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A Smooth Evolution of Machine Tool Control



"Machine tool computer numerical control (CNC) has just experienced a dramatic evolution - one that expands the concept far beyond what a machine's control typically represents," said a Mazak spokesperson. "At the heart of this evolution is a new complete process-performance technology platform that spans the entire part production landscape from programming and set-up to actual metal removal operations to automation to monitoring/data collection and transfer."

Called SMOOTH TECHNOLOGY, and developed by Mazak, the all-encompassing concept is designed to combine the advanced capabilities of today's machine tools and leading-edge CNC processing and software technologies with that of Mazak's process engineering expertise.

"With manufacturing technologies continuously growing more complex, SMOOTH TECHNOLOGY embraces and incorporates those latest advancements and presents them in an easy to use and understand, intuitive and highly dynamic platform that continues to evolve and expand," said the spokesperson. "As such, it always fulfills the process control needs of each specific industry sector while providing today's manufacturers with the tools they need to increase productivity."

For its SMOOTH TECHNOLOGY, Mazak engineered a new CNC called MAZATROL SmoothX as well as new machine hardware and servo systems. Mazak developed every function of the MAZATROL SmoothX CNC in direct response to real-world issues and customer input. "Its functionality and ergonomics make it the industry's most progressive machine tool control," said the spokesperson.

Mazak reported that it has essentially quadrupled the new CNC's interpolation speed over previous generation controls. The new control interpolates code and sends it to the machine tool servos in the shortest time possible. With such high performance, Mazak said that shops can eliminate two of the most common CNC bottlenecks - sluggish hardware and slow processing speeds - to dramatically shorten machining times and enhance such operations as full simultaneous 5-axis machining and complex mold machining.

To further strengthen performance and reduce machining cycle times, MAZATROL SmoothX CNC technology is designed to deliver innovative new functions such as Intelligent Pocket Milling, Seamless Corner Control and Real-Time Tuning.

Intelligent Pocket Milling 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," said the spokesperson. "This results in the full use of a machine tool's power capabilities and up to 35% faster and more efficient machining of even the most difficult-to-cut materials."

MAZATROL SmoothX CNC's Seamless Corner Control is designed to reduce vibrations and help shorten part machining cycle times through cutter path adjustments made when machining into corners. Rather than moving the cutter directly into a 90° corner, the function inserts a preset radial tolerance. "This tolerance eliminates any dwell resulting from a rapid deceleration in the axial movement often associated with conventional corner machining," said the spokesperson. "Thus, corner surfaces are smoother, the risk of cutter gouging is reduced and cutters can feed much faster."

With the Real-Time Tuning function of the MAZATROL SmoothX CNC, turning machine tool turrets index quicker to help shorten machine tool non-cut times. Whether turrets are fully loaded, partially loaded or have heavier tools on one side as opposed to the other, Real-Time Tuning detects turret loads and automatically adjusts the acceleration and deceleration of the turret indexing speed to maintain an optimum balance.

Besides its performance functions, the MAZATROL SmoothX CNC provides up to six user control security settings. Shops can set data editing/overwriting permission for every input box on every screen per particular user. Users can access screens and view program data, but depending on their preset security level, they may be limited as to what they can and cannot change. A screen may have 24 inputs, and a security level could be set so that certain users can edit or overwrite only one input, other users only 10 and a select few users all of them. This helps prevent errors and ensures that only those who are qualified can make changes.

On the part programming side, MAZATROL SmoothX CNC offers several innovative functions designed to streamline and simplify the process. These include Quick MAZATROL, Quick EIA, full 5-axis 3D simulation and soon to be added View Surf, to name a few.

Quick MAZATROL allows for the direct importation of 3D CAD models into the MAZATROL SmoothX CNC. And with that data, users can then view a part model and click on a specific geometry or geometries for which they will develop a MAZATROL conversational program. The function then pulls the coordinates from the solid model to provide programming assistance.

"Prior to such technology, shops had to physically look at a blueprint, make calculations and then enter the necessary values to create the program," said the spokesperson. "With the actual solid model imported into the machine's control, a single mouse click eliminates all those time-consuming steps when programming at the machine on the shop floor."

