As a Level 4 machine in Mazak’s Five Levels of Multi-Tasking, the INTEGREX i-200ST turns, drills, taps and mills, while offering off-centerline and full simultaneous 5-axis contouring. Mazak developed its Five Levels of Multi-Tasking as an effective way for manufacturers to determine the best multi-tasking technology for meeting their specific application and process needs.

Within the Five Levels of Multi-Tasking, Level 1 machines typically offer a single turning spindle and drum-style turret with rotating tool capability for processing minimally complex workpieces. Level 2 machines add Y-axis functionality for off-center operations and Done-In-One machining together with either a twin spindle and milling turret or twin spindle/twin turret machine configuration. Level 3 Multi-Tasking machines feature independent milling spindle headstocks with B-axis indexing, as well as Y-axis travels and tool storage magazines. Level 4 machines emphasize automation and processing large or highly complex workpieces using full, simultaneous 5-axis machining. Level 5 is the addition of specialized machining tasks, such as gear cutting, honing and grinding, that transform Level 4 machines into Level 5 Ultra-Tasking machines that process even the most demanding and complex parts complete in single setups.

Both turning spindles on the INTEGREX i-200ST provide equal high performance with spindle speeds of 5,000 rpm and C-axis turning control. And both have a bore capacity measuring 3″ (76 mm) in diameter.

For C-axis contouring versatility at either turning spindle, the INTEGREX i-200ST vertically mounted milling spindle provides 30 hp (22 kW), 12,000 rpm and a rotating B-axis range of -30° to +240°. Mazak’s unique roller cam drive for the B-axis ensures higher accuracy and rigidity, while providing zero backlash. A 36-tool (72-tool optional) magazine allows for fast tool changes and provides ample tooling for continuous part processing.

The lower turret on the INTEGREX i-200ST model comes standard for 9 turning tools. The lower turret working in combination with the machine’s milling spindle that can be applied to either side of the machine headstock reduces machining cycle times.

Mazak incorporates its MX Hybrid Roller Guide System into the INTEGREX i-200ST for durability and reliability that result in long-term accuracy. The MX Hybrid Roller Guide System dampens vibration to extend tool life, handles higher load capacities, accelerates and decelerates quicker to shorten cycle times, consumes less oil for “Greener” operations, and lasts longer with less required maintenance.

For a compact multi-tasking center, the INTEGREX i-200ST provides an ample Y-axis travel of 9.8″ (249 mm) and vertical X-axis of 24.2″ (615 mm), with 4.92″ (125 mm) below centerline. The machine accommodates parts up to 25.9″ (657.8 mm) in diameter. And because its tool magazine is located at the front, machine operators can do programming and tool setup with minimal required movement. Additionally, all machine lubrication points and gages are gathered into a single panel for ease of viewing and maintenance.

Source: www.mazakusa.com

The company originally started with only one machine have slowly expanded, now employing 35 full-time tradesman and host a variety of machines including manual and CNC borers, CNC milling machines, CNC lathes and two new Mazak Integrex CNC multi-tasking machines, which were purchased from John Hart within the last twelve months.

John Hart were chosen largely, as Darryl Lindsay (Operations Manager at Austbore) puts it, “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 (Integrex 200S MkIV & Integrex e-420 x 3000) were initially bought as a way of combating long cycle times. Because all work at Austbore is jobbing with some one-off parts, cycle time is incredibly important and since the introduction of these machines, Austbore have been able to expand the variety of work they 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 Integrex e-420, there are more options than you could ever dream for.”

“The only problem 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 complement.”

“Mazaks 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 e-420, Austbore have been quite creative with its use, creating a fixture that bolts onto the chuck, which allows the operators to perform milling operations on all four sides of a part without changing setups.

“The advantage of this 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 require milling on four sides, including bores, interpolation of the bores, milling of threads and seal areas 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.”

This reduction is possible thanks to Mazaks “done-in-one” technology which comes standard with all Mazak Multi-tasking machines. The operators have also succeeded in exploiting the e-420’s capabilities, to complete a task normally reserved for a machining centre.

John Hart initially provided a week’s worth of training and a couple of days here and there where necessary. Considering that, operators have found the machines easy to transition to and between.
Darryl explains, “The controllers on the 200S and e-420 make operating the machines quite separate experiences. Considering each operator has had to learn two different controllers simultaneously, they haven’t had too much of an issue. Any minor problems we solved with a call to John Hart.”

“We currently have two operators working between the 200S and the e-420 and while we’d ideally like 2 more to split the workload, experienced operators are hard to come by in this part of Queensland.”
Rather than trying to attract experienced operators to their shop in Mackay, Darryl says Austbore are making internal training a priority, using their Mazak VTC as a stepping stone in order to prepare operators for the Integrex’s.

If Austbore can maintain this balance between expanding their knowledge of the Integrex’s and internally training their operators, their capabilities will continue to increase, and Austbore will be able to run extra shifts, increasing workload. The Mazak Integrexs, and especially the e-420 provide unlimited possibilities, and increasingly lay the pathway to manufacturing of the future.

