With both affordability and high performance for job shops in mind, Mazak has officially launched the new Ez machine series, the new MAZATROL SmoothEz control and the accompanying MazakUSA.com/Ez website. The new machine family and control were developed specifically to help remove the cost barriers to acquiring the latest manufacturing technology without sacrificing machine capability or production performance, while the new Ez website further streamlines the customer experience and offers visitors focused access to Mazak’s newest product line.

Machine configurations within the new series include both horizontal turning and vertical machining center models, all of which feature the MAZATROL SmoothEz control and are designed and built in Kentucky. Among the turning center configurations are the QTEz 8, QT-Ez 10 and QT-Ez 12 models each offered in a 2-axis, M, MY and MSY versions.

M versions include milling capability, MY machines feature milling and Y-axis offcenterline capability and MSY machines are a combination of both milling and Y axis capability paired with second turning spindles for complete DONE IN ONE® part processing. For further increased productivity and unmanned operations, the machines seamlessly integrate with bar feeders and robots.

Each QT-Ez model number indicates the standard chuck size, but Mazak also offers a smaller size optional chuck for each machine to provide greater maximum rpm capability. These include a 6” chuck option for the QT-Ez 8, an 8” for the QT-Ez 10 and 10” for the QT-Ez 12. Each model is available in a 20” bed length and an optional 40” bed length for the QT-Ez 12 model. Available machine turrets include 2-axis drum style, with a bolt-on or BMT55 turret for rotary tool applications, and tailstocks are offered with either manual positioning with hydraulic quill or servo positioning capability.

Mazak’s VC-Ez Vertical Machine Series begins with the initial introduction of the VC-Ez 20, and soon will include both smaller and larger machines, the VC-Ez 16 and VC-Ez 26. All VC-Ez Series machines sport C-frame designs with X and Y axis motion via moving table and saddle along with Mazak’s high-rigidity MX linear systems and pretensioned ball screws that together ensure rigidity, accuracy and reliability.
Axis travels for the VC-Ez 20 measure 41.34” in X, 20.08” in Y and 25” in Z that allow the machine to accommodate maximum workpiece sizes of 49.21” long, 19.37” wide and 22.4” tall and weighing up to 2,204 lbs. All within an ergonomically designed machine that has a 26.5 percent smaller foot as compared to other models and one that measures only 102.65 sq-ft for significant floor space savings.
The VC-Ez 20 features a powerful 40-taper, 12,000-rpm, 25-hp spindle and 30-tool magazine automatic tool changer. Options include a versatile 15,000-rpm, 29.5-hp spindle with 81.13 ft-lb torque and a 50-tool capacity tool changer.

For fast and easy QT-Ez and VC-Ez machine programming, Mazak’s new MAZATROL SmoothEz CNC provides dual 800 MHz processors, 512 MB of RAM and a vibrant 15″ capacitive touch screen that includes a full keyboard and displays up to 60 lines of code. Within the control, EIA/G-code and MAZATROL programming languages support a full range of programming options directly on the machine, while the MAZATROL TWINS function enables offline programming and simulations that draw real-time condition and performance data directly from the machine.

The MAZATROL SmoothEz control also features Mazak’s new LAUNCHER interface, accessible in every screen, and that uses the entire display to make screen selection smooth and seamless. To further streamline programming, the control’s QUICK MAZATROL function simplifies program creation and confirmation through touch screen editing and confirmation of 3D models.

To support the Ez machine series, Mazak’s new Ez website provides customers across the US, Canada and Mexico complete and concise information about Mazak’s newest product line. Launched alongside the new Ez series, the website includes in-depth details on all series machines and on the MAZATROL SmoothEz control. Site visitors can also learn more about the Kentucky manufacturing expertise that Mazak invested in the new machine tools and information about the customer support and financing packages that make owning the machines easy and affordable.

