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. At the heart of this evolution is a new complete process-performance technology platform that spans the entire part production landscape from programming and setup to actual metal removal operations to automation to monitoring/data collection and transfer.
Called SMOOTH Technology, and developed by Mazak, the all-encompassing concept combines the advanced capabilities of today’s machine tools and leading-edge CNC processing and software technologies with that of Mazak’s unparalleled years of 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. 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 brand new CNC called Mazatrol SmoothX as well as new machine hardware and servo systems. Mazak painstakingly 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.
Mazak 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, 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 delivers 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. 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 the most difficult-to-cut materials.
Mazatrol SmoothX CNC’s Seamless Corner Control reduces vibrations and helps shorten part-machining cycle times through cutter path adjustments made when machining into corners. Rather than moving the cutter directly into a 90-degree 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. 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 ten and a select few users all of them. This helps prevent errors and ensures only those qualified make changes.
On the part programming side, MAZATROL SmoothX CNC boasts several innovative functions that 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 just 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, then enter the necessary values to create the program. 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 greatly 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.
“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 don’t have to know how to use a CAM system to work from a solid CAD model to create programs.”
With programming/setup 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 percent and simplifies the process. Plus, there is extremely accurate full 5-axis 3D machining simulation and interference checking capability.
The secret behind the blazing 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. 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 less required test cuts, and that shops get the first part faster. Plus, workpiece surface finishes will be dramatically smoother.
At the human/machine interface (HMI) level, MAZATROL SmoothX CNC features an eye-catching, 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.
And 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. 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.
Plus, 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 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, please visit:
www.mazakusa.com
