Mazak’s Smooth Technology revolutionise machine tool performance

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2016-01-19 13:57:00

SMOOTH TECHNOLOGY has revolutionized the way our machine tools perform. Spanning the entire part-production landscape – from programming to metal removal to data collection – this technology platform significantly boosts productivity at every stage of the metal cutting process.
Intuitive hardware, new high-speed servo systems, enhanced ergonomics and highly optimized MAZATROL Smooth CNC programming are all key components of SMOOTH TECHNOLOGY. Engineering support also complements the platform by factoring in automation integration and plant-wide connectivity as the Industrial Internet of Things (IIoT) continues to transform our industry through big data.
Together, the elements that comprise SMOOTH TECHNOLOGY allow modern Mazak machine tools to offer manufacturers complete ease of use, lightning fast machining speeds and unbeatable performance accuracy. And, as manufacturing technologies continue to advance, SMOOTH TECHNOLOGY has the means to evolve with them.
Hardware
Among the most notable hardware features of SMOOTH TECHNOLOGY are the MAZATROL SmoothX and SmoothG CNC units that put unbelievable programming speed and convenience at your fingertips.
Mazak has reimagined control layouts to bring out an intuitive, flexible human-machine interface that provides optimal data viewing and simple touch-screen navigation similar to a smartphone or tablet. You can also tilt the control panel for optimum positioning.
The home screen for these controls makes it easy for you to see and/or access key data within a single-page view, including machine conditions and process selection. There are also separate process screens for efficiently managing the machining, programming, tool data, set up and maintenance of your machine. You can also quickly and easily jump from these screens to any other sections of the CNC.
Both controls have a CFast card that offers high data-transfer speeds and can hold up to 32GB of information. The standard wired pendent control or optional wireless pendent control works in tandem with our Smooth Manual Pulse Generator to make it easier for you to handle setup operations inside your machine.
Programming
Key elements of the SMOOTH TECHNOLOGY platform, MAZATROL SmoothX and SmoothG CNCs have advanced programming functions that put infinite part processing capabilities and increased productivity at your fingertips.
Smooth Machining Configuration
This cutting condition selection function makes it easy for you to tune the parameter settings on your machine to correspond with the workpiece material and application at hand. This dynamic capability also supports precision across the entire program and improves throughput.
Orbit Machining
This function allows horizontal and vertical machining centers with orientation of the spindle axis to turn features on large, complex-shaped parts such as valves and manifolds while they remain in a stationary position. As a result, you no longer have to program this turning process in EIA/ISO. Plus, you can use the same programming style as you would on a lathe, including nose-R compensation, constant surface feed and fixed cycles.
Position Controlled Hobbing
As gear cutting becomes more commonplace on multi-axis machines, this function brings accuracy and convenience to hobbing and skiving operations. It synchronizes the workpiece and cutter so you can change the spindle override while cutting and adjust spindle speeds during machine operation.
Real Time Tuning
This function helps maintain optimal balance throughout the metal removal process. It detects changes in machine inertia when the rotary table axes are moving and automatically adjusts the acceleration/deceleration of the rapid feed rates based on the weight of the workpiece in real time.
Smooth Corner Control
Based on a preset radial tolerance, this function reduces vibrations and shortens machining cycle times through cutter path adjustments made when machining into corners. This tolerance eliminates any dwell resulting from a rapid deceleration in the axial movement often associated with conventional corner machining. Thus, corner surfaces are smoother, the risk of cutter gouging is reduced and cutters can feed much faster.
Intelligent Pocket Milling
This function engages a high-efficiency toolpath when milling out part cavities. As opposed to conventional offset milling, the function consistently maintains a constant angle of tool engagement and cutting loads to ensure optimum machining conditions. This results in the full use of a machine tool’s power capabilities and up to 35 percent faster and more efficient machining of even the most difficult-to-cut materials.
5-Axis Virtual Machining
Utilizing VOXEL graphics technology, this 5-axis 3D simulation function allows you to run real-life part programs on the CNC to check for errors and machine interferences. These extremely realistic and accurate simulations for both MAZATROL and EIA/ISO programming use the exact same machine movement parameters as your Mazak machine model.
Automation
The modular PALLETECH System, which brings continuous uninterrupted machining operations to any production environment, is key to the automation portion of the SMOOTH TECHNOLOGY process-performance platform.
When using a PALLETECH System as part of a Mazak-driven manufacturing cell, our Smooth PMC software allows you to monitor your operations, make production schedule changes on the fly and manage your part programs from almost anywhere using a smartphone or tablet. The software features a home screen with the same look and feel as the MAZATROL Smooth CNCs.
Data Collection
SMOOTH TECHNOLOGY supports the MTConnect® open communications protocol and includes Mazak API—an Ethernet interface to a library of data-accessing functions for programmers that want to communicate with the machine via an Ethernet network. This also means machines with SMOOTH TECHNOLOGY can have an MTConnect adapter for collecting data from the MAZATROL SMOOTH CNCs.

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