MAZAK INTEGREX i-100H S CNC Multi-Tasking Turning-Milling center – Year 2022

Manufacturer:
Mazak
Model:
INTEGREX i-100H S
Machine number:
328827
Year of construction:
2022
Condition:
good (used)
Functionality:
fully functional
Operating hours:
2,200 h

Technical details
Turning length:
900 mm
Turning diameter:
600 mm
Spindle motor power:
11,000 W
Spindle speed (max.):
6,000 rpm
Spindle bore:
61 mm
Travel distance X-axis:
535 mm
Travel distance Y-axis:
210 mm
Travel distance Z-axis:
900 mm
Mount diameter:
600 mm
Rapid traverse X-axis:
48 m/min
Rapid traverse Y-axis:
40 m/min
Rapid traverse Z-axis:
40 m/min
Milling spindle length:
300 mm
Rotational speed (max.):
20,000 rpm
Type of input current:
three-phase
Torque:
184 Nm
Bar passage:
61 mm
Feed rate X-axis:
48 m/min
Feed rate Y-axis:
40 m/min
Feed rate Z-axis:
40 m/min
Bar diameter (max.):
61 mm
Overall weight:
12,000 kg
Spindle diameter:
152 mm
Equipment:
documentation/manual

The machine is equipped with the latest Mazatrol SmoothAi control, fitted as standard. The ease of conversational program creation in Mazatrol mode is ensured by the intuitive layout of auxiliary functions, supported by graphical and, above all, clear prompts and comments.

TOOL HOLDERS SHOWN IN THE PHOTOS ARE INCLUDED IN THE PRICE.

STANDARD TECHNICAL SPECIFICATION

Working area
Main spindle chuck size 6″
Second spindle chuck size 6″
Max. turning length 600 mm
Standard machining diameter (from upper head) 600 mm
Standard machining diameter (from lower head) 400 mm
Bar machining capacity in main spindle 51 mm
Bar machining capacity in sub-spindle 51 mm

Main spindle
Maximum spindle speed 6,000 rpm
Minimum spindle speed 35 rpm
Through-hole diameter 61 mm
Motor power (40% duty) 11.0 kW
Motor power (continuous) 7.5 kW
Max. torque (15% duty) 184 Nm
Max. torque (25% duty) 161 Nm
Max. torque (40% duty) 143 Nm
Maximum torque (continuous operation) 105 Nm

Second spindle
Maximum spindle speed 6,000 rpm
Minimum spindle speed 35 rpm
Through-hole diameter 61 mm
Motor power (40% duty) 11.0 kW
Motor power (continuous) 7.5 kW
Max. torque (15% duty) 184 Nm
Max. torque (40% duty) 143 Nm
Maximum torque (continuous operation) 105 Nm

Milling head
Type Single spindle with automatic tool changer
Tool holder HSK-A63 / HSK-T63
Tool size (external diameter machining) 25 mm
Tool size (internal diameter machining) 40 mm
Tool size (max. milling tool diameter) 130 mm
Tool size (max. milling tool length) 300 mm
Motor power (40% duty) 24.0 kW
Motor power (continuous operation) 14.0 kW
Max. torque (15% duty) 59.7 Nm
Torque (40% duty) 57.3 Nm
Torque (continuous operation) 46.1 Nm
Max. milling spindle speed 20,000 rpm
Min. milling spindle speed 35 rpm

Feed axes
Rapid traverse X 48 m/min
Rapid traverse Z 40 m/min
Rapid traverse Y 40 m/min
Rapid feed rate B 44.4 m/min
Rapid traverse W 30 m/min
Travel X 535 mm
535 mm (+485 mm / -50 mm)
Travel Z 900 mm
Travel Y 210 mm
B-axis travel range 240° (-30° ~ +210°)
Travel W 900 mm

0850U INTEGREX I-100H S 850U
MR406 Milling spindle 20,000 rpm
SI098 Sub-spindle synchronization
AS080 Overload detection system
CS503 Through-spindle coolant 15 bar / flushing
CS664 Preparation for extraction unit (Gx500)
MB255 B-axis measuring probe (RMP60)
MB650 Calibration sphere + magnetic base
MB624 Smooth Set And Inspect (Multi-Tasking)
CV041 Side chip conveyor (hinged belt)
TE810 Preparation for Multi&Flash system
NO056 Y-1 MAZAK API
NO059 MTConnect adapter
NO066 Smooth synchronous tapping (with milling spindle)
NO072 Automatic peck drilling cycle with load monitoring
NO116 Smooth 5-axis control (EIA/ISO)
NO123 Tool radius compensation in 5-axis machining
NO134 Simultaneous 5-axis machining on the second spindle
NO442 Slope Constant (G00 motion optimization)
NO482 Thread re-entry
NO599 Cylindrical (G07) and polar (G12) interpolation

