Mazak has introduced the low-cost Integrex J series of multi-tasking machines for small- to medium-sized subcontracting companies.

‘Done-in-one machining technology is now accessible for any company, irrespective of size, and they can start manufacturing parts faster, more efficiently and more profitably,’ said Tony Saunders, Yamazaki Mazak’s sales director.

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The Mazak Integrex j series milling and turning centre reduces investment costs, lowers overheads and generates first-off components quicker and easier.

The Integrex machines economically produce small batch sizes, adding flexibility to any machine shop.

Integrex J series machines enable customers to reduce the time to machine the first-off component by 64 per cent, when compared with using CNC turning and machining centres to machine the same part.

To achieve this, Integrex J series machines feature a B-axis milling/turning spindle and tool carousel with 20 tools as standard (36/72 as an option).

Integrex J also makes use of the Mazatrol Matrix control system, which simplifies the complex programming tasks through use of the Mazatrol conversational programming techniques.

When compared with ISO programming, the Mazatrol system typically reduces the number of lines of code by 89 per cent.

The Integrex J-200 is being shown at Mach 2010.

This particular machine features a milling (B-axis) 12,000rev/min (7.5kW/49Nm) spindle with a main 5,000rev/min (11kW and 161Nm) spindle; feed rates of 40m/min; an X-axis stroke of 450mm with 50mm of that below the centreline; and a Y-axis stroke of 200mm, giving +/-100 either side of the centreline (Z-axis movement is 550mm).

The B axis fitted to Integrex J series machines has 220deg of movement in 5deg increments, facing the chuck it can position at 30deg above the machine’s central axis and facing away from the chuck it can achieve at 10deg.

With a 200mm chuck and a 500mm maximum machining diameter, the Integrex J-200 has a machining capacity that contradicts the fact that the floorspace requirement is 3 x 2.43m, which, when compared with using conventional turning and machining centres;to produce the same work, is a reduction of 56 per cent, according to Mazak.

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The flexibility of a CNC ‘mini-mill’, with its 16-tool turret and ease of programming, is making the task of meeting stringent autosport deamnds an easier thing to do.

These days, Terry Kempe, who is responsible for production and quality control at 15-employee Monard Precision Engineering, can still on occasions be found operating one or other of this specialist sub-contractor’s machine tools.

A former apprentice with the English Electric Company, he says that after nearly 40 years in engineering, it is difficult to do ‘cold turkey’.

It’s a trait he shares with fellow director, Paul Barnett, who joined Monard straight from school and now oversees the machine shop.

He, too, is a highly skilled machinist who believes in a hands-on response when tight deadlines demand it.

The ISO 9001 accredited company moved to its 3600ft2 premises in Rugby in 1985, from where it delivers precision machined components to numerous blue chip customers.

It is, for example, an official supplier to Mitsubishi Motors Motor Sport, one of the leading contenders in the 2005 FIA World Rally Championship, as well as supplying parts to manufacturers of laser equipment.

Common to OEMs in both these industries is a preference for design and assembly rather than in-house manufacture.

“Because of this,” says Kempe, ” Monard is closely involved in the ‘design for manufacture’ aspect of - in the case of motorsport - various engine, gearbox and suspension components”.

“Much of this is prototype and development work, although production batches, too, are usually small”.

“Either way, the emphasis is always on high accuracy and on-time delivery.” With this in mind Monard has invested in a 13HP XYZ Mini Mill 560 compact vertical machining centre equipped with a Siemens 810D control running Shopmill conversational programming software.

This latest addition sits alongside several XYZ manual/CNC lathes and mills, machining for the most part stainless steel and aluminium workpieces.

Although the ‘mini mill’ concept originated in the USA in the late 1990s, the objective being a vertical machining centre capable of machining the widest range of components within the smallest possible machine space, the XYZ Mini Mill 560 has taken this concept a step further.

Its 560mm (X) by 400mm (Y) by 500mm (Z) working envelope is contained within an 1800mm (width) by 1980mm (depth) footprint.

This combines small size with a level of rigidity, courtesy of the machine’s Meehanite cast iron construction, that is second to none.

Three Monard employees have been trained to operate the new machine and, says Terry Kempe, since installation the XYZ Mini Mill 560 has done everything required of it.

Shopfloor programming is the norm, but off-line programming is also used, with completed programs transferred via ‘memory sticks’.

Although motorsport is one of the most interesting industries, it is also a hard taskmaster.

Terry Kempe and Paul Barnett enjoy the challenges this brings to Monard but see little point in making life more difficult than it has to be”.

“”We have always prided ourselves on going that extra yard for all our customers,” says Kempe, “Now the flexibility of the Mini Mill 560, with its 16-tool turret and ease of programming, makes this an easier thing to do.”.

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For the manufacture of turned parts up to 7mm diameter, an easy to operate CNC turning centre precisely machines small components to a guaranteed precision of +/-2 micron.

At the UK’s MACH 2008 machine tool exhibition, Tornos will be giving the Micro 7 its UK exhibition debut.

The new Micro 7 guarantees precision of +/-2 micron whilst demonstrating excellent flexibility, productivity and operator simplicity, said Tornos.

Designed for the manufacture of turned parts up to 7mm diameter, the Micro 7 is ideally suited to the precise small component and electronics sectors.

With a maximum workpiece length of 60mm and a spindle and counter spindle speed of 20,000 rev/min, Tornos is offering a highly productive machine proven to outperform the cam-type machines that have dominated this small component sector.

Tornos told manufacturingtalk.com that to enhance processing times the Micro 7 combines its high speed spindles with simultaneous machining in front and back operation modes.

* Flexibility - with flexibility instilled in every aspect of the Micro 7, this remarkable machine can hold up to 20 tools on a 5 + 2 axes configuration (with C-axis), explained Tornos.

The Micro 7 can work with a wide range of tool holders and equipment suited to the exacting needs of every user.

Meeting the productivity, accuracy and flexibility demands of the modern machine shop, the tools on the Micro 7 work independently for flexible manufacture.

* Programming choice - for ease of use and customer simplicity, Tornos is launching this machine with the option of the renowned Tornos TB-Deco programming system or the industry standard ISO system driven by a Fanuc Series 32i control.

All these elements are built upon a strong and rigid construction that delivers the productivity and accuracy benefits associated with the Tornos family of turning centres.

For further information on the Tornos Micro 7 that will be available from the second quarter of 2008 or any alternate turning centres in the Tornos range, please come and visit us at MACH 2008, said Tornos.

* Tornos Technologies at MACH 2008, NEC, Birmingham.

UK, April 21-25, Hall 5, Stand 5575.

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