Hartbeat 2013 - Machine Tools by John Hart

VARIAXIS The All new VARIAXIS i-series

AUSTBORE Expanding possibilities with the INTEGREX e-420

FIREFLY INTL. Burning brighter with the INTEGREX j-200

GEAR DESIGN & SERVICE Big parts require big machines: The INTEGREX e-500

AMIGA ENG. Complex jobs made easy with the INTEGREX i-200S

Austbore: Expanding possibilities with the INTEGREX e-420 Austbore is a large job shop located in Mackay, Northern Queensland that has serviced the mining and resources industry for over twenty years.

Originally started with a single machine, Austbore has since expanded to employ over 35 full-time staff working on a variety of manual and CNC borers, CNC milling machines and CNC lathes. Most recently they added to their capability by investing in two new Mazak INTEGREX CNC multi-

tasking machines from John Hart. Talking with Darryl Lindsay, Operations Manager at Austbore, he noted that John Hart was chosen as their supplier “because of their enthusiasm in regards to supplying the INTEGREX. The process went very smoothly, and communication between Austbore and John Hart was very easy.” The two new INTEGREX machines (INT 200S MkIV and INT e-420 x 3000) were initially purchased to reduce part cycle times. Being a job shop, Austbore does a lot of small batches and one-off parts, which makes the part processing time incredibly important. Since the introduction of the multi-tasking machines, Austbore have been able to reduce their part in process time and expand the variety of work they are able to take on. “These machines have given us greater capabilities and we’ve taken on work

we would never have dreamed of taking on before.” said Darryl, “Especially regarding the INT e-420, there are more options than you could ever dream of.” “The only challenge is the machines are so versatile, after 12 months we are nowhere near where we need to be, because there is so much that can be done on them. That’s not a criticism, that’s a compliment.” “Mazak machines also seem to have more Y-axis travel, and the positioning of the head to 240 degrees provides more capability as well. Comparable machines just don’t look as appealing.” says Darryl Since purchasing the INT e-420, Austbore has been very creative with its application. To increase productivity they use a special work piece fixture that bolts onto the chuck, allowing operators to perform milling operations on all four sides of a part without

changing the setup. “The advantage of this process is we can set a work piece, put the component into the machine, set the zeros, write the program, and pull the finished component out at the end of the day without actually having to reset it. These are pieces which

“We’ve managed to reduce the timeline on each part by two thirds.” require milling on four sides, including bores, interpolation of the bores, milling of threads plus seal and wear areas.“ “Before the e-420, we would have to use two to three setups, increasing the margin for error with each change over. We’ve managed to reduce the timeline on the pieces by two thirds. This is an enormous reduction.”

The clear advantage of Mazak’s famous Done-In-One multi-tasking technology has allowed Austbore to not only reduce their cycle times and remove damaging multi-process compound errors, they have also redefined the capability of jobbing shops throughout the world. Utilising the versatility of the INTEGREX series, the operators at Austbore have also succeeded in exploiting the e-420’s capabilities to complete jobs normally reserved for machining centres. John Hart initially provided a week’s worth of training with follow up support when required by Austbore. Darryl went on to note “The controllers on the 200S and e-420 make operating the machines quite separate experiences. Considering each operator has had to learn two different configurations simultaneously, they haven’t had too much of an issue. Any minor problems we solved with a call to John Hart’s Applications team.”

Rather than trying to find experienced operators for their factory in Mackay, Darryl says Austbore have made internal training a priority by using their Mazak VTC as a stepping stone for operators before moving up to the INTEGREX machines. As Austbore continue to increase their knowledge of the INTEGREX’s capability and expand their in house training, their overall capabilities and production output will also grow. The Mazak INTEGREX series provides them with great production possibilities and lays the path for them to be more flexible and competitive.

1. Darryl Lindsay - Austbore Operations Manager 2. A part ready for milling 3. Finished part 4. A mining part ready for machining

Firefly International: Burning brighter with the INTEGREX j-200

The arrival of their new Mazak INTEGREX j-200 also created considerable interest from new customers who were eager to test Firefly’s new capabilities. Dale Bonetti, head machinist at Firefly visited one of their current customers recently, and commented “I went through their workshop and picked off about a half a dozen jobs we could complete without the INTEGREX, but with the INTEGREX that’s increased to 30 items.”

machines in the factory, which are used to train apprentices before they move onto the CNC machines.

In a global economy with continuing demand for our vast natural resources, the flow on effect has been strong for a range of industries supplying the mining sector. Pneumatic drilling and pumping equipment and their related products have been in strong demand for some time and there are some well established suppliers who have been successful in this market.

Their workshop currently contains a wide variety of Mazak machines, ranging from a QUICK TURN Nexus 150 all the way up to the INTEGREX j-200 series machine. They use the standard Mazak lathes and lathes with milling to produce integral drill steels while the INTEGREX machine is used for more complex work. They also have several manual

The Mazatrol conversational controllers are renowned for their speed of programming and intuitive operation. Coupled with Mazak’s famous machine quality and performance and supported by John Hart’s training and service team, it took Firefly only a few days to get the workshop fully operational with their new Mazak INETGREX bringing real value to their business immediately.

