Under The Covers Of The Mazak

[@chadchrestensen319]

Nice to see someone who has as much passion for machines as I do. I work for Mazak and have the privelage of seeing some of the beautiful and precise work done by the Japanese factories on a daily basis. It’s amazing how powerful yet delicate an integrex can be. Thank you for the video!

[@derick3482]

where do you work exactly?

[@LazyMcCrazy]

Great video! I was in the UK Worcester factory a few months back. Its incredible how much time it takes the skilled people to assemble these machines. They spend hours and hours just on clocking the ways on the cast bed getting them perfectly inline with each other.

[@dougankrum3328]

Ways and beds...that's where the precision starts....

[@dietermeyer9231]

And it only takes a second for an operator to get it out of position.

[@thondupandrugtsang]

That's a huge machine. Thanks for showing the belly of the beast. The drone shot was great.

[@brianbob7514]

that is a serious piece of machinery. Thanks for the great videos.

[@JlerchTampa]

For some reason I always build a mental image that is WAY more complicated than reality! THANK YOU for pulling the covers back and exposing the true mechanical beauty of the Mazak. Oddly enough I hadn't imagined a liquid cooled ball screw, but it makes perfect sense once learned about.

[@aj7utu]

One of the best videos I’ve ever seen on KZbin (in the areas I’m interested in.) Thank you for taking the effort!

[@JeffreyVastine]

That is one big machine! I will bet it takes some time to get everything trammed in. It was interesting to see inside the Mazak. Thanks for sharing!

[@RRINTHESHOP]

That is a large machine. Very cool to see behind the doors. Thank you Pete.

[@mike-lu8di]

Good stuff Peter, glad you put your hand around the ball screw....up to that point the ball screw looked much smaller. your drone takes great video and interesting to see the layout of the land in respect to the city. Good editing with the different camera angles you set up, looking forward to your next video...cheers

[@lorenlieder9789]

Great video Peter nice to see how your machine operates inside!!

[@billdlv]

Great video Peter. Often it's easy to loose perspective of the size of things in video, seeing the size of the ways and ball screws brings things back. It also does not hurt to see you inside the machine next to the second spindle.

[@WatchWesWork]

I had to reseal the B axis on an Integrex once. It's unbelievable how many components are jammed in there. There must be 60 o-rings that have to be replaced. Neat machines.

[@EdgePrecision]

You are correct, although I have never had the B axis apart I have looked at the drawings and there are a lot of parts. Its amazing it all works so reliably.

[@ray-charc3131]

It is a precious sharing video!Thanks! Mantaining this monster is not a easy task, a lot of technical know-how, and physically, it is dangerous.

[@aarondcmedia9585]

Ok this is the kind of thing I asked about (maintenance of the machine) on another vid, and here it is. Very interesting, thanks.

[@teipplestar5586]

Again, thank you for sharing these amazing videos!

[@mtlfpv]

They were putting in a new Integrex at work a while back, had all the covers off the back so I got a good look inside it during an evening shift lol.

[@AB-yu2tj]

It seems like taking care of a live monster. A useful good one, though.. Thank you, some will go a lifetime without seeing how these great machines are put together.

[@metalmogul4691]

Incredible, fascinating, thank you for sharing.

[@michaelskoblin2315]

I am impressed by your skills. They never cease to amaze me. I bet that smells ripe working inside the mazak internals though!

[@motorbreath22]

When someone asks where's the beef ? point them to this video.

[@danielmachado6750]

Daniel Machado - Brazil

[@josefnozkaCZTnv555]

... tohle video se mi moc líbí, ukazuje zákulisí CNC, nastavování a přípravu, to je málokde k vidění..super 👉 👍👍🙋

[@EdgePrecision]

Josef Dík! Vážím si vašeho komentáře z druhé strany světa! Je tak úžasné mít diváky po celém světě, kteří se zajímají o mé videa.

[@davidfarmer]

It looks very similar to my horizontal, except with the spindle mounted on a rotary.

