Heavy Duty 5-Axis Machining of Generator Turbine Components

The heavy duty 5-axis INTEGREX i-630V/6 multi-tasking machine from Mazak Corporation (Florence, KY) uses fast, high torque milling and turning spindles for 5-axis and trochoidal machining of generator turbine components and other large, highly complex parts in the shortest cycle times possible. An advanced spindle cartridge design gives this machine higher horsepower and increased speed, as well as ease of maintenance. Its rigid CAT 50, 10,000 rpm milling spindle tilts in the B-axis -30 deg/+120 deg for complex contour machining. The turning spindle/C-axis features a direct-drive motor and a new bearing design, along with glass scales, all of which further boosts rigidity, stiffness and accuracy. The robust turning spindle with C-axis control delivers 50 hp and 550 rpm.

The MAZATROL SmoothX CNC gives the INTEGREX i-630V/6 unparalleled processing speed and lets shops quickly and easily generate programs for highly complex parts production. The CNC has several advanced functions that allow it to ensure the shortest possible machining cycle times, especially in fine increment programs for simultaneous 5-axis operations and free-form die-mold machining. Among the CNC functions are Super High-Speed Mode for maximum interpolation capabilities, rotary axis speeds for fast gear skiving operations and rotary axis threading, Smooth Corner Control for shorter cycle times and Real Time Tuning for optimal machining balance. Axis travels on the machine measure 56.10 in (1,425 mm) in X and 41.3 in (1,049 mm) in both Y and Z, with each having a rapid traverse rate of 2,047 ipm. The axes incorporate the MX Hybrid Roller Guide System that increases vibration damping, handles high load capacities and eliminates tramp oil in the coolant by utilizing a greener grease-based lubrication system.

Able to accommodate workpieces up to 41.3 in (1,049 mm) diameter and 39.3 in (998 mm) high, the machine comes with a two-pallet changer that accepts square 24.8 in (630 mm) x 24.8 in (630 mm) pallets or round 31.5 in (800 mm) diameter pallets. The pallet changer moves pallets in and onto the machine’s table within 11 seconds. This machine can also be paired with the ToolTech tool system for efficient tool storage, as well as easy loading and unloading of large size, heavy tools. This optional tool-setting system allows shops to set both turning and milling tools from one convenient location. Its compact tool magazine stores heavy and large-diameter tools – diameters up to 14.173 in (360 mm), lengths to 31.5 in (800 mm) and weighing as much as 88.184 lb (40 kg) – within a very small amount of required floor space. Plus, special tool carts and docking stations eliminate the need for operators to manually lift tools in and out of the system, so tooling set ups are faster, easier and safer.

ToolTech accommodates up to 206 tools in the same amount of space required for a 120-tool chain-type magazine storage system. This economical use of space results from the fact that this tool system efficiently organizes tools according to their lengths and diameters and stores them in racks: one type designated for tools with diameters bigger than 3.93 in (100 mm), and the other for diameters less than that size.

For high throughput production of small, simple to complex parts used in power generation applications, the INTEGREX i-100ST multi-tasking machine provides speed, reliability and DONE IN ONEÒ capabilities. Equipped with MAZATROL SmoothX CNC and two turning spindles, a milling spindle and a lower turret, the machine can process first and second machining operations simultaneously or perform required sequential operations on a single workpiece. The MAZATROL SmoothX control makes the INTEGREX i-100ST faster than ever, with potential cycle time reductions ranging from 5 percent up to 40 percent, depending on application. Optimized CNC programming, advanced hardware and high speed servo systems, and improved ergonomics all come together to offer users increased process speed and easy programming in either conversational or G-code formats.

The turning spindles on the INTEGREX i-100ST share high performance capabilities, as they both employ a 7.5 hp integral motor spindle with maximum 6,000 rpm spindle speeds. The main spindle indexes in 0.0001 deg increments for high precision C-axis contouring, while the second spindle provides increments of 0.001 deg. Each spindle features a 6 in (152.4 mm) chuck with a 2.4 in (70 mm) bore size that can accommodate bar stock of up to 2 in (50.8 mm) diameter. The machine employs a 7.5 kW, 12,000 rpm or high speed 22 kW, 20,000 rpm milling spindle mounted in the rotating B-axis with a range of 240 deg in 0.0001 deg indexing increments. And for high accuracy of motion, B-axis scale feedback comes standard on the machine. Its 36-tool (72-tool optional) magazine accommodates tools up to 5.1 in (129.54 mm) diameter when neighboring stations are empty and up to 3.5 in (88.9 mm) diameter when stations are occupied.

The lower drum turret carries nine tools and can work at either the main or second spindle with the same tool, allowing the turret to perform balanced cutting operations on one part working in tandem with the vertical milling spindle. For off-centerline operations, the INTEGREX i-100ST – though compact in size – provides expansive axes travels of 8.2 in (208.28 mm) in Y, 17.7 in (449.58 mm) with a below centerline capability of 1.96 in (49.784 mm) in X and 35.5 in (901.7 mm) in Z, thereby allowing the machine to process a wide range of part sizes and shapes. Furthermore, the machine’s three linear axes attain high speed rapid traverse rates of 1,575 ipm (40 m/min).

For shops needing larger bar capacity and higher milling spindle performance, the big bore turning spindle option of the INTEGREX i-200ST multi-tasking machine boosts DONE IN ONE part processing versatility and significantly reduces setup times. With 60 percent more bar capacity, this machine features two turning spindles, a lower turret and a milling spindle that deliver more horsepower and torque for more part variation, faster material removal and shorter part cycle times. On the big bore version of the machine, the main turning spindle features a 4.4 in spindle bore that accommodates a larger bar capacity of 4 in and 53 percent more spindle torque (651 ft-lb), allowing for more part processing flexibility from one bar, reducing overall setup time between jobs. The high speed 5,000 rpm second spindle features a non-through hole bar capacity measuring 2.5 in (63.5 mm) within its bore diameter of 2.99 in. The two spindles provide equal high performance with maximum speeds of 3,300 min-1, torque ratings of 651 ft-lb and C-axis turning control.

The performance of both the 12,000 rpm and 20,000 rpm milling spindle options each put out 32 hp (24 kW) and generate 96 ft-lb (130 Nm) of torque. For C-axis contouring versatility at either turning spindle, the vertically mounted milling spindle provides a rotating B-axis range of -30 deg to +240 deg. The unique roller cam drive for the B-axis ensures higher accuracy and rigidity while providing zero backlash. A 36-tool (72-tool optional) magazine allows for fast tool changes and provides ample tooling for continuous part processing. The lower turret comes standard for nine turning tools on this machine, with an option for a milling spindle. The lower turret, working in combination with the milling spindle that can be applied to either side of the machine headstock, reduces machining cycle times.

The MAZATROL SmoothX CNC gives the INTEGREX i-200ST unparalleled processing speed and lets shops quickly and easily generate programs for highly complex part production. The CNC uses several advanced functions to ensure the shortest possible machining cycle times, especially in fine increment programs for simultaneous 5-axis operations and free-form machining. For a compact multi-tasking center, the INTEGREX i-200ST provides an ample Y-axis travel of 9.8 in (249 mm) and vertical X-axis of 24.2 in (615 mm), with 4.92 in (125 mm) below centerline. It accommodates parts up to 25.9 in (657.8 mm) diameter and, because its tool magazine is located at the front, machine operators can do programming and tool setup with minimal required movement.

Mazak Corporation, 8025 Production Drive, PO Box 970, Florence, KY 41042, 859-342-1700, Fax: 859-342-1865, www.mazakusa.com.