MACH 2016There were at least three companies at
MACH showing machines that that combined additive and subtractive manufacturing on the one platform.
One of these was Worcester-based Yamazaki Mazak UK Ltd (
www.mazakeu.com), which was showcasing its new Integrex i-400AM hybrid machine (pictured).
This makes use of a built-in 1kW fibre laser to melt metallic powder, which is then applied layer by layer via interchangeable cladding heads. These heads are stored in the machine’s standard 36-tool magazine and provide the ability to automatically change between additive and subtractive tooling, optimising process cycle time.
Once the additive manufacturing process is complete, the machine’s multi-tasking capability finishes the component; and because the machine incorporates a full A and C axes, it can machine and clad using full five-axis operations, further enhancing the range of geometries that can be produced.
The Integrex i-400 AM technology can be used to clad a range of material types, including stainless steel, nickel alloys and copper. This ability to cover a variety of materials makes the machine ideal for a range of applications, from repairing worn or damaged components, to adding critical features or producing new parts.
The show machine was being demonstrated with two new high-performance heads: a high-speed cladding head for high-rate material deposition, delivering a bead size of 3 x 1mm; and a fine cladding head for more-intricate feature generation with a bead size of 1 x 0.5mm, providing robust process flexibility to meet a range ofapplication requirements. Finished parts can also be laser-marked if necessary, using the same head technology.
The machine retains the high level of performance of the Integrex i-series family, including 50m/min rapid-traverse rates, a 30kW 3,300rev/min main spindle and a 22kW 12,000rev/min milling spindle.
It also incorporates Mazak’s latest generation of CNC — SmoothX — which has a 19in touch-screen and can be tilted and rotated to suit the operator.
Richard Smith, managing director of the UK & Ireland sales division, says: “Additive manufacturing is one of the most significant developments in recent years for the world of engineering. Mazak is leading the way in developing a machine that can combine the best of both additive manufacturing and full five-axis subtractive machining — a true example of ‘done in one’ manufacturing.
"Given the potential of additive manufacturing to not only drastically reduce material wastage compared to other manufacturing methods, but also combine a variety of different metals and alloys, we believe the Integrex i-400 AM to be the start of a hybrid machining revolution.”