As you may have already noticed, we’ve recently passed 100,000 video views, which is a great milestone.

To build on this success, over the next year we will be releasing a series of videos presented by our experienced Sales Engineers, that not only showcase new Mazak machines, but also over looked features and how to achieve more with each machine.

Thanks to all those who have been using the channel, please stay tuned over the coming months for our next Mazak video.

ZOLLER products all have the same objective – to make production processes more efficient.

Zoller Website

Contact John Hart Machine Tools regarding the Zoller CNC smile.

The flow on effect has been good for a select range of industries supplying this sector and those supplying the mining industry with pneumatic drilling and pumping equipment and related products to the mining industry have themselves enjoyed buoyant conditions.

Firefly International, located in Newcastle, NSW is one of those companies who have benefitted from their ability to supply a range of smaller components, replacement parts and special items to order in a timely manner. They have been able to do this because of their commitment to the latest machining technology which enables them to produce more accurate and varied parts with greater flexibility and with a quicker turnaround.

Firefly quickly understood that to do this they had to upgrade their old machines with the newer multi-tasking equipment which was faster, more versatile and they could embrace the “Done in One“ or single set up philosophy which enabled them to produce with one machine what previously took two or three older machines.

Firefly have been a Mazak user since their first CNC machine, a Mazak T1 using a universal controller. They were excited by the new Mazak Integrex j-200 series which offered them a chance to machine more complex parts and not only attract new customers, but to expand the range of work they could do with their existing customers. Since their first machine purchase back in 2003, Firefly has more quadrupled their capacity.

The arrival of their new Mazak Integrex j-200 has marked the point of considerable interest from new customers eager to test their capabilities. Dale Bonetti the head machinist at Firefly visited one of their current customers recently, he said “I went through their workshop and picked off about a half a dozen jobs we can complete without the Integrex, but with the Integrex that’s increased to 30 items.”
Their workshop currently contains exclusively Mazak machines, ranging from a Quick Turn 150 to the newer Integrex j-200. They use the QT150 and their QTN200M to produce integral drill steels and the Integrex is used for jobbing. There are also several manual machines, which are used to train up apprentices before being moved to the CNC machines.

Dale Bonetti has pioneered the machining side of Firefly, introducing their first CNC machine 8 years ago, a T1 with a universal controller they have since quadrupled their capacity. He explains his reason for choosing Mazak as their favoured brand: “…they just seem to be the easiest to train with. When using the conversational controls they’re almost effortless to operate.”

Ease of use when training is important as the quicker operators become comfortable with the machine the less downtime is required. The Mazak conversational controller is renowned for its speed of programming and intuitive operation. Coupled with John Hart’s training and service programs, it becomes very easy to change over to a new machine, using the new technology. With the introduction of the Integrex j-200, it took approximately three days to get the workshop fully operational again.

The ERF with two engineers repairs over 250 boards per annum, which represents approx 98% of all repairs undertaken, with the balance going back to Japan for repairs. They’re also called on for unusual field service visits and in house training programs.

The ERF capability includes the repair and;

• Reconditioning and testing for all Mazak/ Mitsubishi CNC systems from T1 to Matrix
• Spindle controllers, both AC and DC
• Servo amplifiers, both AC and DC
• CNC control PCB’s including Input / Output modules, CPU cards, Memory PCBs and servo processors
• CNC software upgrades
• Data backup and CNC system recovery
• LCD and CRT monitor repairs and retrofits

Regardless of their location in Australia, our customers can send faulty electronic / electrical parts, have them fixed and sent back quickly, minimizing machine downtime and loss of revenue.
All parts used meet or exceed original manufacturer’s specifications.

All repairs undergo vigorous testing in our new purpose built, in house testing facility.
To maintain the quality of work, and to keep up-to-date with the technology on newer machines, we are conducting an intensive in house training program for three staff members in November. Each engineer will learn new techniques to approach potential problems and learn about new technologies in the recently released range of Mazak machines.
This will enable our staff to continue to efficiently service all machines in the Mazak range providing a quick response and quality work.

This prestigious event is sponsored by the Industrial Designers Society of America (IDSA) and this year had more than 2,000 entries. There were 27 gold winners, 68 silver and 96 bronze. Each product is judged on functionality and ergonomics as well as aesthetics. The Hyper Variaxis was the only machine tool to receive an award.

For the past thirty years, IDEA has been the most prestigious industrial design award contest in North America.

Visit the John Hart Machine Tools Youtube Channel.

Find out more about the Integrex range here:
Mazak Integrex j-Series
Mazak Integrex i-Series
Mazak Integrex e-H II Series
Mazak Integrex e-V II Series

Contact our Sales Engineers

Robbie O’Brien has an undeniable passion for machining, and the success of his Dandenong-based CNC machining business FlexiCut Engineering is a true testament to how hard work and being good at your trade can pay off.

