CNC Machine Tools Success Stories

Mazak delivers unmatched versatility and precision for ANCA

ANCA Pty Ltd has invested in a Mazak Integrex j-200S, a compact design machine with a large machining area and second spindle.

Mazak Integrex j 200S machining excellence for ANCA

ANCA is a world leading manufacturer of CNC tool and cutter grinders used in many industries including aeronautics and automotive production. The company is headquartered in Melbourne Australia with customers in over 45 countries and offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA's tool grinders are renowned for the flexibility of their tool design software and the capability to produce a wide variety of complex tools. These include grinding endmills, profile cutters, burrs and punches. ANCA's machines are the perfect choice for the production and resharpening of HSS and carbide cutting tools.

Renowned for similar benefits in a different manufacturing process, the Mazak Integrex j-200S provides ANCA the freedom to tackle a wide range of projects in the production of their CNC tool and cutter grinders, with unmatched versatility and precision.

The Mazak Integrex j-200S is a compact machine designed for large workpieces – maximum machining size is 500mm and maximum machining length is 500mm. Additionally, a large machining area is provided thanks to long strokes: X-axis – 450mm, Y-axis – 200mm, Z-axis – 550mm, B-axis indexing range of 220° and C-axis of 360°. The orthogonal Y-axis machine construction is the same as the Mazak Integrex i-150 and Mazak Integrex e series and allows face milling, end milling, and drilling to be performed in the large machining area without C-axis indexing thanks to long Y-axis stroke: 200mm.

The Mazak Integrex j-200S comes with a second spindle, which makes it possible to perform continuous machining operations – completing first and second processes in the same machine set up and as a result, in-process time can be considerably reduced.

Adam Marriott, Manufacturing Engineering Team Leader at ANCA said:

“We are seeing a considerable reduction in cycle time using the new Mazak Integrex j-200S with its large but compact machining workspace and quick tool change. With Kitagawa BR-208 chucks for both spindles in the machine, not only can we do all features in one complete setup we are seeing very high accuracy in spindle transfers which not only delivers more accurate parts but contributes to the shorter cycle times due to reduced manual intervention.”

ANCA optioned up to a 72-tool Capto storage magazine for reduced set-up and longer unmanned running.

Both turning spindles on the Mazak Integrex j-200S provide equal high performance with spindle speeds of 5000 rpm and C-axis turning control, though the main spindle has a 76mm bore and the second spindle a 61mm bore. The main headstock features an integral spindle/motor that accommodates a wide range of applications, from heavy-duty cutting at low speed to high speed cutting of aluminium and other non-ferrous materials. The rigidly clamped C-axis indexes in 0.0001-degree increments and delivers high accuracy. The second spindle also features an integral spindle/motor to ensure high efficiency machining for secondary operations.

Mazak increases machining capabilities at ANCA