Mazak will display their new Done In One^® part-processing machines at IMTS 2018 with their new Hybrid Multi-Tasking series. These new machine tools combine additive and subtractive processes into a single machine so that complex parts can be manufactured in a single setup and program.

Mazak Done In One part processing. Source: Mazak

The aim of Mazak's Done In One concept is to incorporate all machining processes from raw material to final machining into a single machine. To achieve this capability, Mazak has incorporated features such as a second turning spindle and a milling turret or a two-spindle, two turret configuration. This leads to increased productivity, reduced production time, increased machining accuracy and lower operating expenses.

According to Mazak, the capabilities of the Done In One concept include:

• Increases capacity, flexibility, productivity and profitability
• Improves machining accuracy and overall part quality
• Streamlines production and boosts output with fewer machines and fewer increases in workforce
• Maximizes use of floor space
• Enhances overall management and enables the production of parts on demand
• Reduces part costs via fewer fixtures and less tooling
• Keeps manufacturers competitive

New machines include the VC-500 AM and INTEGREX i-400 AM 5-axis, hybrid multi-tasking machining centers. The "AM" in the machine names stands for additive manufacturing. The latest machines from Mazak feature new technologies such as friction stir welding and wire arc AM, making them suitable for advanced joining techniques as well as gear production.

The VC-500 AM is a vertical machining center that combines full 5-axis capability and additive technology to reduce time-to-market and cut R&D costs. Mazak boasts that the hybrid multi-tasking machine can build part features to near net shape up to 10 times faster than comparable systems without wasting time or material. The machine features face cladding capabilities and direct metal deposition for both additive and subtractive capabilities.

Featuring Done In One processing, the VC-500 AM can handle parts up to 19.7" in diameter and 12" high, weighing up to 440 pounds. The spindle uses a standard 40 spindle taper and runs up to 10,000 rpm. The magazine has a 20-tool capacity and the indexing C-axis table can rotate a full 360 degrees.

Mazak VC-500 AM Hybrid Multi-tasking Vertical Machining Center. Source: Mazak

The INTEGREX i-400AM has additive manufacturing capabilities by melting metal powder using fiber laser heat. Cladding heads or additive manufacturing nozzles apply this molten metal, which solidifies as each layer is applied and the desired shape grows. The machine can also join different types of metals together, which allows for the efficient repair of existing worn or damaged components such as aerospace turbine blades.

The INTEGREX i-400AM incorporates Done In One processing and features a milling spindle with -30/+120 degree movement, a turning spindle with full C-axis contouring, high-speed or high-accuracy cladding heads, an automatic tool changer and a fully programmable NC tailstock.

Mazak INTEGREX --400AM Hybrid Multi-tasking Machining Center. Source: Mazak

Visit Mazak at IMTS 2018 booth #432000 in the West Hall showcasing the new HYBRID additive and joining manufacturing processes, as well as at Mazak's main booth #338300 in the South Hall.