High Speed Machining of Small to Mid-Sized Aluminum Aerospace Parts

The 5-axis HCR-5000S single-table horizontal machining center from Mazak Corporation (Florence, KY) provides the aerospace industry with numerous technological innovations for efficient small to mid-sized aluminum component processing. The machine offers a range of high speed spindle options, from a standard 12,000 rpm spindle up to 30,000 rpm unit, and each feature an integral spindle/motor and ball screw core cooling that minimize vibrations for higher accuracy. A 40-tool Auto Tool Changer, which is expandable to a 160-tool capacity, further boosts productivity with a chip-to-chip tool change time of only 2.8 seconds. Linear roller guides allow the HCR-5000S to achieve 60 m/min rapid traverse rates, 1G acceleration/deceleration rates in the X and Y-axes and 0.8 G in its Z-axis to significantly shorten overall machining cycle times. With low friction, high rigidity guide designs, this machine delivers aggressive feeds and speeds for everything from heavy duty to high speed cutting applications.

The HCR-5000S achieves unmatched precision with its single-table design that incorporates a high rigidity bed, solid base X-axis construction and roller gear cam systems for the A and C-axes. The extremely accurate tilt/rotary table provides rapid traverse rates of 50 rpm in its C-axis and 30 rpm in the A-axis. The table positions in 0.0001 deg increments and accommodates parts weighing as much as 500 kg and measuring up to 700 mm diameter and 644 mm high, depending on the cutting orientation. In addition to full 5-axis machining capability, the tilt of the table – along with a chip conveyor and flood coolant – ensures efficient chip management and evacuation. To further optimize chip flow, the horizontal spindle orientation also makes it possible to machine a part inverted while a standard 800 L coolant tank accommodates a Niagara coolant configuration. For even higher levels of productivity and unmanned operation, the machine can be outfitted with an automatic two-pallet changer as well as a Multi-Pallet Pool (MPP) system, or be incorporated into a fully automated PALLETECH System.

A MAZATROL SmoothX CNC provides operators with complete control of the HCR-5000S. SmoothX enables 3D part program visualizations via its touch screen to further improve ease of use in terms of programming and program checking. Cycle times are reduced between 10 percent and 20 percent, and surface finishes improve thanks to the control’s Smooth Machining Configuration options, such as Seamless Corner Control, Active Vibration Control and Variable Acceleration.

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