Firefly International, located in Newcastle, NSW is one such company, which supplies specialised components to the mining industry. Their strength is their ability to supply a range of high quality smaller components, replacement parts and special items to order, in a timely manner. They have been able to achieve this through their commitment to utilizing the latest machining technologies. From the start Firefly understood that to be a market leader they had to have the most productive and advanced technologies available. As a result they invested in the Mazak j-200 multitasking machine which enabled them to machine more complex parts in a faster, more versatile and efficient manner. The knock on effect was to not only attract new customers, but to expand the range of work they could do with their existing customers.

Dale Bonetti - Head Machinist at Firefly International

Dale who has overseen the development of the machine shop at Firefly, quadrupling their capacity since 2003, explains the main reason for choosing Mazak machines “they just seem to be the easiest to train with. When using the conversational controls they’re almost effortless to operate.”

The all new VARIAXIS i-series The new Mazak VARIAXIS i-series is a 5-axis fully simultaneous multi-tasking vertical machining centre range that offers all the advantages of Mazak’s Done-In-One technology. It allows five face and fully simultaneous five axis machining in a single setup. The benefit to manufacturers is a reduction in production lead times, increased machine capability, reduced work in progress, higher part accuracy and faster complete part to customer time. Furthermore, it can tackle a wide range of applications, from heavy-duty cutting through to high-speed cutting of aluminium and other nonferrous materials. The VARIAXIS i-series comes standard with a fast, high-rigidity 12,000 rpm, 22kW 40-taper spindle with a compact nose design that helps optimise the machine’s Z-axis stroke and overall machining stability by allowing the use of shorter tools. An optional 18,000 rpm, 35kW spindle is also available.

Model

VARIAXIS i-500

The tool magazine has a standard 30 tool capacity with options allowing up to a maximum of 120 tools. Speed and increased productivity are gained through the fast rapid traverse rates of the VARIAXIS i-series, as well as from its use of Mazak’s MX Hybrid Roller Guide System in the X-, Y- and Z-axes. The machine rapid traverses as fast as 60 m/min in the X- and Y-axes and 56 m/min in the Z-axis. Rotary A and B axis are at 18,000° / min The MX Hybrid Roller Guide System delivers levels of rigidity, durability and reliability that result in long-term accuracy. Mazak’s MX Hybrid Roller Guide System reduces vibration, extending tool life, handles higher load capacities, accelerates and decelerates quicker to shorten cycle times, consumes less lubrication for “Greener” operations, and lasts longer with less required maintenance.

software functionalities, which deliver fast, high accuracy performance and increased productivity. Control hardware performance is much faster than previously, with higher processing speeds for small increment operation. Furthermore, a 5-axis spline interpolation function included in the control’s software provides smooth tool-paths from long block-by-block programs, easy tool vector control and shorter cycle times as well as superior surface finishes.

The VARIAXIS i-series features Mazak’s new MAZATROL MATRIX II CNC control. Within the control are both enhanced hardware and

VARIAXIS i-600

Mazak VARIAXIS i-600

VARIAXIS i-700

VARIAXIS i-800

Table size

φ 500 × 400 mm

φ 600 × 500 mm

φ 700 × 500 mm

φ 800 × 630 mm

Travel (X/Y/Z)

350 / 550 / 510 mm

510 / 910 / 510 mm

630 / 1100 / 600 mm

730 / 850 / 560 mm

Travel (A/C)

-120 ~ +30°/ ±360°

Rapid traverse rate (X/Y/Z) 60000 mm/min / 56000 mm/min 60000 mm/min / 56000 mm/min 60000 mm/min / 56000 mm/min 42000 mm/min / 42000 mm/min Rapid traverse rate (A/C)

18000°/min

Spindle

12000 rpm, 22 kW *

10000 rpm, 37 kW *

Tool shank

MAS BT-40

MAS BT-50

Tool storage capacity

30, **60, **80, **120

30, **40, **80, **120

Floor space requirement

2400 × 3060 mm

2200 × 3806 mm

2400 × 4121 mm

2695 × 5364 mm

*Optional 18000 rpm, 35kW spindle, **Optional tool storage capacity

Gear Design & Service: Big parts require big machines: The INTEGREX e-500

Gears are an important part of everyday life and can be found in everything from large mining machines to children’s toys. Gear Design & Service (GD&S) is a Melbourne based company that specialises in everything gear related. As Clayton Sanderson (Co-Owner) puts it, “if it doesn’t have teeth, we don’t take it.” GD&S as the name suggests, design

and service gears for companies all around Australia, and while the majority of work comes from companies within or related to the mining industry, they do work for a variety of other industries, including food, marine and even vintage car restoration. Their workshop is well established with as many as 100 machines on the floor. While smaller manual machines take up much of their workspace, it’s easy to spot the bigger machines which dwarf everything in comparison. In their first work bay is a large 1.2 metre capacity KLINGELNBERG C100U spiral bevel generator which was purchased from John Hart Machine tools. Clayton proudly claims “it is the largest in the southern hemisphere, or at the very least the only one in Australia”. Alongside is the just as impressive Mazak INTEGREX

