CNC Machine Tools Success Stories

Hercus gears up with John Hart

Hercus Pty Ltd have just taken delivery of a new Mazak Integrex i-400S AG from John Hart, the very first HYBRID AUTO GEAR (AG) machine in Australia, significantly increasing their capabilities in gear-cutting and 5-axis machining.

Hercus gears up with John Hart

Hercus Pty Ltd Tradesman Nick Robins (left), General Manager/Owner William Durden (middle) and Tradesman Adam Sawyer (right) with the new Mazak Integrex i-400S AG.

Based in Regency Park, South Australia. Hercus Pty Ltd has been a key supplier of general engineering and manufacturing services for over 100 years to Australian and overseas customers.

With the latest technologies at its disposal, Hercus Pty Ltd is a leader in supporting the mining, steel production, and other key support industries with design and general engineering services including gear cutting, CNC machining, gearbox refurbishment and a comprehensive range of transmissions and equipment.

The Mazak Integrex i-400S AG is a perfect example of the company’s commitment to providing world class engineering services through a continual reinvestment in the latest technologies.

The Mazak Integrex i-400S AG HYBRID multi-tasking machine delivers maximum versatility and throughput. The machine combines the capabilities of a high-powered turning center and full-function machining center to produce parts in single setups, along with innovative HYBRID functionality.

This machine configuration features a second turning spindle (S) for DONE IN ONE machining and the HYBRID AUTO GEAR (AG) package with a full range of SMOOTH TECHNOLOGY solutions for DONE IN ONE gear production.

The SMOOTH AG software package includes SMOOTH Gear Skiving, SMOOTH Gear Hobbing and SMOOTH Gear Milling for producing external and internal spur, helical and spline-type gears. Optional SMOOTH Gear Check Plus adds in-machine measuring for further process optimization.

Additionally, the machine significantly reduces lead times and improves part accuracy through the elimination of multiple setups. With full 5-axis capability, the machine easily processes fully prismatic parts from solid blocks or castings (chucked or bar fed work), round parts or sculptured parts such as aerospace components.

John Hart delivered complimentary solutions alongside the Integrex AG including KISSsoft Gear development software and hyperMILL CAM software, to build a very unique capability for Hercus.

The team at Hercus cite this complete package offering from John Hart as one of the major factors influencing their purchase decision.

KISSsoft is a modular gear calculation program, ideal for the design and manufacturing of gears with complex geometries such as bevel, worm and wormwheels, crossed helical, hypoid and face gears. 

hyperMILL is the high-performance, complete CAM solution from OPEN MIND Technologies AG. hyperMILL is a modular and flexible CAM solution for 2.5D, 3D and 5-axis milling as well as mill turning and machining operations such as high-speed cutting (HSC) and high-performance cutting (HPC), with everything integrated in a single interface.

Coupling KISSsoft and hyperMILL with a state-of-the-art multi-tasking machine gives Hercus unparalleled ability to machine parts of any complexity.


Machining a spiral bevel gear based on geometry from KISSsoft and machining cycles using hyperMILL

Machining a threaded shaft using the feature of ATC tail centre in 2nd spindle using W axis thrust control