In addition to the Ez website, Mazak recently rolled out its reimagined Virtual Technology Center to extend the product and technology experience beyond traditional events, as well as bring the benefits of its 800,000 sq. ft. campus to customers across North America on demand. The Virtual Technology Center features a rotating lineup of groundbreaking machines, automation systems and digital technology, as well as the ability to request quotes, schedule in-person visits and innovative ways for customers to connect with Mazak experts.

Unmanned system combines machining centers and high-rise AS/RS

Mazak continues to provide the most advanced and highly productive manufacturing technologies available through strategic collaborations with other key OEMs. As the result of such a collaborative effort with Murata Machinery, Ltd. (Muratec), Mazak developed its new MAZATEC SMS (Smart Manufacturing System) that provides unmanned, lights-out manufacturing and high output, as well as IIoT connectivity.

The MAZATEC SMS combines Mazak’s machining, automation and Smart technologies with Muratec’s automated high-density storage and retrieval system. The MAZATEC SMS pairs multiple Mazak Horizontal Machining Centers and/or Multi-Tasking Machines with a Muratec vertically orientated, space-saving stocker-type system that has pallets, a material bucket and high-speed stocker crane. To match each manufacturer’s specific production and floor space needs, the modular system can have up to 150 stockers (in different sizes) in a six-level configuration that increases space efficiency by as much as 67 percent.

As key components of the MAZATEC SMS, Mazak’s SmartBox IIoT technology and Smooth PMC production management software along with Muratec’s automated system control all interconnect/synchronize with a customer’s enterprise resource planning ERP/MRP host and MES execution systems. These highly advanced digital innovations and complete connectivity make the MAZATEC SMS a smart factory solution for process control, monitoring and optimization to produce a variety of workpieces – even in small lot sizes – with extremely high efficiency.

The MAZATEC SMS can incorporate various sizes and types of machine tools into the same automated manufacturing system. Such flexibility is possible because the stocker system sets up faster and easier as well as accommodates different size machine tool pallets, as does the system’s single stocker crane. This capability also allows manufacturers to apply the MAZATEC SMS across a more expansive spectrum of part numbers/types for cost effectiveness and increased ROI.

Peripheral equipment for the MAZATEC SMS includes individual stations for loading and centering, tilt loading, raise and lower loading, work set up and part washing. In addition to keeping the machine tools supplied with work, the system’s stocker crane handles the MAZATEC SMS overall input of raw parts and the output of finished ones.

“With the combined technologies of Mazak and Muratec, the MAZATEC SMS advanced manufacturing system will significantly increase the competitiveness of manufacturers in today’s IIoT environment,” said Brian Papke, chairman of Mazak. “We at Mazak believe that such collaborations with other innovators in the manufacturing industry effectively foster new ideas and ways to combine processes and apply new technologies to improve the manufacturing performance of customers.”

For its part of the collaboration, Muratec contributes AS/RS durability and reliability. The company and its systems are well entrenched in the automotive and other industrial manufacturing environments. Unlike other comparable systems that tend to be standard in nature, Muratec’s base units are much more customizable and configurable for a wider range of applications.

Mazak has a long history in the production of factory automation systems, such as its earliest one the MAZATROL FMS (Flexible Manufacturing System) developed in 1984 and its current systems that include PALLETECH and the single machine MPP (Multiple Pallet Pool). Similarly, Murata Machinery has extensive experience as a provider of material handling systems to manufacturing facilities worldwide.

As one of the newest members of the Mazak additive machine family, the VARIAXIS j-600AM (Additive Manufacturing) Vertical Machining Center features an innovative Wire Arc-type metal deposition system. The technology takes the additive process to whole new levels in terms of speed, allowing shops to quickly and easily grow part features then employ the machine’s advanced 5-axis multi-surface subtractive capabilities to produce high-precision parts complete in single setups.

The VARIAXIS j-600AM’s Wire Arc system incorporates a standard wire arc-welding head mounted on the machine’s headstock to deposit material layer by layer and grow near-net-shape 3D forms. The system deposits material faster because it uses wire instead of metal power.