e-500 IIH multi-tasking centre which also dominates the area. After initially approaching John Hart about buying a QUICKTURN 450 lathe, GD&S quickly realised they also required an additional CNC machining centre. Clayton commented “We needed a second machining centre, so the INTEGREX was a great option as it allows us to do both machine milling and turning, and it takes up less space (than two machines).” Since the introduction of the INTEGREX, GD&S have been able to shift their operations up to larger sized gearing. “We went for the 3m INTEGREX as we have another lathe that is bigger in turning capacity, but it doesn’t have the length of the INTGREX e500. It also gives us a bit more flexibility; it allows us to do jobs nobody else can, which is the

main focus of our business.” Clayton went on to say “People come into the factory, and see the INTEGREX and say, I want to put a job on that!” “The real positive is you’ve got one setup, and you can do multiple tasks with the one setup. Instead of 2 or 3 machines, we put a part in the INTEGREX and it comes out finished. You get the program right and can leave it to do its thing. And that is a big advantage.” “Recently we cut a face clutch for a big exploration drill in North Queensland. They brought the part in and they wanted it overnight. Because we’ve got the flexibility of the INTEGREX e500 we can put it in the machine and get it out the next day.” Mazak make up the majority of GD&S’s CNC machines and

Mazak’s Mazatrol conversational programming system plays a large role in helping them be more efficient with their complex machining.

another $30K on a CAM program system. The operators can have a job setup, programmed and running in less than 30 mins, that’s the real key to the Mazak brand I believe.”

“People come into the factory and see the INTEGREX and say, I want to put a job on that.”

To support the installation John Hart Applications Engineers completed training over a couple of days, enabling GD&S to quickly get up to speed and take on more complex jobs, with the operators comfortably transitioning to the multi-tasking style of machining.

“The Mazatrol programming system makes it so much easier to operate; we do all our programming on the controller which saves us heaps of time, otherwise we’d need to spend

Mazak has been the world leader in the development and installation of multi-tasking for over thirty years. Multi-tasking brings together the benefits of turning and milling into one machine enabling single setup jobs, increasing production capability, improving part quality, reducing work in progress and increasing company profitability.

1. Clayton Sanderson with the INTEGREX e-500H II 2. The 1.2 metre capacity KLINGELNBERG C100U Spiral Bevel Generator 3. Gears cut on the INTEGREX & C100U

Amiga Engineering: Complex jobs made easy with the INTEGREX i-200S Amiga Engineering has been a key manufacturer in Melbourne for over 23 years. They have over time remained strong and been able to expand their own business through the process of modernising their workshop and intercompany mergers. Michael Bourchier originally created Amiga Engineering through the bringing together of some former employees and customers. They then acquired Bradley Technologies, a medical component manufacturer, and Genet and Wood, one of the last Australian industrial gearbox companies.

replace their older CNC Lathes and the prospect of gear hobbing machines. Since the introduction of the travelling column style Y-axis, the INTEGREX i-200S is able to cut larger gears than previous models, which makes it ideal for Amiga’s requirements.

is why we bought the INTEGREX.” The Mazak INTEGREX i-200S is the newest addition to the company and was purchased from John Hart for its multi-tasking functionality and 5-axis simultaneous machining capabilities. It will be utilised to produce small fittings, medical components and gear box components. “A lot of the work we do is turning orientated, but with aspects of milling and complex features. We look at the INTEGREX as the best starter (into new technology) for us. We will see where that takes us.” As manufacturing in Australia becomes more competitive, local companies must find ways to be more versatile and efficient. The INTEGREX series offers this edge through reduced job setup time, done-in-one operation, increased part quality and reduced work in progress. In Amiga’s case, they’ve managed to replace four machines with one INTEGREX. Amiga had spent several years looking at the INTEGREX series as an option to

Talking with the guys at Amiga they commented that they had purchased the INTEGREX specifically with the gear hobbing functionality as a way of tackling the more complex jobs. “Small splined shafts and gears are notoriously difficult for everybody, but we will be able to churn them out quickly and easily in the INTEGREX.” Trust was also a major factor in moving forward with John Hart and Mazak, “I think the main reason we went with the Mazak, was I felt we would have better support. There are many of these machines in the manufacturing industry which are working well. I wanted to take on something that I trusted to be the point of entry into this new technology. In addition to that, we had access to the machine fairly quickly and John Hart were very helpful in getting us set up.”

The now expanded business is run out of their Tullamarine workshop which has 17 staff and more than 30 machine tools. Michael noted the CNCs now outnumber the manual machines after the company recently completed a clean out of obsolete machinery. He commented “The next few months we will be throwing out all the old equipment, bringing the company forward in terms of technology, which

CNC MACHINE TOOLS

Michael Bourchier and operator with INTEGREX.

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