INTEGREX i-Series machining centers are an innovative development of the Integrex machine
concept, manufactured continuously since 1988. This family of multi-tasking machines enables the
execution of complex machining operations in line with the “Done in One” concept – producing a
finished part in a single setup on one machine.
The total investment cost of an Integrex i-series machine is lower than that of a separate lathe and
machining center intended for the production of the same parts. Additional benefits include reduced
cost of workholding systems, shorter setup and changeover times, and higher machining accuracy
thanks to eliminating the need to re-clamp and transfer parts between a lathe and a machining
center. Low tooling costs, easy programming, and short changeover and reconfiguration times make
investment in an INTEGREX i-series machine exceptionally effective and significantly reduce payback
time.
Integrated Spindle Technology
Thanks to the use of an integrated-motor spindle, vibrations during high-speed machining are
minimized. The machine allows both heavy-duty cutting at low spindle speeds and high-speed
machining of aluminum and other non-ferrous materials.
The speeds of the first and second spindle can be synchronized.
Analogously to the turning spindle, a milling spindle with an integrated motor is used, which
eliminates vibrations during high-speed machining.
An automatic tool changer is also provided, allowing tool changes with minimal operator
intervention. The milling spindle guarantees excellent performance for a wide range of applications –
from machining steel to high-speed machining of aluminum.
MAZATROL SmoothAi CNC Control
The machine is equipped with the latest standard control system: Mazatrol SmoothAi.
The ease of dialog-based programming in Mazatrol mode is ensured by intuitive arrangement of
auxiliary functions, supported by graphic, clear prompts and comments.
Yamazaki Mazak’s experience in applying such innovative features, which significantly accelerate both
programming and industrial production, dates back to 1981, when the company introduced the first
machine tool with dialog control. Many years of practical experience in this area have created the
current programming system, which has no equal in terms of ease of use.
STANDARD TECHNICAL SPECIFICATION
Working Area
• Size of main spindle chuck: 6″
• Size of second spindle chuck: 6″
• Maximum swing: 600 mm
• Standard machining diameter (from upper head): 600 mm
• Standard machining diameter (from lower head): 400 mm
• Bar capacity in main spindle: 51 mm
• Bar capacity in second spindle: 51 mm
Main Spindle
• Maximum spindle speed: 6,000 min⁻¹
• Minimum spindle speed: 35 min⁻¹
• Through-hole diameter: 61 mm
• Motor power (40% duty cycle): 11.0 kW
• Motor power (continuous): 7.5 kW
• Max. torque (15% duty cycle): 184 Nm
• Max. torque (25% duty cycle): 161 Nm
• Max. torque (40% duty cycle): 143 Nm
• Max. torque (continuous operation): 105 Nm
Second Spindle
• Maximum spindle speed: 6,000 min⁻¹
• Minimum spindle speed: 35 min⁻¹
• Through-hole diameter: 61 mm
• Motor power (40% duty cycle): 11.0 kW
• Motor power (continuous): 7.5 kW
• Max. torque (15% duty cycle): 184 Nm
• Max. torque (40% duty cycle): 143 Nm
• Max. torque (continuous operation): 105 Nm
Milling Head
• Type: Single spindle with automatic tool changer
• Tool holder: CAPTO C6 / HSK-A63 / HSK-T63 / KM4X63
• Tool size (external diameter machining): 25 mm
• Tool size (internal diameter machining): 40 mm
• Max. milling tool diameter: 130 mm
