"To keep pace with the continuously changing needs of today's manufacturers, every aspect of each model in a new series of multi-tasking machines was designed with flexibility in mind to process a practically endless variety of part types without additional capital expense," said a Mazak spokesperson. "Not only does the series allow for shops to add a multitude of automation options as production levels dictate, but it also lets them do so in the field long after the initial purchase of the machine."
This completely new design concept is the INTEGREX i-H Series of Multi-Tasking Machines from Mazak. The machines within the series have new compact footprints and require less floor space. Additionally, Mazak equipped them with faster and more powerful turning spindles, space saving milling spindles and a new type of lower turret with live tooling capabilities. The company also expanded tool capacities for lower turrets and for tool storage magazines and offers a wider range of chuck size options for each machine in the series.
Because production needs never remain the same as when a machine was initially purchased, the INTEGREX i-H Series machines allow shops to have various automation options retrofitted in the field to accommodate those changes in production. Such retrofitted options are packaged as kits for fast and easy installation by Mazak service technicians. This easy integration means that shops can purchase an INTEGREX i-H machine as a standard configuration, then down the road, add, for example, an overhead gantry loader, a parts unloader and parts catcher, a bar feeder, automatic chuck jaw changers for either a machine's main or second spindles, or a pedestal-type standalone robot.
Automatic front door capabilities and various openings for automation, among other machine features, are what make it easy to retrofit an INTEGREX i-H machine with automation in the field. For example, machine side panels are removable when access is needed for adding a parts catcher, and there is a top removable panel for overhead gantries. The machines also feature full-size, top-to-bottom front doors that can be retrofitted in the field for automatic operation to accommodate a standalone robot operating at the front of the machine.
Another retrofittable option for INTEGREX i-H machines is new magazine-style automatic jaw changers for main turning spindles and now for second spindles as well. With such capability at both spindles, the machines basically reduce job changeover times down to the time it takes the auto jaw changer to switch out the jaws for a new job. As opposed to an operator taking maybe 10 minutes to change over jaws one day and maybe 20 minutes the next, the auto changer time remains constant without faltering.
Besides consistency, auto jaw changing allows shops to equip a machine in such a way as to make a wide variety of parts from one size of bar stock. For instance, with a 4" diameter bar feeder and auto jaw changer for the second spindle, a shop could use Mazak's job scheduling software to run a wide variety of parts/diameters from that single size of bar stock. This eliminates having to stop the machine to change out the jaws on the second spindle to accommodate the various job part diameters.
For over 40% faster part loading, shops can equip their INTEGREX i-H machines with a new redesigned gantry loader (GL). The system is shorter in height by 16.250" (413 mm) and thus requires less overhead clearance room. It provides A/B-axis swing arm synchronization, connects to service multiple machines if so desired, and with a conveyor at the left side of the machine the GL further reduces load/unload time.
To further boost processing flexibility for a wider range of part types and machine performance, INTEGREX i-H machine configurations include those with just a main turning spindle, milling spindle and tailstock, while (S) configurations feature second turning spindles, and (ST) designated machines have a second turning spindle and lower turret with live rotary tool capability.
On INTEGREX i-H models with main and second spindles, both are equal in power/torque, and Mazak offers various horsepower/torque and bore size options for them. The reason for having both the main and second spindles equal in power/torque is for those shops performing mirror image part processing-one in each spindle-and want to maintain the same cycle times at both spindles. Typically, the torque in second spindles is lower to instead match its speed/RPM to that of the main spindle.
In addition to having equal power/torque for both main and second spindles, INTEGREX i-H machines offer the option for having both turning spindle bore sizes the same as well for easy and stable small to medium size shaft work processing. Consider a shaft part that is 4" in diameter and 12" long and requires machining at both ends. With a machine now having, for instance, a 4" diameter bore size on its second spindle as well as its main, a shop could bar feed the part through the main spindle and perform the first op on the one end.
Afterwards, the second spindle would move in and clamp on to the part to support it while the machine performs a cutoff operation. The second spindle pulls the part out, inserting most of the part's length into the spindle through hole and clamping close to the remaining end to support it for machining.
