Hybrid additive, subtractive multi-tasking part processing

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June 8, 2016

The Integrex i-400AM (additive manufacturing) hybrid multi-tasking machine fuses additive technology and advanced multi-tasking capabilities to reduce part cycle times.

A turnkey system, the machine offers manufacturers an alternative to conventional processing in part design and machining and is suited for small lot production of difficult-to-cut materials. With the additive manufacturing capability, manufacturers can generate or clad near-net-shape component features, complete them with high-precision finish-machining operations, and laser mark parts if needed.

The machine melts metal powder using fiber laser heat. Cladding heads – additive manufacturing nozzles – apply molten material layer by layer, each solidifying as the desired shape grows. The system can join different types of metals together, which is beneficial in the efficient repair of existing worn or damaged components, such as turbine engine blades.

The cladding heads store in the tool magazine, and the standard automatic tool changer loads them into the machine’s milling turret. Based on the intended process and the particular metal powder used, users have a choice of two cladding heads – high speed or high accuracy.

For machining, the unit provides 5-axis capability to process prismatic parts from solid billets or castings (chucked or bar fed), round parts, highly contoured parts, and those with features built using additive technology. The machine provides -30° to 120° B-axis movement in its milling spindle, full C-axis contouring with its turning spindle, and a programmable NC tailstock.

Mazak Corp.

www.mazakusa.com

IMTS 2016 Booth #S-8300