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HARTBEATAutumn 2011 Edition

Mazak’s Five Levels of Multi-TaskingNew Smart SeriesCitizen A32-VIIJayben Australia Pty LtdV & C EngineeringNew Integrex j-Series

HARTBEATMachine Tools

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From the GM’s DeskOver the last 65 years our company has faced and overcome many challenges and as you would expect over such a long time, we have experienced market booms and collapses, significant world events, changes invv governments, global financial crises and natural disasters.

What we learned from this, is that the companies that have excelled over a long period are the ones that have been able to maintain a strong focus and commitment to their customers, have offered great products and support and have been able to embrace new ideas and opportunities.

World leading companies like Mazak and Fanuc, have always been able to create future opportunities by preparing their businesses ahead of the next market cycle. They plan for downturns during market booms and prepare for booms during market downturns. This far sighted approach has meant they are able to hit the ground running when the next market change eventually occurs.

An example of this was when Mazak increased the size of their engineering research and development departments during the recent global financial crisis. While demand for their products had reduced, Mazak continued to invest in new product development and customer support facilities.

The result has been their ability to release over forty of the most advanced, most efficient and smartest new machine tools, just as world markets are starting to improve.

As we start to move into a growth cycle, now is the ideal time to invest in your company with the most advanced and efficient machine tools and robotics on the market. Taking advantage now of the recent investment made by our Principals in better products, will help position your business to take full advantage of the market upturn.

After 65 years, John Hart remains committed and focussed on supporting customers Australia wide. We offer market leading products and have a comprehensive support structure to help your business gain that competitive advantage.

I hope you enjoy our new look stand at Austech this year, I look forward to seeing you there.

Nicholas Rehfisch

John Hart News

John WoodbridgeWell known and well respected over many years with John Hart as Victorian Branch Manager, John has taken the opportunity for a move to Port Stevens on the NSW Central Coast, where he joins our NSW sales team as Senior Sales Engineer. John is now focused on supporting our customers in the northern Sydney and northern NSW market.

Ian SwanAnother well known and respected name in the Australian machine tool industry, Ian is a welcome addition to John Hart’s Victorian sales team as Senior Sales Engineer.

Peter ConroyBuilding on the experience of serving in a variety of technical roles over more than 20 years with John Hart, Peter has recently taken on the role of Victorian Support Supervisor. Peter will no doubt “raise the bar” on customer service and technical support delivery to our Victorian customers.

John Hart is pleased to welcome a number of new faces to our technical support teams across Australia: Luke Lazzara - Service Engineer VIC Davide Azzollini - Service Engineer SA Dragan Boskic - Service Engineer NSW Kevin Cullen - Applications Engineer NSW

Check our new web site at www.johnhart.com.au for the latest news from John Hart.View latest machine tool models and applications at John Hart on Youtube at www.youtube.com/user/JohnHartPtyLtdThe latest John Hart news and machine tool deals are also found on Machines 4 U at www.machines4u.com.au/directory/John-Hart-Pty-Ltd/443/

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ON THE WEB

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Mazak’s Five Levels of Multi-TaskingYamazaki Mazak continues to grow the industry’s most comprehensive product offering of Multi-Tasking machines with the introduction of its new Integrex j-Series machines and the expansion of its Integrex i-Series machines. The j-Series and i-Series are part of Mazak’s Five Levels of Multi-Tasking matrix, which has been developed to ensure that customers choose the Multi-Tasking machine that best meets their application needs.

Mazak’s new five levels of Multi-Tasking technology streamlines the machine selection process. Using this five-level matrix, the full range of Mazak’s Multi-Tasking machines are organised based on their functionality, capabilities, and on the workpiece types and production volumes for which they are best suited.

Each level in Mazak’s Multi-Tasking segmentation represents a progression in machine capability and complexity of application. Collectively, the five levels encompass small to large machines providing simple to complex functionality and applications ranging from prototyping to high-volume production.

