Horizontal Machining Centers with Honing Take Production to New Heights

Honing is one of the more expensive machining processes to perform, but is crucial in the production of pumps, valves and gears. Because today’s OEMs demand smoother surfaces to make automobiles and other products quieter and more reliable, finding more efficient ways to complete this high-precision process is more important than ever.

At IMTS, we will demonstrate our popular HCN-4000 horizontal machining center with enhanced Multi-Tasking capabilities including high-precision honing and orbital machining. When you visit our booth, you will see the HCN-4000 machine a variety of real world components, including a pump housing part. It will not only mill, bore and hone the housing, but will use advanced orbital machining techniques as well.

Together with honing technology leader Sunnen Products Company, we developed the special hone tooling needed for the horizontal machining center integration. To position and adjust the abrasive pads/stones, the machine uses wireless electronic feedback. Honing stops when the stone position is reached via feedback to the machine. The system then provides closed-loop feedback on hole ID size to our new Smooth PMC software for in-process adjustments.

This advanced machine with these new integrated capabilities answers many of the challenges of producing pump and valve-type components. By adding honing and orbital machining to a Multi-Tasking machine, you can more efficiently produce complex parts in single-setups which not only lead to gains in productivity, but also enhances the quality of the finished parts by eliminating the need to move parts from machine to machine.

We will also demonstrate how you can ramp up production even further with advanced automation by incorporating the HCN-4000 into our PALLETECH System, which is now controlled with our new Smooth PMC software. This can take your production to new heights through DONE IN ONE® processing from raw material to finished part.

If you’re not familiar with our PALLETECH system, be sure to check it out at IMTS. PALLETECH is a highly flexible system that configures into one, two or three levels for completely automated and continuous production cells. These cells accommodate different types of Mazak machine tools so that you can mix and match machine types – such as horizontal machining centers with vertical machining centers – to meet your specific processing needs.

PALLETECH combined with our new SMOOTH PMC cell control software efficiently manages and maximizes the system’s operations. The software allows you to look ahead with production simulations to forecast needed tools, machine loads and output levels for up to a week’s worth of scheduled cell workflow. SMOOTH PMC also allows for advanced PALLETECH cell connectivity, analytics and performance data outputs in graphical formats via a smart phone.

Our highly capable MAZATROL SmoothG CNC with Smooth Orbiturn function makes both the honing process and the orbital machining possible on the HCN-4000. Enhanced with Mazak’s SMOOTH TECHNOLOGY, orbital machining techniques enable horizontal machining centers to turn round and eccentric features on large, odd-shaped parts such as valves and manifolds while the components remain stationary. Because the process uses standard tooling, it is a productive, cost-effective and easy-to-apply solution for performing milling and turning operations in single setups – further increasing the HCN-4000’s multi-process ability.

We can’t wait to show you how much more efficient you can produce parts that require honing and orbital machining. Make sure to stop by our booth S-8300 to check out this amazing machine tool and many more. 

About Mazak Corporation

Mazak Corporation is a leader in the design and manufacture of productive machine tool solutions. Committed to being a partner to customers with innovative technology, its world-class facility in Florence, Kentucky, produces over 100 models of turning centers, Multi-Tasking machines and vertical machining centers, including 5- axis models. Continuously investing in manufacturing technology allows the Kentucky Mazak iSMART Factory™ to be the most advanced and efficient in the industry, providing high-quality and reliable products through its “Production-On-Demand” practice. Mazak maintains eight Technology Centers across North America to provide local hands-on applications, service and sales support to customers. For more information on Mazak's products and solutions, visit www.mazakusa.com or follow us on Twitter and Facebook.