sheltonmachinery.com
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
Gary Anderegg
Machine Toolworks, Inc.
14600 Interurban Avenue South
Tukwila, WA 98168
206-575-3390
ganderegg@machinetoolworks.com
www.machinetoolworks.com
OR
Alex Madsen
Machine Toolworks, Inc.
27350 SW 95th Ave., Ste. 3032
Wilsonville, OR 97070
503-682-9030
amadsen@machinetoolworks.com
www.machinetoolworks.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