“Mazak has long been equated with Multi-Tasking, and has never stopped innovating when it comes to this technology,” said Brian Papke, President of Mazak Corporation in the U.S. “We continuously improve our Multi-Tasking technology products by developing new machines to meet the specific needs of our customers, as well as adding to and improving on the functionality of our existing lineup. Over the years, we have improved spindles, making them more compact while increasing torque ratings. We have also developed new technologies for faster rapid traverse rates, quicker automatic tool changes, and shorter part cycle times.”

“Not all Multi-Tasking machines on the market today are created equal, and Mazak provides the most advanced and largest selection available. We continue to push beyond past capabilities to expand the limits of this technology to maintain our standing as the leader in Multi-Tasking machines. Categorising our Multi-Tasking machine offering into five levels, from simple Multi-Tasking to our Ultra-Tasking, allows customers to easily navigate our product lines and select the best Multi-Tasking machine for specific applications.”

Level OneLevel one Multi-Tasking includes simple turning, milling, drilling, and tapping operations done on machines with one turning spindle and one drum-style turret which includes rotating-tool capabilities. Mazak product families in this level include the Quick Turn Smart, Slant Turn Nexus, Megaturn Nexus, and IVS Turning Centre.

Level TwoLevel-two Multi-Tasking involves level-one Multi-Tasking operations performed with the added implementation of Y-axis functionality for the machine drum turret. Level-two machine families include Mazak’s single-spindle (or with second spindle) and single-turret Quick Turn Nexus machines and its Hyper Quadrex and Mulitplex machine families, all of which can include a second spindle and second turret.

Level ThreeLevel-three Multi-Tasking operations progress with additional machining capabilities provided by an independent milling spindle headstock with B-axis indexing, longer Y-axis travel motion, and tool magazine for increased tooling capacity. With an added milling spindle and tooling magazine, level-three machines boost efficiency for 4½-axis Multi-Tasking operations. Mazak’s new Integrex j-Series forms the foundation of its third level of Multi-Tasking.

Level FourLevel-four Multi-Tasking is full, simultaneous, five-axis machining, with an emphasis on automation and machining large heavy parts.

Three product families in level four are the Integrex i-Series, Integrex e-Horizontal Series, and Integrex e-Vertical Series of machines.

Mazak’s expanded i-Series provides shops with increased tooling capacities and the ability to automate through a barfeeder or gantry loader. The Integrex i-Series of machines are Mazak’s progression of the current Mk IV Series. Integrex e-Horizontal Series and Integrex e-Vertical Series machines deliver full simultaneous, five-axis machining capabilities for larger, longer, and heavier parts.

Integrex e-Horizontal Series machines can be automated with robots, while Integrex e-Vertical Series machines achieve automated operation through Mazak’s Palletech system.

Level FiveMazak’s Ultra-Tasking fifth level is comprised of level-four full-function Multi-Tasking, but with additional special-task capabilities. These additional capabilities include nontraditional processes for this style of machine and include gear cutting, honing, grinding, and polishing operations.

Each machine model in Mazak’s five levels of Multi-Tasking feature the company’s new MX Hybrid Roller Guide System, which increases rigidity, durability, speed, and accuracy and the Mazak developed “Intelligent” functions, which give the machines a “central nervous system” enabling them with the ability to react to changes in their environment. These are essential components on Mazak’s highly versatile machine tools.

The new Integrex i-Series

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Quick Turn Smart Series

Mazak Super Turbo-X MkIII

Mazak’s New High Productivity Quick Turn Smart (QTS) Series Turning Centre Ideal for Job Shops

The QTS Series is the latest in the lineage of one of the most popular CNC machine tool ever made – the Mazak Quick Turn. Since it’s introduction in 1981, the Mazak Quick Turn quickly gained a reputation for efficiency, quality, affordability and unquestionable reliability. The QTS Series features the new Mazak MX Hybrid Roller Guide

System on the X- and Z-axes to ensure high rigidity and smooth cutting. The QTS Series also features X-axis ball screw pretension for high accuracy.

The Mazak MX Hybrid Roller Guide System is integrated into the QTS 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 recently developed Mazak Smart CNC control simplifies turning operations on the QTS series. Mazak Smart is designed for ease

of operation and offers a 10.4” LCD colour display and the familiar QWERTY keyboard. A pointing device, acting like a mouse, is also at the operator’s fingertips. Conversational part programming can also be accomplished. Mazak SMART control also accepts EIA/ISO programs.