Machines capable of both additive and subtractive operations offer many advantages. Such machines significantly slash production time and conserve large amounts of expensive raw materials typically machined away when parts are completely produced using only subtractive operations. Plus, they reduce the number of machines required in a facility and save floor space.

The VARIAXIS j-600AM also features a 12,000-rpm B-axis tilt spindle and C-axis indexing table.

The machine is well suited for a wide variety of applications, including the production and repair of aerospace parts, molds and dies and oil-drilling components so that these parts retain their original durability and wear resistant properties.

Kentucky-built machine opens doors for shops to take on long, heavy parts production

The new Mazak VTC-805E Vertical Traveling Column Machining Center brings high versatility and productivity to those shops that need to tackle long and/or heavy parts. The machine combines an increased Y-axis stroke, long bed/table size, high spindle speed and torque and Mazak’s new SmoothG CNC control for efficient, powerful machining.

For manufacturers that need as much Y-axis travel as possible, the VTC-805E provides an extended Y-axis travel of 32″ as a cost-effective alternative to a bridge-style machine. The machine’s fixed table measures 82.7″ x 32.3″ (2100mm x 820mm), while its moving column design provides a 69.3″ X axis and 28.3″ Z axis.

With an optional center partition, it is possible to transform the VTC-805E’s table into two separate work areas to process parts on one side, while operators load/unload parts on the other for an overall reduction in cycle times. A special turret-style magazine accommodates 40 tools for longer periods of uninterrupted production as well as for more part-processing versatility.

Mazak equipped the VTC-805E with a powerful 30-hp, CAT 50-taper, 6,000-rpm spindle that easily tackles a wide variety of materials including titanium, aluminum, steel and cast iron. And for even more power and speed, Mazak offers an optional 40-hp, CAT 50-taper, 10,000-rpm spindle.

The VTC-805E features the new MAZATROL SmoothG CNC that makes it easy to generate programs for off-centerline machining as well as angled drilling, milling and tapping operations. Several innovative programming, performance and monitoring functions bring optimum speed and accuracy to complex part production. Advanced hardware including a tilting CNC panel and intuitive, multi-touch control screen allows for complete ease of use, while an SD card stores up to 32GB of program data.

HYBRID Multi-Tasking machine features innovative multi-laser deposition technology

Mazak continues to fortify its industry leadership in HYBRID Multi-Tasking machine technology with the introduction of its new INTEGREX i-200S AM (Additive Manufacturing). With an innovative multi-laser deposition system, the machine provides both additive and subtractive capabilities. Shops can not only turn, mill and drill, but also build part features and perform laser marking all on the same machine and in single setups for DONE IN ONE production.

The INTEGREX i-200S AM excels in challenging applications, such as aerospace components, metal cladding for chemical plant valves and the repair of dies and turbine blades. Ideal for the production of mid-size complex components, the machine makes it possible to quickly and easily grow part features. This capability significantly slashes production time and conserves large amounts of expensive raw materials typically machined away when parts are completely produced using only subtractive operations.

In addition to its two turning spindles and milling turret, the INTEGREX i-200S AM features dual laser cladding heads/additive manufacturing nozzles that provide options for both high and fine rates of metal deposition. Essentially, the two cladding heads complement each other much like roughing and finishing tools work together in common chip making operations. The cladding heads reside in the tool magazine with the machine’s automatic tool changer that loads/unloads them into/from the milling turret as needed.

During operation, the INTEGREX i-200S AM uses fiber laser heat to melt the chosen metal powder that will be used to the grow near-net-shape 3D forms. The cladding heads apply the molten material layer by layer, each of which solidifies as the desired part surface or features grows. Once the part features are grown to near net shapes, the INTEGREX i-200S AM then applies one or more of its advanced subtractive operations, including full 5-axis milling, turning, hobbing and contouring, to process the part complete.