In addition to a standard slant type lower turret, there is a new orthogonal type of lower turret available with INTEGREX i-H Series ST designated machine models. Besides providing a faster 10,000-RPM milling spindle, expanded capacity of 12 tools and the elimination of chip accumulation problems, the new turret allows shops to run larger size parts, use longer tools and have the turret work at a machine's main or second spindle without interference.
What this means is that the INTEGREX i-H machines/orthogonal lower turrets can perform a wider variety of part processing operations for increased flexibility. For instance, shops can perform pinch turning and pinch milling operations where the lower turret works together with the milling spindle as both perform milling or turning operations on the same part at the same time to shorten cycle times. The lower turret might do rough turning as the milling spindle follows behind with a static turning tool doing the finishing pass. If a part has an 8-hole bolt hole pattern, for example, around a circumference, two holes could be drilled simultaneously, reducing the operation time by half.
Because the new turret allows for longer tools, INTEGREX i-H Series machines can perform deeper boring and drilling operations when compared to typical slant-type lower turrets. For such operations, the new turret can house a steady rest for shaft type workpiece support.
On the milling side, INTEGREX i-H Series machines feature new compact milling spindles with shorter lengths that further contribute to a greater variety of part types/sizes that can be processed on one machine. For the same reason, Mazak offers the spindles in standard, high-power and high-speed versions for various applications, and speeds range from 12,000 to 20,000 RPM. Plus, the spindles maintain their full torque ratings throughout the entire range of their spindle speeds.
To keep pace with extended automated operations, the new INTEGREX i-H machine tool magazine storage capacities are expandable up to 112 tools. The magazines are mounted at the rear of the machine, and shops have the option to load or set up tools at either the front or rear of the machine. This allows them to now load large amounts of tools at the back of the machine or if only one or two tools are needed, from the front of the machine.
All INTEGREX i-H Series machines feature Mazak's new MAZATROL SmoothAi control that includes enhancements on the MAZATROL side and added flexibility on the EIA/ISO side, along with an optional second screen model. The second monitor displays the status of multiple connected Mazaks within the same shop.
With the control's Solid MAZATROL function, shops can now work from solid models to generate programs for specific part features. To further optimize machining operations, the control provides cutting condition monitoring through its Smooth Ai Spindle function and thermal stability with its Ai Thermal Shield function. MAZATROL SmoothAi also has specific functions for advanced robot automation and unmanned operations.
To boost the output of existing workforces and effectively compete against offshore manufacturing, shops can construct highly flexible and fully automated cells with INTEGREX i-H Series machines. Equipped with pedestal-type gantry robots, these cells offer automated processing of a variety of part types/jobs and production lot sizes.
The self-run gantry robot positioned at the front not only moves workpieces in and out of the machine as well as to and from work stocker units, but it also transports tooling, chuck jaws and end-of-arm robot tooling between the machine and individual stocker units for each. Within the cell, the machine itself incorporates a front tool set-up unit and automatic chuck jaw changing capability.
For more information contact:
Mazak Corporation
P.O. Box 970
Florence, KY 41022-0970
859-342-1700
www.mazakusa.com
Southwest
Chris Papke
Mazak SW Technology Center
10950 Greenbend Blvd.
Houston, TX 77667
281-931-7770
cpapke@mazakcorp.com
www.mazakusa.com
LA
Richard Cahn
Dixie Mill Machine Tools Co.
901 Tchoupitoulass Street
New Orleans, LA 70152
504-525-6101 / 888-462-9519
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
935 S. Kimball St., Ste. 151
Southlake, TX 76092
800-642-6110 / 817-329-6290
cpapke@mazakcorp.com
www.mazakcorp.com
W. TX
Chris Edgar
Magnum Precision Machines, Inc.
12025 Rojas Drive, Suite A
El Paso, TX 79936
915-856-7900
cedgar@magnumabq.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 Pkwy
Suwanee, GA 30024
678-985-4800
dkennedy@mazakcorp.com
www.mazakusa.com
NC, SC, VA
Crotts & Saunders, LLC
2709 Boulder Park Ct.
Winston-Salem, NC 27101
336-765-7250
www.crottsandsaunders.com
TN
Dennis McCurry
Pinnacle Machine Tools, Inc.
5912 Toole Drive
Knoxville, TN 37919
865-951-0260
mccurry@pinnaclemachine.net
AL, FL Panhandle
Jerry Edwards
Pinnacle Machine Tool Inc.