The Quick MAZATROL function reduces the number of keystrokes needed to generate a program. "Machine idle time thus drops significantly, and operators can quickly perform real-time checking/comparing of the model form to that of how it will be machined in the part," said the spokesperson.

"Think of it as a hybrid born from the marriage of a CAM system and conversational programming," said Neil Desrosiers, Applications Engineer/Developer at Mazak. "Shops are now able to use a solid model to obtain part geometries, but still program conversationally. This means that with SMOOTH TECHNOLOGY users do not have to know how to use a CAM system to work from a solid CAD model to create programs."

With programming/set-up speed in mind, Mazak equipped its MAZATROL SmoothX CNC with Quick EIA, which allows users to generate any toolpath prior to running the program. "But most importantly, the function boosts toolpath simulation speed by as much as 99% and simplifies the process," said the spokesperson. "Plus, there is extremely accurate full 5-axis 3D machining simulation and interference checking capability."

According to Mazak, the secret behind the fast simulation speed of Quick EIA is that the MAZATROL SmoothX CNC incorporates the use of today's new advanced graphics technology. These are, according to Desrosiers, basically the same type used to generate the graphics for gaming systems.

Mazak also applied these advanced graphics to the 5-axis 3D simulation function of the MAZATROL SmoothX CNC. With such capability, users can run real life part programs in simulations to check for errors and machine interferences. According to the company, these extremely realistic and precise simulations use the exact same machine movement parameters as actual Mazak model machines.

Once a toolpath is generated, the upcoming View Surf function in the MAZATROL SmoothX CNC will provide toolpath data analysis. Users will indicate that they wish to check G-code, and the function will generate the whole toolpath on the screen and indicate all errors. Once users simply zoom in and click on those specific error locations, the function will automatically bring up the exact corresponding line in the actual program. This will eliminate the need of having to scroll through the entire program to find one exact point along the toolpath.

"The View Surf function means fewer test cuts will be required, and shops will get the first part faster," said the spokesperson. "Plus, workpiece surface finishes will be much smoother."

At the human machine interface (HMI) level, MAZATROL SmoothX CNC features an entirely multi-touch home screen that, within a single page view, presents all critical data to operators. This allows them to instantly jump from the home screen to any other area or section within the CNC. They can also use a fingertip to pan, rotate or zoom and otherwise manipulate a 3D part rendering of the component being machined. Or, they can flick an area of the screen to scroll through the displayed program G-code. All MAZATROL SmoothX CNC screen functions are similar to those of a smart tablet.

The control's streamlined navigating/dashboard-type screen displays typical data output such as machine rapid speeds, horsepower, axis positioning, machining loads, estimated time of part completion and more. There are location buttons and an EIA window that displays G-code lines of the program.

Additionally, the new control provides the capability to monitor up to five additional machines that may be together in a cell or near each other. Thus, operators responsible for multiple machines can easily track their status from one machine display to eliminate the need to physically go to each machine in the group.

Because of advanced screen technology, MAZATROL SmoothX CNC consoles are the same physical size on every machine. In the past and depending on the machine type, the number of buttons determined its size. "The new control, however, will never vary in size because Mazak has designed it to include the necessary information, options and features for every Mazak machine type," said the spokesperson. "Also, a common bank of buttons remains constant from one control panel to the next, which makes it even easier for operators to go from one type of Mazak machine to the next."

With its larger machines in mind, Mazak made the Manual Pulse Generator (MPG) for the MAZATROL SmoothX CNC wireless. This gives operators freedom to move around and inside the machine untethered for executing manual operations, such as touch probing.

For digital manufacturing functionality, SMOOTH TECHNOLOGY supports MTConnect and includes an NC Data Library - an Ethernet interface to a library of data-accessing functions for programmers if they wish to write software to communicate with the machine via an Ethernet network. This also means that machines can have an MTConnect adapter and that users can collect data from the CNC.