The Mazak HQR-250MY+Tailstock Multi-Tasking Turning Center delivers faster cycle times and more efficiency than other comparable machines thanks to its advanced Y-axis machining capability, twin-turrets, fully programmable tailstock and leading edge MAZATROL SmoothG CNC. The machine provides shops with unequaled part-processing opportunities, including enhanced DONE IN ONE® capabilities.

For fast and reliable production, the HQR-250MY+Tailstock can completely machine parts from bar slug and/or bar material in single setups. Also, the balanced cutting of the machine’s upper and lower turrets, together with Y-axis machining, ensures high part throughput with simultaneous turning and milling operations on the same part.

Because the twin turrets operate independently or together on the same workpiece, the machine can process two different features on a workpiece simultaneously, or follow a balanced strategy where two tools work together on the same workpiece feature.

In cases where the part configuration permits, balanced machining can potentially remove up to 25 percent of the cycle time.

Both the upper and lower turrets accommodate 12 tools (16 tools optional) each and have 4″ (102 mm) Y-axis travel capability for off-centerline operations. And unlike other comparable machines that offer only upper-turret live tooling, both turrets on the HQR-250MY+Tailstock accommodate rotary tools and at any tool position. Rotary tool spindles on each turret deliver 6,000 rpm and 7.5 hp for milling and drilling multi-tasking functionality.

For perfect part support, the HQR-250MY+Tailstock’s MT#4 servo-driven tailstock, with brake, delivers a maximum thrust of 225 to 1,574 ft-lb (1-7 kN) programmable in increments of 22.4 ft-lb (0.1 kN). Plus, the thrust amount can be adjusted while the tailstock is engaged. To help shorten non-cut time, the tailstock rapid traverses at speeds up to 315 ipm (8 m/min).

Large diameter bearings support the machine’s spindle for high rigidity. The spindle features a 10″ (254 mm) chuck, 3.1″ (78.740 mm) bar capacity and 35-hp integral spindle motor that provides a maximum 4,000-rpm speed. With full CNC C-axis control, the spindle positions and contours with indexing increments of 0.0001 degrees.

The machine comes equipped with the new MAZATROL SmoothG CNC that makes it fast and easy to generate programs for high-speed multi-axis processing of complex parts through off-centerline machining as well as angled drilling, milling and tapping. For the HYPER QUADREX 250MY+Tailstock, the control also includes hobbing software.

Through the SMOOTH TECHNOLOGY platform, the MAZATROL SmoothG CNC offers programming with MAZATROL and/or EIA. There are also several other advanced programming functions.

For those shops looking to boost productivity as well as profitability, Mazak’s QUICK TURN-250MSY Turning Center sports several new productivity-enhancing features. These include a new direct-drive turret design, higher torque main spindle, a faster more powerful milling spindle and the recently introduced MAZATROL SmoothG CNC control.

The QUICK TURN-250MSY – with Multi-Tasking functionality – has two turning spindles, a rotary tool milling spindle and Y-axis capabilities for single setup Done In OneÒ precision part processing operations. The machine’s new 12-position, direct-drive turret eliminates the use of belts for improved part surface finishes and reduced maintenance. It accepts both VDI and bolt-on tooling.

The turret’s new DIRECT DRIVE rotary tool spindle is now 10-hp, 6,000 rpm standard. The faster rotary spindle provides 52 ft-lbs of torque, essentially double of what was possible before with the previous version. And with an optional tooling package, 10,000 rpm is available.

The machine’s headstock features a 10″ main chuck mounted on a 35-hp, 4,000-rpm integrated spindle motor for heavy-duty metal removal. To effectively tackle today’s tough part materials, Mazak bumped up the torque output of the spindle by almost 30 ft-lbs. The main turning spindle also serves as a C-axis that is programmable in 0.0001-degree increments to accurately position parts for square facing and slotting cuts and precisely drilled holes. The C-axis spindle is a full-function CNC controlled axis for milling. A second turning 15-hp, 6,000-rpm spindle with a 6″ chuck allows the QUICK TURN-250MSY to machine small diameter workpieces with speed and accuracy.