[@hztn]

2:48 - Instead of metal shields there is a lot of chips on a surfaces inside it, which is not good for rails and for ballscrew. Is this usual for it's work, or they'd felt down from somewhere during the cleaning process?

[@EdgePrecision]

On a CNC machine or any machine shavings get into everything. You would think that the way covers or strainers in the coolant system would stop them. They only keep the large ones out. Take the coolant system for example. The chip conveyor has small holes to let the only coolant thru. The coolant tank still gets full of shavings. Not large ones but small ones. I have to periodically clean the tank. Where the coolant exits the conveyor there is a basket to catch these shavings. That can fill in a mater of hours when the machine is running. It depends on the material being machined and the machining processes. materials or processes that produce small sliver like shavings. Machining Inconel with ceramic tools is one of the worst. Cast iron is almost as bad. Roughing with adaptive or trochoidal machining can produce very thin splinter like shavings. It seems that no mater what kind of covers or filters there are, shavings get by or thru them. The roller ways and ball screws also have wiper seals the help deflect away the shavings. Sort of a second line of defense.

[@ke6gwf]

At the end of the video (love the inner look by the way!) when you were testing the travel of the machine, it looked like it exceeded the limits on the Z axis and just kept going up! Lol

[@EdgePrecision]

Thanks ke6gwf ‼️👍The machine has of course soft limits on its travel. So it’s impossible to exceed the travel limits. BTW on a lathe the Z axis is the horizontal axis the vertical axis is the X axis. Unless you have the coordinate system rotated as on this machine at 90 degrees around the B axis than the Z is vertical and X plus is toward the chuck and Y plus it toward the front of the machine. Look at my video on machine coordinate systems. I explained this in detail.

[@ke6gwf]

@@EdgePrecision, when I said the Z axis, something in the back of my mind was face palming, but I didn't feel like Googling it lol. yes, I was forgetting that this falls under the lathe coordinates scheme. And part of my background is in industrial automation, so what I said about exceeding the limits was a joke because the spindle was going up, and then the camera shot keeps going up with the drone shot ;) If you didn't do that on purpose, that would be a cool effect to have the camera on the spindle and then continue out the roof, or maybe running the length of the bed, through into the tool changer, down that tunnel, and then cut to the drone flying down the street or something lol

[@normanj844]

Great video Peter! Two questions for you. First, how has the Mazak been in terms of maintenance, getting service, and reliability? Second, I spotted what I think is a Renishaw receiver in the Integrex, yet in the videos I have seen you have used more traditional methods of finding a "zero". Whether or not you have a probe on the Integrex, why would you use a Haimer over a probe? Also, wanted to let you know that seeing the inside of the machine was really cool. Even more impressive on the inside than it looks from the outside. It is a rare opportunity to see the inside of such a machine, thanks for sharing!

[@EdgePrecision]

Norman J In Houston there is a Mazak service center. If you want to pay high dollar they do good. There are also independent companies that are good and less expensive if your not in warranty. I do have a probe but I find it's just more convenient to use the Hiamer indicator.

[@normanj844]

Thanks for the info. How often do you have to do repairs on the Integrex? I have heard that mill turns are much higher maintenance than your typical vmc.

[@EdgePrecision]

Norman J I have owned the machine for about four years. The machine is a little over ten years old. I have had some issues mostly electronic not unusual for a ten year old machine. These machines are less forgiving of machinist mistakes. You can knock it out of wack more easily than my horizontal mill. They are not what I consider a high production machine. If you have complicated parts with critical alignments they are the way to go.

[@normanj844]

Thanks as always for the response, looking forward to your next video.

[@886014]

Great video Peter. This is way outside my area of expertise, but hopefully one day ;) Other than the work envelope is there anything a 5 axis VMC can do this machine can't? It seems to be an extraordinarily versatile machine from the way I've seen you set it up with tailstock and steadies.Definitely subscribed to your channel and look forward to learning more about this side of things. Thanks

[@bcbloc02]

No re check of alignment after torquing the hardware?