Mazak is also applying SMOOTH TECHNOLOGY to its PALLETECH Manufacturing Cell (PMC) software and will call it PMC Smooth. Additionally, the company's Cyber Production Monitoring software will transition to what will be known as Smooth Production Center. Both of these new systems will have the same graphical look and functionality as the SMOOTH TECHNOLOGY applied to Mazak's machine tool CNCs.

For more information contact:

Tasha Riddell

Mazak Corporation

P.O. Box 970

Florence, KY 41022-0970

859-342-1700

triddell@mazakcorp.com

www.mazakusa.com

Southwest

Dana R. Scott

Mazak SW Technology Center

10950 Greenbend Blvd.

Houston, TX 77667

281-931-7770

dscott@mazakcorp.com

www.mazakusa.com

LA

Richard Cahn

Dixie Mill Machine Tools Co.

901 Tchoupitoulass Street

New Orleans, LA 70152

504-525-6101

800-462-9519

rcahn@dixiemill.com

www.dixiemill.com

OK, AR

Butch Cumminsky

David James

Machinery Resources Inc.

5550 South 94th East Avenue

Tulsa, OK 74145

918-622-6495

800-448-1878

butch@mritul.com

www.mritul.com

N. TX

Chris Papke

Mazak Corporation

2000 East Lamar Blvd, Ste. 600

Arlington, TX 76006

800-642-6110

El Paso, TX

Felipe Arvizo

Magnum Precision Machines Inc.

12025 Rojas Dr. Suite A

El Paso, TX 79936

915-856-7900

farvizo@magnumep.com

www.magnumprecisionmachines.com

NM

Chris Edgar

Magnum Precision Machines, Inc.

8448 Washington Place NE

Albuquerque, NM 87113

505-345-8389

cedgar@magnumabq.com

www.magnumprecisionmachines.com

Southeast

Dave Kennedy

Mazak Southeast Technology Center

1075 Northbrook Parkway

Suwanee, GA 30024

678-985-4800

dkennedy@mazakcorp.com

www.mazakusa.com

TN

Dennis McCurry

Pinnacle Machine Tools, Inc.

5912-A Toole Drive

Knoxville, TN 37919

865-951-0260

mccurry@pinnaclemachine.net

AL

Jerry Edwards

Pinnacle Machine Tool Inc.

141 Nick Fitcheard Road

Huntsville, AL 35806

256-852-0900

edwards@pinnaclemachine.net

NC, VA

Rick Smith

MachineTech, Inc.

8100-J Arrowridge Blvd.

Charlotte, NC 28273

704-665-6301

rick@machinetechcnc.com

www.machinetechcnc.com

GA, SC

Tim Kramer

Premier Engineering Co.

1635 Lakes Pkwy. Ste. U

Lawrenceville, GA 30043-5858

678-442-8382

tim@premierengineering.com

www.premierengineering.com

MS

Richard Cahn

Dixie Mill Machine Tools Co.

901 Tchoupitoulass Street

New Orleans, LA 70152

504-525-6101

rcahn@dixiemill.com

www.dixiemill.com

FL

John Grabenau

Premier Machinery Inc.

990 Sunshine Lane

Altamonte Springs, FL 32714

407-786-2000

doc@premierequipment.com

www.premierequipment.com

Northeast

New England, E. NY, NJ

Steve Wilkins

Mazak Northeast Technology Center

700 Old County Cir.

Windsor Locks, CT 06096

800-436-8900 / 860-292-4400

SWilkins@mazakcorp.com

www.mazakusa.com

E. PA, MD, DE

Jim Rutan

Mazak Mid Atlantic Office

1275 Glenlivet Drive

Allentown, PA 18106

jrutan@mazakcorp.com

www.mazakusa.com

W. NY

Bill Miller

A.W. Miller Technical Sales

East Aurora, NY

716-652-8282

bmiller@awmiller.com

www.awmiller.com

W. PA

Russ Weis

A.W. Miller Technical Sales

3 Tara Drive

PO Box 220

Harmony, PA 16037

724-453-1690

rweis@awmiller.com

www.awmiller.com

Midwest

Kevin Bates

Mazak Midwest Technology Center

300 East Commerce Drive

Schaumburg, IL 60173

847-885-8311

kbates@mazakcorp.com

www.mazakusa.com

ND, SD, MN

Joel Lundin

Tony Bailey

Northwest Machine Technologies, Inc.