The QUICK TURN-250 machine models without second turning spindles feature Mazak’s new NC servo-drilling tailstocks as standard. The fully programmable tailstock drives the W-axis on its own AC servomotor and ball screw. Through the part program, the tailstock will retract to a known position and its center makes contact with the part with consistent holding pressure. Thrust settings are completely adjustable – high thrust or low thrust – without having to re-touch the part.

Mazak’s MAZATROL SmoothC and SmoothG CNCs offer EIA/ISO programming as well as conversational programming that makes it easy to generate programs for complex drilling, milling or tapping operations. The controls also feature advanced hardware and software functions that help ensure high productivity and performance accuracy in challenging part production operations.

As a higher level control, the MAZATROL SmoothG incorporates a wide variety of advanced programming functions for ease of use and to ensure high-speed, high-accuracy machining performance. These functions include High Gain Feed Forward Control, Fast Rotary Axis Speeds, Variable Acceleration Control and Intelligent Pocket Milling.

A variety of automation strategies can be integrated with the QUICK TURN-250MSY, from an automatic bar feeder to gantry robots, for improved spindle utilization and a significant boost in productivity.

When machining unique medical devices used to administer radiation treatments for cancer patients, high quality and fast turnaround is of utmost importance. Luckily, Sanford, Florida-based .(dot)decimal has found a way to achieve both. The shop conducts all its business on a completely digital, automated, internet basis, enabling it to receive job orders before 12 p.m., process them on a variety of machine tools from Mazak Corp. (Florence, Kentucky), and ship them complete by 6 p.m. that same day.

.decimal produces mostly filters/apertures that regulate the width and depth of radiation treatment beams. The devices are used for treatments involving proton (very precise), photon (blurry) or electron (low-mass) beams, depending on the tumor type and location. These different beam characteristics dictate filter requirements in terms of part specifications and feature geometries.

According to CEO and President Richard Sweat, each device is as unique as a snowflake. For the 100 to 200 patient-specific jobs shipped per day, the shop has no clue what part geometries it will have to machine until the orders are received from hospitals and research facilities.

The process begins when doctors/facilities load CT scans and MRI results into a special software and build a 3D virtual model of the patient to map out the tumor. Then, they use the company’s custom software called planning.decimal (p.d) to help design, visualize and order the needed devices. The software uploads the necessary digital files and sends them via the internet to be manufactured.

Once at the shop, the company’s in-house-developed manufacturing automation software, automate.decimal (a.d), controls all its processes, automates workflow and generates the tool paths. It also controls communication with the Mazaks and manages their functions to ensure effective machine utilization and part quality. The software is a vital link between device/aperture specifications and the machine tool programming language.

At the heart of the shop’s part-production operations is what Mr. Sweat calls a “farm” of 26 Mazak machines, the bulk of which are Vertical Center Nexus (VCN) vertical machining centers along with an Integrex 200S multitasking machine. The company recently added two full five-axis Vertical Center Universal (VCU) 400A 5X VMCs to efficiently process apertures used in a new type of proton-radiation-beam therapy.

Customer orders populate the company’s servers with incoming orders throughout the day, and the software tracks each patient’s device through manufacturing, invoicing and shipping. It determines which machines are open and allocates job files accordingly. The software also displays real-time job status, tracks part material back to the foundry and tracks who machined it on which Mazak. It also shows current machine status. According to Kevin Erhart, chief technical officer, many of these steps are critically important to maintaining the levels of traceability required by the Food and Drug Administration.

“The extreme stability of our processes results from the elimination of variation,” Mr. Erhart explains. “That is why we have all Mazaks. They not only provide reliable and consistent high performance, but also fast and precise machining.”