The machine also features an NC servo-driven tailstock to enable automated processes. The tailstock is fully programmable, driving the W-axis on its own AC servomotor and ball screw. Through the part program, the tailstock will retract to a known position until its centre makes contact with the part with consistent holding pressure. Further, because of its positive independent drive system, the tailstock can be used to drill holes on a shaft centreline adding versatility to the jobs it can process.

Mazak’s new Super Turbo-X Mk III is a flexible, rugged workhorse designed to offer significant technical advantages and standard features for a variety of material types and thicknesses.

The Mark III has been designed utilising Mazak’s proven hybrid platform with an easy access table. It features a proprietary vibration dampening frame and integrated laser resonator that ensure stable, high accuracy cutting. The constant-beam length construction provides uniform cutting performance across the machine table.

It incorporates leading edge laser technology. The Mark III utilises many features developed for Mazak’s Hyper Series machines. They include intelligent setup functions for automated nozzle spatter removal, a three station nozzle changer and focal point measurement and adjustment capability. The Mark III also incorporates a new Servo Focus Torch. This servo driven system significantly reduces piercing time and increases productivity. Additional new technology includes a

High Accuracy Auto Centering Lens and Nozzle design that further reduces setup and increases productivity

The combination of rugged reliability and the implementation of leading edge technology delivers Rock Solid Performance.

STX 48 Mark III STX 510 Mark III STX 612 Mark IIIMachine Design HybridTable Sizes 101.6 x 203.2mm 127 x 254mm 152.4 x 304.8mmResonator 2.5 kw (.87” CRS), 4.0 kw (1” CRS)X, Y Positioning ±0.01/500mmRepeatability 0.005mm

All machines come with Servo Focus Torch, Automated Nozzle Spatter Removal, Automated Nozzle Changer, Automated Focal Point Measurement & Adjustment, Scrap Conveyor System and Auto Material Clamps.

The Mazak Super Turbo-X 510 Mark III Laser Centre

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Vertical Centre Smart Series

Citizen A32-VII

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.

The Citizen A32-VII offers 32mm large diameter machining at an unbeatable low price. Although inexpensive the machine is strong, powerful and rigid giving it exceptional cutting performance.

With features like a rapid feed rate of 45m/min, high speed processing

with the latest NC unit, and Citizen’s unique streamline control, it achieves 30% higher productivity than previous machines. To make high-accuracy machining possible the design takes thermal displacement into account carefully considering factors such as the shape of the bed and the placement of the electrical cabinet.

As standard the machine is equipped with 7 axes, 6 turning tools, 4 rotary tools for cross-machining, 9 tools for back-end machining and 5 tools for front-end machining. This gives a total of 23 tools allowing great flexibility. Many different tooling configurations are available to tailor the machine to your requirements.

Maximum cutting length is 320 mm in one chucking. However,

with the optional long work piece unit, components up to 400 mm can be machined. The main spindle is driven by a 5.5 kW motor and the sub-spindle has a 2.2 kW drive. The rotary tool drive also has a 1 kW, AC spindle motor with a maximum speed of 5,000RPM.

Rapid traverse rate is increased to 45m/min for a large reduction in idle time from previous models.

Comprehensive standard equipment, space-saving design, easy operation, low running costs and high productivity - all at an extremely attractive price makes the A32-VII a must-have purchase for both newcomers to sliding head and existing users looking to increase their capacity.

Mazak’s Vertical Centre Smart

HARTBEATMachine Tools

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Jayben Australia Pty Ltd

An interview with the Ken Johnson, the Managing Director of Jayben Australia Pty Ltd

What type of products does your company produce?

Our company is involved in three industries: We’ve got a manufacturing license with GKN Walterscheid to manufacture parts for a range of agricultural driveline products in Australia for the Australian and New Zealand market.

We are a major supplier to Caterpillar, or Cat Underground in Tasmania of driveshaft’s and drive shaft components and some other components.