[@EdgePrecision]

I can’t remember what I showed in the video(it’s been a while). But I always check the alignment after tightening the screws. Thanks.

[@raulvargas4322]

I was thinking to make a really rigid little CNC machine for hobby but this is just insane

[@douro20]

Is that an active air counterbalance on the column? I've used machines which had them, but they were much lesser machines than this.

[@cksQx1]

Another great video, very informative on machine details not usually shown. I am curious do you have a sense of how will this machines (or any CNC machine) precision will degrade over time - is it justs after X hours - when would a professional shop just replace the machine versus repair/maintenance?

[@EdgePrecision]

If a machine is properly maintained and not abused (That means not crashed) its accuracy should not degrade with time. Things do wear out, hydraulic pumps ball screws bearings and electronics. These can be replaced or rebuilt as needed. Usually a business might replace a piece of equipment after its been totally depreciated on their books for financial reasons or a tax incentive. I have found that if the machine is starting to cost more to maintain than buying a new machine. Or the technology has changed to the degree that it is more economical to replace it its time to do so. All the machines I own are more than ten years old and they still have acceptable accuracy. I have replaced a few servo drives and the hydraulic pump on the Mitsubishi Mill. The Mazak has had to have a very expensive power supply ($13.000 with 25% core exchange) replaced and the B axis spindle position encoder sensor replaced and readjusted. This requires a very special oscilloscope to do so. The chillers pump is about ready to be replaced also ($3.000 you can only buy the pump with the motor from Mazak). But neither machine has had any mechanical issues that haven't been my causing.

[@cksQx1]

Thank you for taking the time to provide an informative response - I enjoy watching your videos - interesting seeing both high end professional ones and the well equipped hobbyist stuff

[@eformance]

I assume you were resetting the B axis zero reference because there is a curvic coupling that locks at that position?

[@EdgePrecision]

The B axis couples in at 0,45,90,135,180 deg's to the coupling. All other angles are not clamped. If the clamped angles aren't exactly on. The only way to get them back in to mechanically move the coupling's housing angle. This is done by losing the bolts and jacking around the housing. There is jacking screws specially for this purpose. A test bar is mounted in the spindle and indicated for this alignment. Sort of similar to aligning a Bridgeport's head.

[@DougHanchard]

I'd hate to clean that back enclosure area with all the cables and electronics! Is there a procedure for it published by Mazak?

[@drewrogge4798]

You mentioned hydraulic lines in the video. Does the machine have hydraulic servos or electrical?

[@EdgePrecision]

No the machine has electrical servos. It does use hydraulic pressure for clamping the rotary axis and to release the tools. Also some of those lines carry coolant and air as well as wiring.

[@germannunez6868]

Is like a house!

[@skirifles2076]

Good stuff again Peter! Your drone takes awesome video, I'm considering buying one. I like the one you have, it's compact too. I sent you an email about some tooling to see if you could use it, let me know if you can and thanks for the great vids!

[@policebox1092]

Did you work in Mazak?awesome

[@perceive8159]

Great stuff. What kind of running hours does Mazak give to the ball screws before servicing ?

[@EdgePrecision]

I'm not sure. Of all the machines I've owned over the years I have never replaced a ball screw for wear.I have had one fail. On one of the Quantum Q1500V mills the screw broke at the bearings at the servo end. I think there might have been a miss alignment and over time it stressed the shaft until it failed.

[@kevinbowers3917]

What is the cost and service life of such a machine?

[@fredrezfield1629]

hi Mr edge got a question for you? how much did you have to remove before you got to your X ball screws? and did you find anything loose there?

[@EdgePrecision]

I didn't do anything with the ball screws. But for the X axis on this machine. It would be a much bigger job then I show in this video. It is the one that holds up this whole B axis spindle.