After completing a fitting and turning apprenticeship in one of Australia’s leading V8 Supercar race teams, Mr O’Brien worked for John Hart specialising in CNC machining and training before taking the gamble and investing in his own business.

Mr O’Brien is quick to give credit where credit is due and says he has a great deal of respect for the professional training and valuable experienced gained during his time at John Hart,

“John Hart not only taught me the ins-and-outs of the latest in CNC machinery and associated technologies, but also instilled their motto of how experience and technology can equal success which has been the foundation on which we’ve built FlexiCut Engineering.”

Showcasing the latest in CNC machinery with an impressive Mazak machine workshop and many years of experience of CNC machine tooling and CAD/CAM programming, FlexiCut Engineering caters to all CNC machining requirements.

Mr O’Brien states the success of his business is, “as simple as, offering our customers an efficient service of superior quality at a competitive price” – all critical qualities within motorsport.
As a direct result of working within the motorsport industry for many years, Mr O’Brien quickly learnt the importance of his workshop delivering exceptional quality work on time – every time.

Understanding what clients expect of them and that there is no such thing as ‘near enough is good enough’, Mr O’Brien is quick to communicate the responsibility CNC machinists have and why he instils the importance of each part meeting its technical specifications before it leaves the front door.

“Through years of working within motorsport I have learnt how critical it is to deliver quality parts by focusing on cost-effective, technically superior manufacturing techniques, vigilant quality control and short manufacturing lead times,” says Mr O’Brien.

Mr O’Brien has built FlexiCut Engineering with that attitude and always follows three important rules in order to maintain his success explaining, when producing parts, “it’s got to be done fast, the quality has got to be there, and it must be cost effective for everyone involved.

“Race teams can’t afford to waste money on poorly manufactured parts that aren’t delivered on time – there’s no room for error in this sport”.

In motorsport in particular, if the required part is not manufactured to the highest quality and on time, the race car is loaded onto the truck incomplete and that can cost the team time and money. Mr
O’Brien goes on to state how there is a direct correlation between how well you achieve in the workshop to how well you perform on the track.

“Having good race results at the end of the day make up the most memorable moments of working within a race team, and even knowing how FlexiCut is contributing to a team’s success today makes all the hard work worthwhile.”

Speaking to Robbie about his company, it’s easy to see why he’s been so successful. His passion for engineering and motorsport is infectious, although he’s quick to point out how hard work has been the biggest factor in growing his business, putting in long hours, working all night in order to complete parts, “CNC machining is an amazing trade that can provide great satisfaction at the end of the day when you see how your components are being used to achieve great things,” says Mr O’Brien.

Mr O’Brien describes how the Australian motorsport industry is cut-throat, and if you want to be running up the front of the pack you need to have state-of-the-art equipment in the workshop and in-house design facilities, “It’s a competitive industry and time and money are critical components in running a successful race team.”

Traditionally teams would buy race components off mainstream suppliers resulting in over 30 cars on the track running identical parts. Whereas today’s advanced CNC technology allows teams to precisely manufacture individual components to perform with perfection.

CNC machining is an essential component in any successful team’s setup. Their ability to convert raw material to a finished component in a single machine set-up, multi-tasking machines provide innovation to 21st century manufacturing industry.

The VCS Series features an 18kW, 12,000 rpm BT-40 taper spindle that provides impressive metal removal rates. A 30 tool magazine with tool-to-tool change time of just 1.3 seconds helps optimize productivity.

A variety of Intelligent Machine Functions further simplify operation and boost reliability and productivity. AVC (Active Vibration Control) increases accuracy and tool life by minimizing machine vibration. ITS (Intelligent Thermal Shield) further ensures accuracy by actively managing heat displacement. IMS (Intelligent Maintenance Support) aids with preventive maintenance by tracking and reporting the status of the machine’s perishable items, such as filters and cover wipers.

Ergonomics received special attention throughout the design of the VCS Series. The machine provides convenient loading and unloading of parts by offering a large front door opening and a tool clamp/unclamp switch located next to the spindle. Additionally, the operator door includes a top cover opening to facilitate use of a crane for materials handling.

The new Mazak MX Hybrid Roller Guide System is integrated into the VCS Series to deliver levels of durability and reliability that result in long-term accuracy. The Mazak MX Hybrid Roller Guide System increases vibration dampening to extend tool life, handles higher load capacities, accelerates and decelerates quicker to shorten cycle times, consumes less oil for “Greener” operations, and lasts longer with less required maintenance.

The Mazatrol Smart CNC control keeps operation easy by offering conversational and/or EIA/ISO programming and simplified set-up, allowing for the fastest possible completion of a first part.
The Smart CNC control also tracks and provides detailed tool information and offers the ability to perform time study analysis of operations.

The VCS Series represents further extension of Mazak’s Smart line of machines, which was introduced via the Quick Turn Smart series in late 2009. Made in Japan, the Smart Series machines seek to optimize user-friendliness, while providing reliable, high productivity performance at an affordable price point.