The Mega8800 is a horizontal machining center for heavyduty machining of materials such as Inconel or titanium

Heavy-Duty HMC for Hard Metal Cutting

Oct. 10, 2012
Continuous 4,000-rpm, 100-hp integral motor spindle Table rotates 90 degrees in 3.2 seconds Cam-driven tool changing, 60-tool magazine

Among more than 20 high-performance CNC machines that Mazak exhibited at IMTS 2012, the Mega-8800 horizontal machine stands out for its highly rigid design that makes the heavy-duty machining of tough materials — like Inconel and titanium —efficient, accurate and productive.

While it’s built for stability, the Mega-8800 also deploys a continuous 4,000-rpm, 100-hp (74 kW) integral motor spindle that generates 774 ft-lbs of torque. It achieves a rapid traverse rate of 1,219 ipm in the X and Z axes, and 1,016 ipm in the Y-axis. Also, with 5,530 ft-lbs of torque in the X and Z axes, and 5,800 ft-lbs in the Y-axis, it provides the thrust necessary for heavy-duty cutting.

Machine travels measure 55 in. (1,400 mm) in X, 47 in. (1,200 mm) in Y and 52 in. (1,325 mm) in Z, and the Mega-8800 incorporates Mazak’s MX Hybrid roller-guide system, achieving durability and reliability that support machining accuracy over the long-term. This way system also increases vibration dampening, extends tool life, handles higher load capacities, and eliminates tramp oil in the coolant thanks to a “greener,” grease-based lubrication system, according to the machine builder.

Precision, four-axis indexing and machining is accomplished because the Mega-8800’s NC rotary table rotates 90 degrees in 3.2 seconds and features one-degree minimum increments. The table has 360-degree position coupling and accommodates workpieces up to 57 in. (1,450 mm) in diameter and 57 in. (1,450 mm) high.

Cam-driven tool changing on the Mega-8800 reduces non-cut times by ensuring reliable, 5-second cycles, “chip-to-chip,” according to Mazak. The machine has a 60-tool automatic magazine, and accommodates maximum tool diameters of 10.24 in. (260 mm).

Programming of multiple surfaces is made simple on the Mega-8800 thanks to Mazak’s Windows 7-based Matrix Nexus 2 CNC control. The control responds to both conversational and EIA/ISO instruction, so programming for C-axis, Y-axis, and angle machining is simplified. Matrix also provides realistic 3D machining simulations, time-study analyses, and the Mazak Voice Advisor, which assists operators to make initial operations during setup smoother and safer.

The Mega-8800 has a standard two-pallet changer and pre-engineered to interface with Mazak’s Palletech manufacturing system, for unattended operation. The machine’s pallet size is 31.5 in. X 31.5 in. (800 mm X 800 mm), with a maximum load capacity of 4,850 lbs (2,200 kg).

About the Author

Robert Brooks | Content Director

Robert Brooks has been a business-to-business reporter, writer, editor, and columnist for more than 20 years, specializing in the primary metal and basic manufacturing industries. His work has covered a wide range of topics, including process technology, resource development, material selection, product design, workforce development, and industrial market strategies, among others. Currently, he specializes in subjects related to metal component and product design, development, and manufacturing — including castings, forgings, machined parts, and fabrications.

Brooks is a graduate of Kenyon College (B.A. English, Political Science) and Emory University (M.A. English.)