We also have a business based in Tasmania which makes a range of small road sweepers and they’re fabricated and sold out of Tasmania but a lot of the machined components are made here in Adelaide.

Why did you decide to purchase a new machine? And how were you able to internally justify this investment?

Really this latest machine was purely based on workload, particularly for Caterpillar. Our factory here in Adelaide is set up into three distinctive areas.

One cell manufacturers all the agricultural driveline components,

the other cell assembles the driveshaft and does all the dispatch work and a third cell manufacturers all the components for the Caterpillar drive shafts. It’s in that area where we were short of machine capacity and needed an extra machine.

So those operations are completely separate of each other?

There is a little bit of overlap between the different cells depending on the workload at the time, but we try and run them as separate entities.

You purchased a Mazak VCN 510C; why did you purchase this particular machine over others in the Mazak range? And what about this machine makes it a good fit for what you produce?

There was a couple of issues I guess; we really only needed a basic three-axis machining centre because of the type of work we do, but we did specifically want something with through spindle coolant. Along the way, we found we could fit it with a probe system. Quite often, because of the geometric tolerances of the components we make, each part will need to be clocked up before the machining starts. The use of the probe system saves a huge amount of time in changing from one part to the other. We obviously got quotes from

other suppliers, but in the end the thing that really sold us on the Mazak was the delivery schedule.

We needed something really quickly, we’ve got two other Mazak machines in the place, we’ve always been enthusiastic about Mazak’s because of the quality of the machines for a start and secondly the backup (service, technical back up, spare parts) which has always been really good.

John Hart came up with a pretty good deal for a quality machine so in the end it was an easy decision.

Is this the first time you have dealt with John Hart Machine tools?

We bought our first Mazak machine 21 years ago, while there was a bit of a drought in between, we bought a lathe 18 months ago and now we’ve bought this machining centre.

What part of the operation was the lathe bought for?

The lathe was bought specifically for manufacturing these agricultural driveline yolks. Unfortunately because of the workload we’ve had from Caterpillar we’ve never made an agricultural yolk in it, and all it’s doing is assisting in making Caterpillar parts.

But we bought this machine which has live tooling on it, because there are a number of products which have been included in our license with GKN Walterscheid that really lend themselves to a lathe with live tooling. We haven’t actually started to make those products yet, but we need to as soon as we can get into it.

Could you talk about the machine you were using before the VCN and how it differs?

This is a minor upgrade from the machine we used previously, which we’ll continue to use, but the advantages of the new machine are the through spindle coolant, the higher rapid speed, better accuracy, and quicker tool change. Chip-to-chip, it’s much quicker than the machine we used previously.

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Every workshop comes to a point where they need to invest in new machinery. We spoke to V & C Engineering about their recent Mazak purchase and their working relationship with John Hart.

V & C Engineering is a job shop located in Hoppers Crossing, Victoria, owned and run by Bill Valentan. The company’s working relationship with John Hart has spanned almost 30 years.

“I’ve had a long relationship with John Hart,” Bill says, “there have been no problems which is good, and if we’ve got a breakdown you’re not too far away.”

V & C have built up their workshop, purchasing only Mazak machines. Bill says “the reason we chose all Mazaks for our workshop is because of the controllers and ease of programming, and more importantly, because I’m comfortable with the machines.” As a recent addition to the shop they purchased a Quick Turn Smart to replace their 25 year old machine of the same model, although the machine is still running and completing jobs.

The Quick Turn Smart is a smart CNC turning centre, perfect for job shops and other high production environments. The machine combines productivity, high accuracy and high reliability. This was the right machine for V & C given their low volumes and high variety of jobs.

Because the new and old machines are running in parallel they have effectively doubled their output, creating more work and profit for the shop. This is a testament to the hardworking nature of the Mazak machines which work well beyond their use-by date.

The first noticable difference became apparent after running the machines side by side. Bill says “The new machine is a lot faster, it was a bit daunting at first but we are used to it now.”

The operators are finding the new machine easy to use, having only needed a couple of days training to adapt to the improved methods. One of the biggest changes they’ve come across are the safety features on the new Mazaks. As Bill puts it, “The new machine has a lot of new safety features; this means the machine won’t let you do shortcuts, which can be both a good and bad thing.”

