Smoothing the evolution of CNC

While machine tool CNCs continue to evolve, one development expands that process beyond what a control typically represents. Mazak’s Smooth Technology is a complete process-performance technology platform that spans the part production landscape from programming and setup to metal-removal operations to automation to data collection, monitoring and transfer. It includes the MAZATROL SmoothX CNC, as well as advanced machine hardware and servo systems. This approach combines the capabilities of machine tools and CNC processing and software with that of extensive engineering expertise.

Compared to previous-generation controls, the MAZATROL SmoothX CNC’s speed for interpreting code and sending it to the machine tool servos is about four times faster. Such capability lets shops eliminate two of the most common CNC bottlenecks: sluggish hardware and slow data-processing speeds. This dramatically shortens machining times and enhances operations such as simultaneous 5-axis machining and complex moldmaking.

To further strengthen performance and reduce cycle times, the new CNC offers the Intelligent Pocket Milling and Smooth Corner Control functions.

Intelligent Pocket Milling engages a high-efficiency toolpath when milling cavities. As opposed to conventional offset milling, the function maintains a constant angle of tool engagement and cutting loads to ensure optimal 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 difficult-to-cut materials.

The MAZATROL SmoothX CNC has a streamlined navigating/dashboard-type screen that functions similar to a smart tablet. Image courtesy Mazak.

Based on a preset radial tolerance, the Smooth Corner Control function reduces vibration and helps shorten cycle times by adjusting the toolpath when machining corners. This eliminates any dwell resulting from the rapid deceleration in the axial movement that often is associated with conventional corner machining. Thus, corner surfaces are smoother, the risk of cutter gouging is reduced and cutters feed faster.

On the part-programming side, numerous functions streamline and simplify the process: a human/machine interface (HMI), Quick MAZATROL, Quick EIA (Electronic Industries Association), 5-axis 3D simulation and View Surf.

At the HMI level, the MAZATROL SmoothX CNC has a streamlined dashboard-type screen that functions similar to a tablet’s screen. It features a multitouch home screen that, within a single-page view, displays typical data output, such as machine rapid speeds, horsepower, axis positioning, machining loads and estimated time of component completion.

Quick MAZATROL allows for the direct importation of 3D CAD models into the CNC. With that data, users can view a part model and select, via touch, 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. With the actual solid model imported into the machine’s control, a single finger tap eliminates all the time-consuming steps required when programming at the machine.

Quick EIA allows users to plot any toolpath prior to running the program. But most importantly, the function dramatically boosts simulation speed and simplifies the process. Plus, it can accurately perform full 5-axis 3D machining simulation and interference checking.

Once a toolpath is generated, View Surf provides data analysis of it. The function generates whole toolpaths on the screen and indicates any errors. When a user zooms in and taps a specific error location, the function automatically displays the exact corresponding line in the program, eliminating the need to scroll through the entire program to find one exact point along the toolpath.

Additionally, the control provides the capability to monitor up to five additional machines, whether in a cell or near each other. Thus, operators responsible for multiple machines can track their status from one display and eliminate physically going to each machine in the group.

All MAZATROL SmoothX CNC consoles are the same physical size on every machine and include the necessary information, options and features for every type of Mazak machine. Also, a common bank of buttons remains constant from one control panel to the next.

For digital manufacturing functionality, Smooth Technology supports MTConnect. Therefore, machines can have an optional MTConnect adapter for users to collect CNC data. CTE