[@fredrezfield1629]

@@EdgePrecision i see ever had to do the homing on the X axis though? through BS13 parameter? whereyou move axes in X and Y

[@EdgePrecision]

@@fredrezfield1629 The home position on this machine in X is the tool change position Y is the turning spindles centerline. And yes every time I power up the machine I zero return the machine.

[@fredrezfield1629]

@@EdgePrecision no no NO homing like my X value is out by .05 ! for example when clocking an endmill you get a value of -43.1 on the H position or horizontal position that value has changed to -43.15 do you know what i mean?

[@EdgePrecision]

@@fredrezfield1629 I can’t say why it changed. But does it now always go to the same place now after zero return? If so you can reset the zero position or use a fixture offset. If it isn’t returning to the same position it’s probably something wrong with the encoder on the servo motor.

[@dbcrewforever]

Peter, I really enjoy watching your videos here but at first sight I does not make sense to me to tighten the bolts at the spindle head. What´s behind that?

[@EdgePrecision]

To align the B axis the builders of the machine have provided a method. There is bolts around the perimeter of the flange that holds the B axis rotational axis to the end of the Y axis. If you loosen than snug the bolts. Than there is a adjustment/jack screw mechanism to move the B axis to get it aligned. I have a precision test bar to put in the spindle. I can use it to indicate the alignment. Typically I like to get it to less than .0005”.

[@dbcrewforever]

Edge Precision That makes sense. I thought you tightened them only to compensate a potential relaxing or creeping of the bolts. Thanks for your reply!

[@andreasharl9115]

Have this machine in the linear axis rollerbearings or ballbearings? Locks like linear ballbearings....?

[@EdgePrecision]

Linear ball slides. The new ones have roller slides.

[@andreasharl9115]

@@EdgePrecision hey cool, thank you for the fast Answer! Greetings from Salzburg!

[@00savage25]

Mazack known for putting chillers in the most inaccessible place possible.

[@dietermeyer9231]

This is the small e-500h? Just wait until you see its big brother e-800h with 6 meter travel in Z-axis. That is a beast.

[@EdgePrecision]

No it’s the e650H 120” between centers.

[@tansit2344]

Yeah that thing has some pretty massive bearing surfaces, but I can totally see how it could get kicked out of alignment easily.

[@douro20]

Yeah, it's not like the Doosan or WFL machines where the milling head is held on its rotary axis with a massive double-bearing yoke. It's the biggest weakness of Integrex machines.

[@มานิตย์เรืองคํา-ฦ6ล]

Hi what new process

[@tomsemo8186]

Is there a warm up time or you just leave it running. Massive!

[@EdgePrecision]

I don’t personally do warmups with my machines. I figure they can warm up doing work. I have never had any trouble doing this.

[@CalvinoBear]

I was just looking to see this, I am trying to design a very small mill/turn machine

[@EdgePrecision]

Calvin Stence Do you have any questions. I didn't really explain anything.

[@CalvinoBear]

Edge Precision thanks for the reply, I actually do! Do you know what the mechanism used to rotate the spindle is? When you had the covers off, i saw a servo which looked tangent to the spindle rotation, maybe it's a special worm drive? I'm wondering how it handles the backlash of such a mechanism.

[@EdgePrecision]

Calvin Stence The B axis is rotated by a special roller gear driven by a worm like worm. Imagine a series of rollers like cam rollers mounted on the OD of a disk equally spaced. Than a worm that drives against the rollers. As to backlash I'm not sure the fit must be very close. The B and the C axis can resolve to .0001 deg. The C axis is a normal worm drive. It engages by rocking the worm into the gear. First the turning spindle orients than the worm and its servo drive mounted on a pivoting frame swings into the gear. It held it by a hydraulic cylinder with a over center lever with a precise stop to control the preload of the worm. According to Mazak the B axis roller worm drive is quite reliable and they have no trouble with it. I hope this answers your questions.