• Max. milling tool length: 300 mm
• Motor power (40% duty cycle): 12.0 kW
• Motor power (continuous): 11.0 kW
• Max. torque (15% duty cycle): 59.7 Nm
• Torque (40% duty cycle): 57.3 Nm
• Torque (continuous): 46.1 Nm
• Max. milling spindle speed: 12,000 min⁻¹
• Min. milling spindle speed: 35 min⁻¹
Feed Axes
• Rapid traverse X: 48 m/min
• Rapid traverse Z: 40 m/min
• Rapid traverse Y: 40 m/min
• Rapid feed rate B: 44.4 min⁻¹
• Rapid traverse W: 30 m/min
• X-axis travel: 535 mm
o Effective stroke: +485 mm / −50 mm
• Z-axis travel: 900 mm
• Y-axis travel: 210 mm
• B-axis swivel range: 240° (−30° ~ +210°)
• W-axis travel: 900 mm
Other
• Coolant tank capacity: 290 L
• Required power (continuous): 52.23 kVA
• Air pressure: 0.5 MPa (0.5 MPa to 1.0 MPa)
• Total air consumption: 323 L
Machine Dimensions
• Center height: 1,350 mm
• Length: 3,415 mm
• Width: 2,170 mm
• Height: 2,500 mm
• Weight: 12,000 kg
Automatic Tool Changer and Tool Magazine
• Tool magazine type: Chain type
• Tool magazine capacity: 38 tools
• Max. tool diameter (with adjacent tool): 90 mm
• Max. tool diameter (without adjacent tool): 130 mm
• Max. tool weight: 5 kg
• Max. tool length: 300 mm
• Tool selection method: Fixed pot, shortest path
STANDARD EQUIPMENT
Basic Options
• AS250 – Automatic tool changer with recovery function
Activates in case of an interrupted tool change and returns mechanisms to their home
position.
• AT001 – Tool setter mounted on the front of the machine
• CO032 – Chuck air blow on second spindle via NC command
• EL110 – Power transformer for European market
• MM007 – Digital tool magazine display
• MO575 – Roller-type linear guideways
• NO823 – USB port
• PL089 – Status light
• SB802 – Main spindle through-hole diameter 61 mm (2.4″)
• SD120 – Manual tool kit
• SD130 – Foundation plate set
Supporting Software
• NO539 – Smooth restart function
Tool Magazine
• AT708 – 38-tool HSK magazine (without tools)
Documentation
• SD073 – Set of manuals in English (CD)
Spindles
• SR273 – First spindle 6,000 rpm
Second Spindle Speed
• OP350 – Second spindle 6,000 rpm
Automation-Related Systems
• AS092 – Automatic machine power on/off + warm-up
Milling Spindle
• MR369 – Milling spindle 12,000 rpm (12 kW, oil and air)
Spindle Motor
• SP049 – First spindle AC motor 11 kW (15 HP)
• MISSING TRANSLATION FOR “SPINDLE MOTOR (2ND SPINDLE)”
• OR070 – Second spindle AC motor 11 kW (15 HP)
B-Axis
• YI300 – B-axis contouring with resolution 0.0001°
C-Axis – First Spindle
• SI044 – C-axis increment of 0.0001° (first spindle)
C-Axis – Second Spindle
• SI091 – C2-axis indexed every 0.001°, no simultaneous machining possible
Machine Colour
• SD717 – Standard machine colour
Safety Systems
• SF079 – Absolute positioning system (linear axes)
• AS028 – Operator door lock with latch
• SD030 – Work area lighting
Positioned to ensure operator safety and to facilitate machine operation.
• SD755 – Global-standard safety systems
• SD020 – Full enclosure of the work area
To prevent unwanted ingress of chips and coolant into the work area.
• MO110 – Hydraulic system protection
Safety unit for detecting excessive oil pressure, shutting down the system, and stopping the
machine.
• CO077 – Dual lower switch (first and second spindle)
• SD765 – New safety measures 2021
Cooling System
• CS367 – Chip flushing for spindle HD1
• CS370 – Through-spindle coolant
• MO551 – Ball-screw cooling (X, Y, Z axes)
• SD010 – Complete coolant system
Includes pumps, valves, piping and nozzles for efficient production of high-quality
components.

