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