20851 Commerce Blvd.

Rogers, MN 55374

763-493-3660

tbailey@nwmtec.com

www.nwmtec.com

NE, W. IA

Duane Ohlrich

Industrial Systems & Supply Inc.

2760 E. 29th Avenue

Columbus, NE 68601

402-564-4445

ohlrich@industrial-systems-supply.com

www.industrial-systems-supply.com

E. IA

Kevin Bates

Mazak Midwest Technology Center

300 East Commerce Drive

Schaumburg, IL 60173

847-885-8311

kbates@mazakcorp.com

www.mazakusa.com

MO, S. IL

Bill Summers

Municipal Tool & Machinery Co.

2465 Rock Island Blvd.

Maryland Heights, MO 63043

314-994-9905

bsummers@municipaltool.com

www.municipaltool.com

KS

Paul Domurat

Concept Technical Sales, Inc.

6240 W. 135th St.

Overland Park, KS 66223

913-647-5366

pdomurat@concepttechsales.com

www.concepttechsales.com

WI

Mike Cekanor

Machinery Systems North

3280 Gateway Rd.

Brookfield, WI 53045

262-781-4850

mikec@machsys.com

www.machsys.com

IL, N.W. IN

Ron Mager

Machinery Systems Inc.

614 East State Parkway

Schaumburg, IL 60173

847-882-8085

ronm@machsys.com

www.machsys.com

E. MI

Peter Addy

Addy Machinery Co.

36055 Groesbeck Highway

Clinton Township, MI 48035

586-741-3000

800-ADDY-NOW

peter@addymachinery.com

www.addymachinery.com

W. MI

Peter Addy

Addy Machinery Co.

3757 Broadmoor Ave SE, Ste. A & B

Grand Rapids, MI 49512

800-AddyNOW

peter@addymachinery.com

www.addymachinery.com

S. OH

Greg Papke

Mazak Corp.

8025 Production Drive

Florence, KY 41042

859-342-1700

gpapke@mazakcorp.com

www.mazakusa.com

IN, KY

Jim Shelton

Shelton Machinery, Inc.

9900 North by Northeast Blvd.

Fisher, IN 46037

317-845-5588

jshelton@sheltonmachinery.com

www.sheltonmachinery.com

N. OH

Frank Gibbons

Numerequip

4810 Briar Road

Cleveland, OH 44135

216-265-0400

fgibbons@numerequip.com

www.numerequip.com

West

CO, E. WY

Randy Breitenbach

Action Machinery International

4950 Oakland Street

Denver, CO 80239

303-532-2900

randy@action-machinery.com

www.action-machinery.com

WA, N. ID

Gary Anderegg

Machine Toolworks, Inc.

14600 Interurban Avenue South

Tukwila, WA 98168

206-575-3390

ganderegg@machinetoolworks.com

www.machinetoolworks.com

OR

Alex Madsen

Machine Toolworks, Inc.

27350 SW 95th Ave., Ste. 3032

Wilsonville, OR 97070

503-682-9030

amadsen@machinetoolworks.com

www.machinetoolworks.com

AZ

Chris Edgar

Magnum Precision Machines

3614 E. Southern Ave. #1

Phoenix, AZ 85040

602-431-8300

cedgar@magnumabq.com

www.magnumprecisionmachines.com

UT, S. ID, MT, W. WY

Clark Smith

Smith Machinery Company

41 W. Guest Avenue

Salt Lake City, UT 84115

80l-263-6403

csmith@smithmachinetools.com

www.smithmachinetools.com

S. CA

Richard McCauley

Mazak West Regional Headquarters and

Aerospace Technology Center

1333 West 190th Street

Gardena, CA 90248

310-327-7172

rmccauley@mazakcorp.com

www.mazakusa.com

N. CA

David Lindenmuth

Mazak San Francisco Sales and

Technical Center

1497 N. Milpitas Blvd.

Milpitas, CA 95035

408-941-2240

dlindenmuth@mazakcorp.com

www.mazakusa.com

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