MAZAK SHOWCASED CUTTING-EDGE MACHINES AT AMB
Mazak recently participated in the AMB Exhibition 2024 in Stuttgart, where it showcased seven cutting-edge machines with highlights including Multi-Tasking capabilities, advanced automation, innovative auto gear technology and comprehensive remote service and support for increased productivity.
A world debut specialist gear-cutting machine was among the seven solutions on show from Yamazaki Mazak, while another world debut was the first in a new range of turning centres that will offer customers increased levels of productivity and efficiency.
A central component of the show was the company’s Go Green environmental manufacturing initiative, highlighted by the new NEO range of machines that have been designed to help customers achieve a more sustainable future with higher productivity, accuracy and environmental performance.
There were two NEO machines on display at AMB that have been purposely designed with a range of technological advancements to be able to deliver up to a 30% reduction in energy consumption compared to the original models.
The VARIAXIS i-700 NEO, a high-rigidity, next-generation 5-axis machining centre has an exceptionally wide machining area making it ideal for large workpieces, as well as a tilting/rotary table for high-accuracy machining over an extended period. The VARIAXIS is equipped with the advanced SmoothAi CNC.
The HCN-4000 NEO, which was displayed with a 20,000-rpm high-speed, high-output spindle for maximum productivity was exhibited with a two-pallet changer that ensures it can machine workpieces on the first pallet, while a second pallet is prepared.
Gear machining was an important part of Mazak’s stand with a specialist gear-cutting machine on show. The INTEGREX i-250H ST AG seamlessly brings together Mazak Multi-Tasking technology with gear cutting and measurement capability. The INTEGREX is capable of three different gear machining methods – gear skiving, hobbing and end-milling – making it ideal for high-mix, small-volume production and large production batches.
The QUICK TURN 250 MSY with Turn Assist and equipped for skiving applications, was also on display. The machine has a milling function, second spindle and Y-axis, 5,000-rpm spindle with the option of 10,000 rpm for ultimate productivity. It is controlled by SmoothG CNC, providing machine users with complete ease of use and ensuring high-speed, high-accuracy machining performance. The QUICK TURN 250 MSY was exhibited with a TA robot, making it ideal for lights-out and unmanned machining.
Also on display was the VARIAXIS C-600 tended by a part-loading and unloading third-party automation system.
Visitors were able to witness a live digital twinning demonstration involving a CV5-500 5-axis machining centre. The process was shown to create an identical digital copy of the machine in an office environment, saving operator time during setup, programming, fixturing and tooling to improve process and quality control.
The CV5-500 is one of Mazak’s entry-level machining centres, offering a cost-effective 5-axis solution that can be easily integrated with automation to further enhance productivity.
Visitors were able to view more information about Mazak iCONNECT – a digital service for existing Mazak customers that has a suite of free services including access to product manuals and e-learning options – along with a Machine-2-Mazak (M2M) subscription service. M2M enables remote real-time machine monitoring for proactive maintenance strategies including remote support to detect problems, remote optimization of machining processes with increased uptime, as well as access to Mazak applications, project engineers and service operators.
Newly available through Mazak iCONNECT is MAZATROL DX, a new productivity software that provides users with the capability to optimize their production process with the ability to generate rapid and automatic quotations, automated part programming, virtual machine simulation and machine process analysis and optimisation.
A variety of machined parts were on display to showcase some of the innovative ways Mazak is closely collaborating with its customers to drive innovation and push boundaries of what is possible.
Marco Casanova, Managing Director at Yamazaki Mazak for the DACH region, said “Our machines and technologies are designed to make our customers better, faster and more competitive. The new NEO machines combine best-in-class performance with exceptional environmental credentials; our gear-cutting machines bring a new age of productivity to a specialist machining process and our MAZATROL DX CNC offers even greater process optimization.
MAZAK NEW 2D LASER MACHINE FOR SHEET METAL CUTTING
Yamazaki Mazak last year completed the development of a new 2D laser machine for top-notch sheet metal cutting operations. The brand-new Cutting Head MCT3 and the innovative MAZATROL SmoothLX CNC Control system are just a few of the technical standouts installed on the OPTIPLEX 3015 NEO.
The large working area allows processing workpieces up to 1525 mm x 3050 mm through a 15 kW fiber laser resonator. The unique Beam Shaping Technology automatically adjusts the beam diameter and energy concentration to ensure the best possible result on various materials and thicknesses.
Automation is the key word here. The newly-designed Cutting Head MCT3 boasts multiple intelligent functions to streamline the operator’s job even more: Auto Nozzle Changing to optimise laser cutting and reduce assist gas consumption, Auto Focus distance adjustment for faster cutting speeds, and Auto Calibration of the nozzle-workpiece distance drastically improve productivity.
Automating the overall setup time can lead to 95% quicker preparations compared to standard laser machines. Moreover, Intelligent Cutting functions such as Flash Cutting and Fine Power Ramping can enhance the overall process even more. Instead of stopping at each axis, the laser is turned on and off through Flash Cutting—synchronising the axis and laser movements leads to greatly reduced cutting times. Fine Power Ramping is used instead to adjust the laser power and feed rate when cutting corners and straight lines to minimise dross without compromising the cutting speed.
A wide assembly of sensors installed on the cutting head enable the OPTIPLEX 3015 NEO to accurately monitor piercing and cutting operations and detect processing abnormalities and defects. For example, when plasma is detected, the Plasma Detection function adjusts the cutting speed to ensure good edge quality and minimise cutting imperfections. If instead burning occurs when cutting mid to thick mild steel plate, the Burn Detection function automatically stops the process to reduce failure. The Pierce Detection function detects when piercing has been completed and automatically begins the cutting process, reducing downtime considerably.
The OPTIPLEX 3015 NEO has been specifically engineered to help operators in their daily work. Before the actual cutting takes place, Mazak Smart System can generate process data – thanks to two sets of cameras above the work area – to optimise sheet utilisation in order to handle urgently required work and exploit the machine’s full potential. The new MAZATROL SmoothLX’s large 21.5” screen displays parts nesting at a glance, and the touch panel provides easy access to necessary information such as cut conditions or nozzle settings. Nest Programming, Cut Monitoring, Production Scheduling, and Machine Maintenance are just some of the many functions available to the operator. Also, the optional dual monitor allows multiple applications to run simultaneously.
Excellent Accessibility completes the picture. Large front and side access doors reduce the floor space needed and make material loading and unloading hassle-free; the tilting and rotating CNC control panel allows the operator to work at the front or at the side of the machine; the easily accessible work area enables direct control over the material while the nozzle centring camera allows <1 min adjustment times.
For more information, please contact HI-TECH Machine Tools – Tel: 011 608 0088.