[@CalvinoBear]

Wow, that is incredible (and absolutely answers my questions). I always wondered how very accurate incremental rotation was done on trunnions and other machines like this, this method makes a lot of sense. This video interests me greatly as I was curious about the general size ratios of the different machine motion assemblies. It helps one get an idea of what component sizes are appropriate for good machine stiffness, and how much material you really need to use, as it is safe to say that they are done correctly here.

[@TheFelipeaugustopixo]

10:08 torquimetter?

[@EdgePrecision]

I have had that pipe calibrated.

[@сашапашп]

Thanks! Very interesting!

[@gptech2444]

That things a beast! How far out was the adjustment?

[@EdgePrecision]

GP Tech , It was out .0015 along the test bar in the B rotation. This won't make any difference for turning tools but for milling tools it's like having your Bridgeport head out or square.

[@сашапашп]

Awesome and interesting vodeo! So thanks! Also, it will be so cool, if you take a shot of other mashines interesting mechanics, if you had a chance..)) Big thanks, awesomely interesting!!))

[@James-fs4rn]

Very interesting. Thanks

[@agie170hss2]

Peter, the X axis is what goes up and down? Is it counterbalanced in some way? I see what looks like some sort of piston or large rod to the left of the (vertical) ball screw. thx. The only thing more impressive than the machine is your know-how when it comes to running it!

[@EdgePrecision]

Yes it has a gas/hydraulic counter balance mechanism. There still is quit a bit on constant load on the X axis servo motor.

[@agie170hss2]

@@EdgePrecision I'm guessing the entire (moving part) of the X axis must weigh?.... many thousand pounds? btw: Keep up the great videos! I started machining when I was about 12 in my dad's business (well, truth be told I started cleaning the sumps in the cylindrical grinder, as I recall). haha! Anyways... I'm 61 now, and have been around the block a few times, but have never messed with parts of the scale you do (99% of the parts I've made can be held in one hand). I love the way you use that Mazak just like it's a little Haas or Fanuc, or something like that. Really terrific to see. It appears you use mostly Esprit to program the Mazak? (sorry to be so long-winded).

[@dietermeyer9231]

@@EdgePrecision: You are supposed to fill it with nitrogen from time to time and lubricate the seals once or twice a year. If the nitrogen disappears quickly, you must replace the seals.

[@dtiydr]

Those ball screws and ways are most likely the cost of a car or more likely two or three.

[@docobo2948]

I have mazak and okuma in my work. I like the mazak program (easily to change conditions), but mazak has a lot of problems, electronical problems. Okuma has worst program but is more fiable in all the other parameters.

[@85CEKR]

Really, we don't have any mazaks, but we have lots of okuma's and a few other Japanese brands, everyone love the controller on the okumas the most, how old are your okumas?

[@artmckay6704]

thanks! :)

[@rabi3aljassem241]

man u r awesome

[@mickemazak]

Nice!

[@tunnel7]

Cannot get over you getting in machine while powered on them things can move on there own without prior warning I know I've seen happen

[@max_eley]

Very very rare, ive only seen it once on an old shit bag haas vf4, it ran out of nowhere into its hard limit at full rapid and alarmed out, luckily i was not inside the machine, should of heard the sound.., i doubt the mazak would do that.

[@Uzik]

Once iam use jog when my body inside the machine-boss kill me)

[@danmoeser3863]

fixin your own machine nice!!!!!

[@mitchcumstein9808]

Big machine, big industrial park, what’s that they say about Texas again...

[@parmaralpesh2984]

Mind boing m/c

[@abdalrohmanmousa7405]

I just hat Mazak they are thermally unstable and badly build the control is very good

[@bhleblanc]

Could easily kill someone working in the back of that thing if it got turned on.

[@anonimov9107]

Mazatron ♨

[@stefanstamatov7725]

oh Peter i hate to tell you this ,but this is a rip off.They sold you a cheap chineese copy of Mazak.Mine Optimum is better quality.Sorry for the bad news .

[@stefanstamatov7725]

but for cheap copy it runs very smooth.love your vids man

[@douro20]

lol

[@mariocortes1337]

Thanks