After the software sends a tool path to the shop floor, machinists load raw parts into the designated Mazaks, each of which is dedicated to run only one specific type of material, mainly for recycling purposes. Once completed, parts move on to cleaning, inspection and finally shipping.

Aperture/filter tolerances are typically ±0.010 inch; however, the shop actually machines to much tighter tolerances because the Mazaks enable parts to be produced well within Six Sigma requirements, Mr. Sweat says. The apertures/filters are made from brass, acrylics, copper, aluminum and wax, with brass and copper filters used most often for apertures that restrict the lateral shape of the beam and keep it from spreading beyond the tumor area. The aperture patterns are a stencil or profile of a tumor’s periphery and are machined completely through the part.

Devices known as range and tissue compensators require variable-depth pockets/closed cavities to be machined out. Their varying depths are what regulate the intensity or penetration depth of the radiation beam. Thicker portions of the cavity will block or limit the beam, while the thinner areas allow more of it to pass through to the patient.

Variable-angle-beam, divergent-corrected-type apertures spurred the company’s latest venture into full five-axis machining. Used for a relatively new proton-radiation-beam therapy, these devices are similar to standard apertures in that they require machined cavities. However, the cavity contours in these apertures include variable-angle walls. These angles further pinpoint the proton beam to provide a better beam resolution to spare nearby healthy tissues from receiving high doses of radiation.

Initially, .decimal machined the new apertures using a Mazak Integrex-type multitasking machine with second turning spindle and milling spindle. However, that machine provided much more capability than was needed for the particular job, Mr. Sweat says. What he wanted was high performance, but at a more cost-effective price. That was when he discovered Mazak’s VCU 400A 5X full five-axis machine.

“It’s all about matching the angles of the proton-beam divergence since the physics of radiation blocking and scattering make these angles a highly critical feature of the design,” Mr. Sweat explains. “Our two Mazak five-axis VCUs enable us to machine these angles more accurately than using our existing bolt-on rotary-table-type machines and much more cost effectively than using the Integrex machines. Our processes demand quality, stability, reliability, affordability and consistency. The VCUs give us all that, and they have operated flawlessly since we added them.”

The VCUs machine only the proton-beam-aperture parts. For precise five-axis machining, the machines’ trunnion-style rotary/tilt tables are constructed with durable high-speed roller gear cam drive technology for high
torsional rigidity and positioning accuracy. The tables tilt +95 degrees/-45 degrees in the B axis and rotate 360 degrees in the C axis, and they can accommodate workpieces weighing as much as 440 pounds.

While it is a small footprint machining center, the VCU provides .decimal with travels measuring 19.88 by 15.74 by 17.12 inches (505 by 400 by 435 mm) in the X, Y and Z axes, respectively. A high-speed rapid traverse rate of 945 ipm (24 meters per minute) in the machine’s three linear axes help reduce the shop’s non-cut times.

Aperture part cycle times at the shop typically fall between 10 and 20 minutes, and compensator/filter devices can range from 30 minutes to several hours, depending on part size and surface complexity. While the shop tries to optimize cycle times whenever possible, there is a point of diminishing return in which the cost of wear and tear to the machines outweighs the benefits of seeking shorter machining time.

“For us, we’d rather run parts at a reasonably fast speed while also getting the most life out of our machine ballscrews and spindles,” Mr. Sweat says. “We are process maniacs, and key to controlling our processes is having consistency and repeatability in our machine tools. We want stable machines for stable production together with maximum tool and machine lives.”

Business continues to grow for .decimal, and the shop plans to increase its international deployment. Mr. Sweat says that being digitally automated with the in-house-developed software enables the shop to make any internet-accessible machine tool part of its farm. He envisions several shops full of Mazaks in strategic countries, with the main Florida facility funneling the incoming jobs to them. All of which will help get much needed devices to cancer patients even faster.

