With such a wide variety of machines available, users can specify anything from the entry level model to a machine that has two spindles, two turrets and automation systems.

Adding value by process integration With such a wide variety of machines available, users can specify anything from the entry level model to a machine that has two spindles, two turrets and automation systems. With such a wide variety of machines available, Yamazaki Mazak's Integrex range can be tailored to suit almost any budget. Users can specify anything from the entry level model to a machine that has two spindles, two turrets and a range of automation systems from a simple barfeed through gantry loading to integration into a full flexible manufacturing system (FMS).

Through using the multi-function capability of the Integrex machines a true cost-effective machining environment is created.

'To achieve this,' says Lawrence McCann, Yamazaki Mazak's, Deputy Application Manager, 'the machine must have true milling and turning capabilities'.

'When developing the Integrex we also coupled this with a rigid construction that allows use of the torque and power available at the milling and turning spindles.' A major element in cost-effective machining is the Integrex's ability to machine the majority of features in a single set-up thanks to its best use of tool positioning provided by a combination of c and b-axis control.

This ability enables components to be machined using, in most cases, nothing more complex than chuck jaws to grip the component and, therefore, greatly reduces the reliance on specialist and costly fixturing.

The elimination of unnecessary set-ups and manual intervention also has a beneficial effect on component quality as part handling and repositioning is greatly reduced or eliminated.

A further benefit, and one not immediately obvious, is the fact that the process sheet no longer dictates the machining of component features and they can now be machined in the ideal sequence.

In one example an Integrex being used in the manufacture of pumps in the aerospace industry eliminated seven set-ups and reduced the actual cut-time from 2.5 hours to one hour.

Further examples of where true multi-function meets cost-effective machining are when Integrex machines are used for applications such as gun drilling, hobbing and turn milling, where the turning and milling spindles are in action simultaneously.

This is one area that Yamazaki Mazak paid particular attention to when developing its Mazatrol Fusion control.

The Mazatrol system sets the Integrex apart from more conventional multi-axis machines.

Two versions of the control are available, the smaller machines in the range are equipped with the 640MTPro while the MPro version is fitted to the larger and even more versatile e-machines.

The difference is that the MTPro is an integration of turning and milling controls, while the MPro control is a full machining centre-based controller with turning capability.

Each Mazatrol control generates programs using English language through the conversational system.

The control retains the program in its original format for its life, so that each time the program is run it internally post-processes; this means that should any changes be made to geometry or tooling it is simple for the operator to modify the program in its original, recognisable format.

Or, alternatively, more complex CAD-generated programs can be downloaded in ISO format.

An important feature when machining complex components is the addition of ISO five-axis simultaneous capability and Mazak's Rotary tool control Point (RTCP), which gives the user the ability to change any tool length within a five-axis program.

For a machine operating a five-axis machining program, the salient details are the positions of the component and cutting tool relative to the linear and rotary axes.

Knowing the position of the component on an Integrex is simple as it remains relative to the machine centreline although the tool position is varying.

What RTCP does is to calculate the tool length and re-post-process the axis points of the rotary axes every single time a movement is made.

This can happen hundreds of time per second and is, in effect, 'post-processing on the fly,' says McCann.

Of course the true measure of cost-effectiveness is the measurable increase in productivity, and profits, that a machine tool delivers.

And here the biggest factors are reducing set-up time, eliminating manufacturing costs such as fixturing and workholding, improving quality/consistency of finished components.