The Mazak Integrex AG series for gear cutting

Integrating multi-tasking machining with gear cutting processes such as gear milling, gear skiving and gear hobbing. Done-In-One processing with gear cutting and measurement functions.

Mazak is perhaps the company most associated with multitasking – multi-axis machines that turn, mill and more to make complex parts complete in a single setup. However, a new class of machine from Mazak is driving multitasking to a whole new level by bringing still more processes into the mix.

Mazak’s new hybrid lineup combines additive manufacturing and joining processes including laser and multi-laser metal deposition, hot wire deposition (an arc welding process), and friction stir welding. In the past, many parts produced with an additive process would need finishing with traditional subtractive CNC machining. But these hybrids require no separate second machine and no additional setups, bringing “done-in-one” multitasking to a wider range of applications.

The hybrid lineup also offers new ways to make gears on five-axis machining centers
Current manufacturing in most industries makes wide use of high-mix, low volume production in which a wide variety of components are produced in small lot sizes. The production of gears today follows this same trend. Conventional gear production is performed by several processes by both conventional machine tools and dedicated gear equipment to produce gears. However, todays demands are for equipment that can be integrated in flexible production lines that provide reduced lead times for a wide variety of components. Required gear sizes range from small 0.5-1.5 module (50.8-16.9 DP) gears for automotive transmissions up to 8 module (2.95 DP) gears for planetary gears used for construction machinery and aircraft geared turbofans.

The new Mazak Integrex AG series are multi-tasking machines integrated with gear machining, such as skiving, hobbing, endmilling and gear measurement. This makes it possible to perform all gear machining processes including turning, gear measurement with Renishaw scanning probes. As a result, this process integration realises high accuracy gear machining and reduction of in-process time.

The Integrex e-1250V/8 AG hybrid multi-tasking machine combines full 5-axis milling, powerful turning and pallet changing with the Smooth Gear Cutting software package to productively process complex parts and gears up to 1 450mm in diameter and 1 600mm high in single setups.

The machine employs a 10 000rpm, 37kW milling spindle that has a B-axis tilt of -30/+120 degrees for accurate 5-axis operations. Its 500rpm, 40kW direct-drive C-axis turning table enables 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, aluminium and steel.

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 dampens vibrations, extends tool life, handles higher load capacities and eliminates tramp oil in the coolant via a greener grease-based lubrication system. Axis travels on the machine measure 1 875mm in X, 1 250mm in Y and 1 345mm in Z.

Mazak’s Smooth gear milling, gear skiving and gear hobbing processes apply software that makes gear production easier, reducing the need for complex programmes or specialised machines for the production of both external and internal spur, helical and spline-type gears.

For more information contact Hi-Tech Machine Tools on TEL: 011 608 0088 or visit www.hitech.co.za