AT&F, a world leader in large- scale metal fabrication, has expanded the array of services  available to its customers with the addition of a five-axis water jet cutting system. The water jet cutting system allows AT&F to cut and process  a variety of materials including titanium, stainless steel, aluminum, and composite materials, providing a solution when a heat-affected zone is undesirable. The five-axis head design will allow for a variety of intricate  and complex angle cuts from 0-90 degrees, including beveled edges and weld landings. In addition, the system possesses one of the largest cutting envelopes available, able to handle sections of material up to 14 feet by 30 feet and up to 15 inches thick.

The addition of water jet technology allows AT&F to complement its other cutting technologies, giving customers a full spectrum of material cutting services. “This new technology allows us to bring additional services to our customer base,” said Ken Hagan, AT&F’s Vice President of Business Unit Operations. “We are now a one-stop shop for all material-cutting requirements, even on projects that require complex cutting and processing on specialized materials.”AT&F CEO Michael Ripich said the addition of the water jet cutting system is consistent with the company’s key strategy, “We Invest in Customer Success.”“We are excited to offer this service to our customers,” said Ripich. “Our expanded capabilities better serve our customers’ needs, allowing us to do more from a single location and deliver on our promise of BIG innovation.”

Perfect for high-volume job shops as well as aerospace and construction manufacturers, the Mazak INTEGREX e-1250V/8 Multi-Tasking machine combines full 5-axis milling, powerful turning and pallet changing to productively process complex parts up to 57″ in diameter and 63″ high in single setups.

The machine employs a 10,000-rpm, 50-hp milling spindle with a B-axis tilt of -30/+120 degrees for accurate 5-axis operations, while a 500-rpm, 54-hp direct-drive C-axis turning table with roller gear cam technology eliminates backlash for smoother, high-precision rotation in heavy-duty cutting operations. High-speed and high-torque milling spindle specifications are also available so the machine can successfully meet a broad range of application requirements involving materials such as titanium, aluminum and steel.

Mazak situated the machine’s automatic tool changer, available in tool storage capacities of 42, 84, 120 or 162 tools, near the CNC so operators can perform quick visual tooling checks. Such positioning also puts the cutting tools closer to the spindle for faster change outs. Furthermore, this high-speed, rack-type tool magazine is expandable after the machine’s initial installation. Axis travels on the INTEGREX e-1250V/8 measure 73.82″ in X, 49.21″ in Y and 52.95″ in Z. The axes incorporate Mazak’s MX Hybrid Roller Guide System to achieve high levels of durability and reliability that result in long-term accuracy. The innovative way system increases vibration dampening, extends tool life, handles higher load capacities and eliminates tramp oil in the coolant via a greener grease-based lubrication system.

The machine features Mazak’s all-new MAZATROL SmoothX CNC, which offers the industry’s fastest processing capabilities. As a key component of the company’s new SMOOTH TECHNOLOGY process-performance platform, the CNC offers several productivity advantages that reduce machining cycle times, especially in fine increment programs for simultaneous 5-axis operations and free-form die-mold machining. Highly beneficial to part manufacturers focused on high-volume production, the INTEGREX e-1250V/8 comes with a two-pallet changer that provides unattended operations and off-cycle part setup. This simple, efficient form of automation allows operators to load, unload and inspect parts on one pallet while the machine works on the other undisturbed.

For those seeking lights-out operations, the machine also integrates with the company’s PALLETECH System, an advanced pre-engineered palletized manufacturing solution.