Dynamic manufacturing platform will feature several new industry-leading solutions at IMTS

Mazak continues to expand its SMOOTH TECHNOLOGY platform with more new and innovative solutions that keep today’s manufacturers productive, efficient, competitive and at the forefront of innovation. Unique to the industry, Mazak’s SMOOTH TECHNOLOGY is a platform that spans the entire part production landscape from programming and metal removal to automation and data collection.

At IMTS, Mazak will highlight a wide range of new solutions and advanced technology functions under its SMOOTH TECHNOLOGY umbrella.

MAZATROL Smooth CNC controls are an integral element of the SMOOTH TECHNOLOGY platform and offer the world’s fastest processing speeds and user-friendly programming capabilities. The family of controls includes the MAZATROL SmoothX, SmoothG and the new MAZATROL SmoothC.

HYBRID Multi-Tasking machines combine full 5-axis capability and additive technology to revolutionize product design, shorten time to market and reduce R&D costs.

SMOOTH Gear Cutting is the combination of advanced Multi-Tasking machines and Mazak’s latest developments in SMOOTH Gear Cutting processes such as SMOOTH Gear Skiving, SMOOTH Gear Milling and SMOOTH Gear Hobbing, all of which increase accuracy and productivity with Mazak’s DONE IN ONE® part processing.

Mazak Oval Turning function allows users to quickly machine highly accurate oval/cam shapes on a turning center that incorporates a special oscillating integrated linear motor synchronized with the machine’s spindle.

SMOOTH Orbitturn programming function reduces machine operations by giving horizontal machining centers turning capability for specific features on large, cumbersome parts.

SMOOTH Engraving function lets users quickly and easily program for engraving operations.

SMOOTH Set & Inspect software featured on Mazak machines with MAZATROL SmoothX or SmoothG controls simplifies the programming of tool setting and part probing macros and is ideal for users that want to perform accelerated at-the-machine inspection cycle programming.

SMOOTH Volumetric Compensation removes 6 DOF (Degrees of Freedom) errors on each machine axis to provide consistent positioning and ensure high-accuracy work.

SMOOTH Tool Management and SMOOTH Tool Data Converter are intelligent process monitoring solutions – MTConnect® ready – that help protect expensive tools as well as secure and optimize their performance while overseeing processes and detecting machine faults.

SMOOTH Spindle Analytics give users the ability to monitor the spindle’s drive and vibration levels in real-time.

SMOOTH Link CNC monitoring software makes it possible to monitor and manage machine status via Wi-Fi, which gives operators complete control even when they are away from the machine.

SMOOTH Monitor is MTConnect ready and allows for equipment monitoring and utilization analysis via any MAZATROL Smooth CNC.

SMOOTH PMC software works within a machine’s MAZATROL Smooth CNC and lets users forecast/simulate up to a week’s worth of scheduled operation – required tools, machine loads and output – for a Mazak PALLETECH automated manufacturing cell.

Yamazaki Mazak is taking 12 machines to AMB 2016 in Stuttgart, exhibiting the full breath of its machine range and new SMOOTH Technology, the world’s fastest CNC.

The Mazak stand, which is themed ‘It’s all about you’ in recognition of the company’s continued focus on developing machines which solve specific machining challenges faced by its customers. The Mazak stand will showcase horizontal and vertical machining centres, 5-axis machines, turning centres, a new machine from its entry-level range and, for the first time at a German show, all three variants of the company’s new SMOOTH Technology, namely SmoothX, SmoothG and SmoothC control.

The highlight of the show is likely to be the new INTEGREX i-400 AM, a revolutionary hybrid machine which combines additive manufacturing with multi-tasking capability. The i-400 AM integrates Direct Energy Deposition additive manufacturing technology into a 5-axis multi-tasking machine to offer machine users unrivalled hybrid technology and subtractive manufacturing in one platform.

The INTEGREX i-400 AM makes use of a built-in 1kW fiber laser to melt metallic powder, which is then applied layer-by-layer via interchangeable cladding heads. The heads are stored in the machine’s standard 36-tool magazine and enable the automatic change from additive to subtractive tooling, optimising process cycle time.