High-Pressure Cooling Systems
• CS502 – Through-spindle coolant 5 bar
Coolant pump (typically used for through-spindle and flood coolant).
Chuck
• CO011 – Automatic chuck open/close (spindles 1 and 2)
• CO021 – Chuck open/close confirmation (spindles 1 & 2)
Chucks
• JA019 – 6″ through-hole chuck B-206A0515 (first spindle)
Chucks – Second Spindle
• JA172 – 6″ through-hole chuck B206 for second spindle
o Internal diameter: 43 mm
o Non-through cylinder RNKP105 (Matsumoto)
o Cylinder adapter
Measuring Tool
• MT032 – Automatic “Tool Eye” measuring device
Tool wear offset compensation and broken-tool detection.
High-Precision Options
• SF205 – Pitch error compensation for X, Y, Z axes
Chip Disposal Systems
• CV506 – Preparation for side chip conveyor (hinge-type)
• MISSING TRANSLATION FOR “MAZATROL ”
• NO369 – Solid Mazatrol
CAD/CAM Software
• NO003 – Built-in McAfee controller
• SD121 – SmoothAi thermal shield
NC Options
• MO318 – 1st spindle and milling spindle speed display (EIA/ISO)
• MZ200 – Displacement detector
• NC204 – Mazatrol SmoothAi control unit
• NC322 – 19″ colour LCD display (touch screen)
• NO097 – EIA/ISO package
• NO098 – Operation in EIA/ISO mode (standard)
• NO139 – Additional EIA/ISO functions
• NO483 – Thread cutting function
• NO142 – “Inverse Time Feed” function
• NO136 – G37 automatic tool length measurement
(laser probe required)
• NO509 – Polar coordinates (EIA)
• NO144 – Compare-stop function
• NO481 – Extended workpiece zero points (300 pairs)
• NO051 – Macro variables (600 variables)
• NO075 – Tornado-type tapping/boring cycle (EIA)
• NO516 – EIA copying cycle (grid, arc)
• NO149 – Inclined machining plane
• NO420 – Coordinate system conversion
19 3-D CO-OR ROT.
Transformation of the 3D coordinate system (G68.5 for lathes, G68 for machining centers).
Creation of a new coordinate system by rotation around the X, Y or Z axis and shifting the
origin parallel to the axis of rotation.
• NO512 – Direct input of dimensions from drawing
• NO827 – LAN port
• NO838 – SD memory card interface
• NP325 – Standard SmoothG control function package:
o NO443 – Mazacc-2D software (geometric compensation)
o NO444 – Mazacc-3D high-speed software package
o NO445 – Geometric compensation for rotary axes
o NO497 – High Smoothing Control (mold machining package)
o Seamless Corner Control – tool feed control in corners
o Variable Acceleration Control – axis acceleration control
o Ultrahigh-Speed Machining Mode
o Rapid Overlap
• SD113 – Intelligent Safety Shield (ISS)
GENERAL SUMMARY
Model
• 0850U – INTEGREX I-100H S 850U
Milling Spindle (Option)
• MR406 – Milling spindle 20,000 rpm (24 kW, HSK, oil and air)
C-Axis – Second Spindle
• SI098 – Counter-spindle synchronization
Factory option only
Safety Systems
• AS080 – Overload detection system
Spindle motor overload detector. Automatically stops spindle rotation and axis movements.
Signal Lamps
• PL083 – Signal tower (3 colours)
High-Pressure Cooling Systems
• CS503 – Through-spindle coolant 15 bar / flushing
Coolant flows from the centre of the spindle and is discharged from the spindle nozzle.
Measuring Systems
• MB255 – Measuring probe B (Rmp60)
• MB624 – Smooth Set And Inspect (Multi-Tasking)
Chip Disposal Systems
• CV041 – Side chip conveyor (hinge-type)
Tools
• TE810 – Preparation for Multi&Flash system
NC Options (Additional)
• NO056 – Mazak API interface
Y-1 MAZAK API
NO066 – Smooth synchronous tapping (with milling spindle)
28 SYNC. MILL TAPPING
• NO072 – Automatic peck drilling cycle with load monitoring
53 AUTO PECKING
Automatic detection of built-up chips during machining and at the beginning of the pecking
cycle. High-efficiency deep-hole machining, unattended. Pecking cycle is performed only
when necessary.
• NO116 – Smooth 5-axis control (EIA/ISO)
40 SIMULTANEOUS 5-AXIS
• NO117 – Tool center point control in 5-axis machining
55 TOOL CENTER POINT CONTROL
Option available for 5-axis machines. Controls the tool tip according to the rotary axis angular
position.
• NO123 – Tool radius compensation in 5-axis machining
52 5-AXIS TOOL COMP.
• NO127 – Engraving cycle
98 ENGRAVING
• NO134 – Simultaneous 5-axis machining on second spindle
(requires C-axis control and 5-axis machining)
96 5-AXIS PARAM SELECT
• NO442 – Slope Constant (G00 motion optimization)
33 G00 SLOPE CONST.
Function starts axis servo drives with constant acceleration or deceleration in rapid traverse
G00.
• NO482 – Re-entry into thread
57 RE-THREAD
It is possible to store the re-threading position by selecting this menu function and inserting
the threading tool into the thread groove, thereby guiding the threading tool through the
stored position.
• NO599 – Cylindrical (G07) and polar (G12) interpolation
38 CYLINDER