ECONOMICAL MULTI-TASKING TECHNOLOGY FOR MACHINE SHOPS

Mazak (Florence, KY) expanded its family of multi-tasking technology products with the Integrex j-Series. Comprised of three size ranges, the Integrex j-Series falls in the middle of the spectrum of multi-tasking innovations.

Mazak's multi-tasking models range from simple, 3-axis machining performance with live tooling, dual spindles and y-axis machining capabilities on the Quick Turn Smart and Hyper Quadrex models to complex, 5-axis ultra-tasking performance with specific task-oriented operations, such as grinding, hobbing, polishing and honing on the Integrex Mark IV and Integrex e-Series models.

"With the introduction of the j-Series, Mazak now offers a complete range of multi-tasking solutions that meet the needs of any manufacturer wishing to implement advanced technology," said Brian Papke, president, Mazak Corporation. "The j-Series creates an option for machine shops that wish to increase their flexibility and productivity with multi-tasking technology and tool changing capability, while providing a reasonable price alternative for customers who want automatic tool changing capability but do not necessarily need simultaneous 5-axis machining capability."

The j-Series performs 4-axis simultaneous machining with 5-axis tool-tip positioning, providing significant advantages in productivity, accuracy and flexibility. Unlike multi-tasking machines with a drum turret type, Mazak's Integrex j-200 accommodates 20 tools in a tool magazine (36 and 72 tool optional) and increases versatility in part production. The machine's main turning spindle with C-axis control features an 8 in chuck mounted on a 15 hp, 5,000 rpm integral spindle motor that generates 119 ft-lb of torque.

The Integrex j-200 also includes a powerful 7.5 hp, 12,000 rpm milling spindle that can be indexed in 5 deg (or optional 1 deg) increments from minus 30 deg to 190 deg (B-axis control), making it possible to perform outer diameter machining, as well as turning, facing, grooving and threading with the same flash tool. It also makes it easily possible to perform incline machining and all other conventional machining processes. Additionally, the milling spindle can be radially indexed and clamped, enabling the same tool to be used for turning in both forward and reverse directions.

Though the Integrex j-200 is compact, it offers a maximum machining diameter and length of 19.7 in with minimum tool interference for large workpieces. Its long axis strokes of 17.7 in (X) and 7.87 in (Y) allow face milling, end milling and drilling to be performed above and below the centerline without C-axis indexing. In addition, the true Y-axis design allows for a larger machine envelope and tool reach, reduced interference and excellent chip evacuation when compared to conventional machines.

With a high rigidity construction and new high-response servo motors, the Integrex j-200 delivers a positioning repeatability of tool tips that is better than 0.00004 in and double ball bar testing that is within 0.0003 in. The MX Hybrid Roller Guide System is integrated into the Integrex j-200 to deliver levels of durability and reliability that result in long-term accuracy. The MX Hybrid Roller Guide System increases vibration dampening to extend tool life, handles higher load capacities, accelerates and decelerates quicker to shorten cycle times, consumes less oil for "Greener" operations, and lasts longer with less required maintenance.

Mazak makes the programming of multiple surfaces on the Integrex j-Series easy with its Matrix Nexus CNC Control. The control allows for both conversational and EIA/ISO programming, and ensures easy programming for C-axis, Y-axis and angle machining. Matrix also provides realistic 3D machining simulations, time study analysis and the Mazak Voice Advisor, which assists operators during setup to make initial operations smoother and safer.

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