These new safety features ultimately make V & C Engineering a safer place to work, providing piece of mind for both workers and the employer.

John Hart have assisted many workshops like V & C in upgrading machines to help them run their businesses as efficiently as possible. Buying a new machine can seem like a financially daunting task but, it can help you run a more efficient workshop and will pay off in the long run.

With the difference between the old and new machine, has the process of creating a part differed? Have you had to create new programs?

No it’s a pretty quick change over, and because the old machine has a Fanuc controller on it, we wanted to rewrite all the programs in Mazatrol. But it’s not a big deal, the Mazatrol system is pretty easy to come to grips with and so whilst we chose to rewrite the programs, we didn’t really have to because the controller could also run in the ISO language

Have your operators found the new machine easy to adjust to?

Yes they have, because the training provided by John Hart is terrific.

The team from the Adelaide Branch trained us. They’re a good bunch of guys with a wealth of information, they’re also great instructors.

We’ve been working on a special project, which is something a bit out of the ordinary for us, and John Hart has been down here two or three days this week helping us.

It’s a big press tool pressing the hub of a radiator fan out of a mining machine, which is a thing we are doing with a company we have a close relationship with. So whilst we would only do this sort of thing once in a blue moon, this machine has enabled us to do it. With the assistance of John Hart, it’s something we can do, otherwise we probably wouldn’t attempt it.

How long has this project taken from start to finish? You weren’t drawing the designs up were you?

We had to create the model for it; this is only an aftermarket part. They gave us some samples of the parts and we had to get a company to do the initial drawings. One of our guys, with the assistance of John Hart, created the model and now the program is up and running.

Is there anything you would like to add regarding the machine or the installation process?

No not really, like I said you can’t argue with the quality of the Mazak and the backup is as good as you would get from anybody and that says it all I think.

V & C Engineering

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CNC MACHINE TOOLS AUTOMATION & ROBOTICS CNC LASERS CAD/CAM SOFTWARE

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Melbourne11 Winterton RdClayton, VICAustralia 3168

P +61 3 9542 6262

Sydney1/323 Woodpark RdSmithfield, NSWAustralia 2164

P +61 2 9634 7011

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P +61 7 3399 6033

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Perth2/32 Robinson RdBelmont, WAAustralia 6104

P +61 8 9277 6100

Mazak offers a full range of Multi-Tasking Solutions with the new Integrex j-Series.

With the introduction of the j-Series, Mazak now offers a complete range of Multi-Tasking solutions that meet the needs of any manufacturer wishing to implement advanced technology. The j-Series creates an option for machine shops that wish to increase their flexibility and productivity by using Multi-Tasking technology with tool changing capability, while providing a reasonable price alternative for customers that do not necessarily need simultaneous 5-axis machining capability.

The j-Series performs 4-axis simultaneous machining with

5-axis tool tip positioning, providing significant advantages in productivity, accuracy and flexibility. Unlike Multi-Function CNC Lathes with a drum type turret, Mazak’s Integrex j-Series accommodates 20 tools in a tool magazine (20 / 30 / 72 alternative) thereby increasing versatility in part production.

The Integrex j-Series also includes a powerful 12,000-rpm milling spindle that can be indexed in 5º (or optional 1º) increments from –30º to 190º (B-axis control), making it possible to perform many machining operations with the one tool. It also makes it easy to perform incline machining and all other conventional machining processes. The true Y-axis design

allows for a larger machine envelope and tool reach, reduced interference and excellent chip evacuation when compared to conventional machines.

The new Mazak MX Hybrid Roller Guide System is integrated into the Integrex j-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.

Mazak makes the programming of multiple surfaces on the Integrex j-Series easy with its Matrix Nexus CNC Control. The control allows for both conversational and EIA/ISO programming, and ensures easy programming for C-axis, Y-axis and angle machining. Matrix also provides realistic 3D machining simulations, time study analysis and the Mazak Voice Advisor, which assists operators during setup to make initial operations smoother and safer.

“The j-Series creates an option for machine shops that wish to increase their flexibility and productivity...”

The New Integrex j-Series