Embracing Complexity with MTM

The growing complexity of components is not lost on machine tool builders, who are responding with more capable and flexible multi-tasking machine designs. In fact, Mazak, which offers numerous MTM options, even provides some tactical advice for machinists with its Five Levels of Multi-Tasking classification system for its machines’ applications and capabilities.

Among Mazak’s new offerings is the Integrex i-200ST multi-tasking machine that it said provides shops with versatility and high accuracy in a compact design, with features like twin spindles, a lower turret and milling spindle that achieve what it called “done-in-one productivity.” Mazak ranks the Integrex i-200ST as a Level 4 machine, because it turns, drills, taps and mills, while offering off-centerline and full simultaneous 5-axis contouring.

The Five Levels is a guide for manufacturers to determine the best multi-tasking technology for meeting their specific application and process needs.

Level 1 machines typically offer a single turning spindle and drum-style turret with rotating tool capability for processing minimally complex workpieces. Level 2 machines add Y-axis functionality for off-center operations and “done-in-one” machining together with either a twin spindle and milling turret or twin spindle/twin turret machine configuration. Level 3 MTMs feature independent milling spindle headstocks with B-axis indexing, as well as Y-axis travels and tool storage magazines. Level 4 machines emphasize automation and processing large or highly complex workpieces using full, simultaneous 5-axis machining. Level 5 adds specialized machining tasks, such as gear cutting, honing and grinding, for machines that process very demanding and complex parts in single setups.

On the Integrex i-200ST, both turning spindles provide equally high performance with spindle speeds of 5,000 rpm and C-axis turning control, and both have a 3-in. (76-mm) diameter bore capacity.

For C-axis contouring versatility at either turning spindle, the Integrex i-200ST vertically mounted milling spindle provides 30 hp (22 kW), 12,000 rpm and a rotating B-axis range of -30° to +240°. Mazak’s roller cam drive for the B-axis ensures higher accuracy and rigidity, with no backlash. A 36-tool (72-tool optional) magazine allows fast tool changes and provides ample tooling for continuous part processing.

The lower turret on the Integrex i-200ST model comes standard for nine turning tools. The lower turret in combination with the machine’s milling spindle can be applied to either side of the machine headstock to reduce machining cycle times.

Mazak said its MX Hybrid roller guide system is integrated to the Integrex i-200ST to impart durability and reliability that result in long-term accuracy. The MX Hybrid roller guide system dampens vibration to extend tool life, handles higher load capacities, accelerates and decelerates quicker to shorten cycle times, consumes less oil (for “greener” operation), and performs longer with less maintenance.

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) in diameter.

Because the machine is designed with its tool magazine at the front, operators can program and set-up tooling with minimal movements. Also, all machine lubrication points and gages are gathered into a single panel for ease of viewing and maintenance.