Multitasking Machines Shorten Cycle Times and Offer Single-Setup Part Processing

Source | Mazak

Mazak’s Integrex j-200 and j-200S NEO horizontal multitasking machines feature single and twin-turning spindle versions with milling spindles to significantly shorten cycle times and provide single-setup part processing. As part of its NEO Series, the company says these machines combine advanced technology and outstanding value with high-performance productivity.

The Integrex j-200 and j-200S NEO multitasking machines feature productivity enhancements such as higher torque integral spindle technology for maximum material removal, specifications for faster spindle rpm, positioning accuracy and higher torque ratings. They also have expanded tool magazine capacities and longer tool lengths. Added heat displacement compensation equipment provides stable machining accuracy, increased operating efficiency and reduced power consumption.

High-performance specifications for the machines offer shops increased spindle torque ratings of 20-hp/240 ft-lbs (15 kW/326 Nm) for main spindles, 20-hp/123 ft- lbs (15 kW/167 Nm) for second spindles and 25-hp/42 ft-lbs (18.5 kW/57.3 Nm) for B-axis milling spindles which provide 0.0001-degree indexing positioning. Tool magazines now accommodate up to 72 tools and maximum tool lengths up to 9.8" in (250 mm).

For heat compensation, Mazak’s Ai Thermal Shield on these machines suppresses changes in the cutting-edge position based on spindle speed and temperature of the machine. The function stabilizes continuous machining accuracy through meticulous machine control, considering temperature changes, machine position, coolant On/Off and other factors. Ai algorithm calculations improve the accuracy of compensation, and with accumulated and learned data from subsequent measurements, thermal displacement compensation is optimized for each machining environment for stable machining accuracy.

Paired with the Integrex j-Series NEO machines, Mazak’s Smooth Coolant System boosts both energy and labor efficiency. The system reduces coolant cleaning frequency for less required maintenance, while integrated inverter controls for multiple coolant system pumps optimize operational efficiency. The company says this results in power consumption reductions up to 20% and less CO₂ emissions. Along with the coolant system, high-capacity coolant tanks enable continuous operation for long periods of time as with fully automated machine operation.

Featuring Mazak’s Mazatrol SmoothG control, the machines excel at high-speed and high-accuracy machining, offering both G-code and conversational programming platforms. The control provides ease of operation with its 19" touchscreen and 3D model-based graphical user interface for intuitive operation similar to smartphones and tablets.

For seamless automation to help shops overcome skilled labor shortages while keeping pace with increasing production demands, Mazak offers its Ez Loader for the new Integrex j-200/j-200S NEO machines. The Ez Loader redistributable automation system incorporates a stand-alone, plug-and-play automation system that uses multiple pallets, an easy-to-use programmable pendent, compact floor space and all necessary equipment for a flexible hassle-free machine integration and lights-out production.