141 Nick Fitcheard Road
Huntsville, AL 35806
256-852-0900
edwards@pinnaclemachine.net
GA
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
Perry Leonor
Mazak Florida Technology Center
6895 McCoy Drive, Suite 100
Orlando, FL 60504
689-205-5626
pleonor@mazakcorp.com
www.mazakusa.com
Northeast
New England, E. NY, NJ, E. PA, MD, DE
Greg Kaufman
Mazak Northeast Technology Center
700 Old County Cir.
Windsor Locks, CT 06096
800-436-8900 / 860-292-4400
gkaufman@mazakcorp.com
www.mazakusa.com
W. NY
Bill Miller
A.W. Miller Technical Sales
7661 Seneca St. / PO Box 69
East Aurora, NY 14052
716-652-8282
bmiller@awmiller.com
www.awmiller.com
W. PA, N. WV
Bill Miller
A.W. Miller Technical Sales
3 Tara Drive / PO Box 220
Harmony, PA 16037
724-453-1690
bmiller@awmiller.com
www.awmiller.com
S. WV
Crotts & Saunders, LLC
2709 Boulder Park Ct.
Winston-Salem, NC 27101
336-765-7250
www.crottsandsaunders.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, W. WI
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
Jeff Everett
Mazak Iowa Technology Center
609 Myatt Drive, Ste. 1
Maquoketa, IA 52060
563-652-6065
jeverett@mazakcorp.com
www.mazakusa.com
E. 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
Nick Shelton
Concept Machinery -
A Shelton Machinery Company
9900 North by Northeast Blvd.
Fishers, IN 46037
317-845-5588
nshelton@conceptmachinery.com
www.conceptmachinery.com
E. WI
Mike Cekanor
Machinery Systems North
3280 Gateway Rd.
Brookfield, WI 53045
262-781-4850
mikec@machsys.com
www.machsys.com
N. IL, N.W. IN
Eric Hilliard
Machinery Systems Inc.
614 East State Parkway
Schaumburg, IL 60173
847-882-8085
erich@machysys.com
www.machsys.com
E. MI
Steve Addy
Addy Machinery Co.
36055 Groesbeck Highway
Clinton Township, MI 48035
586-741-3000 / 800-ADDY-NOW
steve@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 Knox
Knox Machinery, Inc.
375 Industrial Drive
Franklin, OH 45005
937-743-2641
www.knoxmachinery.com
S. IN, KY
Nick Shelton
Shelton Machinery, Inc.
9900 North by Northeast Blvd.
Fisher, IN 46037
317-845-5588
nshelton@sheltonmachinery.com
www.sheltonmachinery.com
N. OH
Motch & Eichele
318 Remington Road
Cuyahoga Falls, OH 44224
800-833-9730
www.mande.com
West
CO, E. WY
Randy Breitenbach
Action Machinery International
7790 S. Wheeling Ct. Unit A
Englewood, CO 80112
303-532-2900
randy@action-machinery.com
www.action-machinery.com
WA, OR
Mark Harris
CNC Machine Services, Inc.
7808 184th St. SE
Snohomish, WA 98296
425-788-4500
sales@cncmachineservice.com
www.cncmachineservice.com
N. ID
Dave Fisher
Dependable Machine
88 W Orchard Ave
Hayden, ID 83835
866-967-0146 / 208-714-4652
sales@dependablemachineryrepair.com
www.dmi-cnc.com
AZ, S. NV
Chris Edgar
Magnum Precision Machines
4848 S. 35th St.
Phoenix, AZ 85040
602-431-8300
cedgar@magnumabq.com
www.magnumprecisionmachines.com
UT, S. ID, MT, W. WY
Tom Weaver, General Manager
Smith Machinery Company
41 W Guest Avenue
Salt Lake City, UT 84115
80l-263-6403
tweaver@smithmachinetools.com
www.smithmachinetools.com
S. CA
Richard McCauley
Mazak Western Technology Center
Aerospace Technology Center
1333 West 190th Street
Gardena, CA 90248
310-327-7172
rmccauley@mazakcorp.com
www.mazakusa.com
N. CA
Richard McCauley
Mazak Northern California
Technical Center
47273 Fremont Blvd.
Fremont, CA 94538
rmccauley@mazakcorp.com
www.mazakusa.com