Mazak INTEGREX i-630V AG

The Mazak INTEGREX i-630V AG adds gear cutting and gear measurement to a vertical 5-axis mill-turn machine with a 2 pallet changer. Mazak's AG series integrates three tooth-cutting methods, gear skiving, hobbing and end milling, so a blank up to 41 in (1,041 mm) in diameter can be turned, have its teeth cut and be measured without leaving the pallet.

Each method fits a different kind of batch. End milling uses commercially available end mills and Mazak's Smooth Gear Milling software to cut teeth one at a time, with functions to correct tooth profile and tooth lead; Mazak notes that hob cutters and their jigs take a lot of preparation time in high-mix, low-volume work, which is the case end milling answers. Hobbing is supported by Smooth Gear Hobbing, whose hob shift function moves the cutting point along the hob on each pass to lengthen the interval between resharpening. Skiving depends on synchronizing the turning table with the milling spindle, and Mazak states that the synchronization holds at the maximum speed of each, which on this model means 550 rpm at the table and 10,000 rpm at the spindle.

After cutting, a touch probe measures pitch, reporting single pitch error, cumulative pitch error and tooth space runout and calculating the pitch circle centre. Gear profile and lead are measured with a scanning probe. The machine can also identify the centre angle of a tooth groove after skiving or hobbing, so keyways, drilled holes and ball end mill deburring are placed in phase with the teeth.

Underneath, the figures are those of a large 5-axis mill-turn: 56 in (1,422 mm) of X, 41 in (1,041 mm) of Y and Z, a 150° B axis, a 3,858 lb (1,750 kg) table load and a 43-tool CAT No.50 magazine. The table motor is rated 37 kW (50 HP) continuous with 3,120 Nm (2,301 ft-lb) of continuous torque. Machine weight is 77,162 lb (35,000 kg), against 71,980 lb (32,650 kg) for the INTEGREX i-630V/6.