The INTEGREX i-400 AM technology can be used to clad a range of material types, including stainless steel, nickel alloys and copper, making it ideal for a range of applications, from repairing existing worn or damaged components or the complete generation of new parts. The machine is equipped with SmoothX control, the 5-axis version of Mazak’s new SMOOTH Technology, which enables the machine to efficiently process prismatic, round and highly contoured work pieces, as well as those near net features which have been created using the integrated additive technology.

Horizontal machining centres will be represented by the HCN 5000/50, a new 50 taper machine with a 500mm square pallet boasting extremely agile performance characteristics, including a 10,000rpm/ 37kW high performance spindle; rapid traverse rates of 60m/min in the X-, Y- and Z-axes; and a chip-to-chip change time of only 3.5 seconds. The 50 taper spindle provides a highly rigid interface for mounting large tools, up to dia. 320mm, enabling a high productivity solution for machining a range of components for automotive, agriculture, construction and the cutting of cast materials.

The machine has the smallest machine footprint in its class, with a floorspace-saving design and overall machine dimensions which measure only 2,544mm x 5,830mm. Importantly, the space-saving design has been achieved without compromising its machining performance and ability to handle large workpieces, with the HCN 5000/50 able to bear components up to dia. 800mm x 1,000mm in height. HCN 5000/50 is also available in a single pallet and A-axis table configuration with integrated hydraulic services, proving a well-designed solution for complex fixturing. The machine on display at AMB 2016 is equipped with the new SmoothG CNC and an 80 tool hive.

Also on the stand will be the VTC-800/30SLR, a new addition to the hugely successful European-designed and manufactured VTC800 vertical travelling column machine series, which is available in both 40 and 50 taper versions. The 800/30SLR incorporates a 1,000mm diameter rotary table capable of carrying a 2,200kg load, which makes it ideal for machining large components, along with a centre partition that enables the set-up and machining of a different component on the right side of the normal table.

The specific machine at AMB 2016 is equipped with a Siemens SINUMERIK 840D sl control for those machine users that have standardised on Siemens control in their operations. The SINUMERIK package includes CNC, Mazak spindle with fully integrated Siemens motor and SINUMERIK drives and servo motors.

Mazak will also exhibit its MULTIPLEX 6200-II Y turning centre, which is ideally suited to high volume applications, such as the automotive sector. The MULTIPLEX combines two NC turning centres with milling capacity and is capable of performing continuous and simultaneous machining by both spindles, including automatic workpiece transfer from one spindle to the other. The machine is equipped with a 5,000rpm main spindle and is capable of rapid traverse rate of 30,000m/min in the X-axis and 33,000mm/min in the Z-axis.

Entry-level machines remain a vitally important part of the Mazak range and AMB 2016 will showcase the new QT COMPACT. The COMPACT is a high specification, entry-level model boasting Mazak’s integrated spindle technology for the main spindle and Tool Eye as standard – which together offer both improved performance and accuracy. The QT COMPACT comes equipped with a Mazak manufactured driven tool turret and an eight-inch chuck. It is capable of a maximum speed of 5,000 rpm and a peak torque of 167 Nm. The machine is equipped with SmoothC control, incorporating state-of-the-art motion control technology.

Martin Engels, Managing Director for Yamazaki Mazak Deutschland GmbH, commented: “AMB has become one of the major European machining shows and we are delighted to be bringing 12 state-of-the-art machines to the exhibition, from the most sophisticated 5-axis and multi-tasking technology through to entry-level machines. All of the machines on display demonstrate our philosophy of focusing on our customers and devising solutions to the different machining challenges they face every day. I am particularly pleased to be exhibiting all three variants of our SMOOTH Technology for the first time at a German show and our new INTEGREX AM hybrid manufacturing machine, which combines additive and subcontract technology in one platform.”