Mazak targets entry-level 5-axis market

Making its UK-debut at the company’s EMO Encore open house in December, the new CV5-500 has arrived. And the icing on the cake – it’s designed, developed and manufactured in Worcester. Dave Tudor takes a closer look.

I use the term ‘entry-level’ somewhat cautiously but certainly deliberately here. In this context, entry-level is my attempt at describing the CV5-500’s target market rather than the capabilities of the machine.

Because make no mistake, specification-wise this is a fully-featured, highly capable simultaneous 5-axis machine with a veritable gamut of highly desirable features: like a rigid trunnion table design supported on both sides for heavy machining; linear roller guides on linear axes; and roller gear cams on the rotary table axes. Entry-level by name perhaps, but not by nature.

“The CV5-500 was launched at EMO specifically to focus on a market segment that in terms of specification and price we hadn’t really targeted previously, so this is a huge deal for Mazak,” enthuses Alan Mucklow, managing director, UK & Ireland, sales and service division.

“Prior to its launch, Mazak customers looking to break into 5-axis machining would be looking at the Variaxis i or j series’ which are both comparatively more expensive and have higher specifications. They’re excellent machines but not entry-level. With the CV5-500 we’re directly targeting SMEs and subcontractors wanting an extremely robust, well-spec’d machine at a very competitive price.

“A significant difference between the CV5-500 and many other machines available at this price point is its ability to offer full, simultaneous 5-axis machining rather than just 3+2 or 4+1,” he adds.

“But the overall benefits extend far beyond the machine itself – customers are also buying into the pedigree of the Mazak brand, our extensive 5-axis machining knowledge and exemplary levels of service and support. Making the first step into 5-axis can be a daunting prospect, so we have 23 applications engineers supporting clients every inch of the way. “

Rock solid accuracy

From a build perspective, probably the most significant aspect of the machine is its bridge-type, thermally symmetrical construction (as opposed to a travelling column arrangement) which not only offers rigidity, accuracy and repeatability, but also is a significant factor in the machine’s compact footprint.

The Y-axis effectively ‘carrying’ the rotary axes and the X- and Z- being supported on the cross rail coupled with an all-cast structure all adds up to an extremely rigid and highly accurate machine.

With a length of just 2,300mm (3,365 with conveyor), a width of 2,570mm (2,945mm with CNC panel) and a height of 2,993mm, the CV5-500 certainly won’t take up much real estate, but its weight is reassuringly substantial at 6,500kg. I’ve yet to meet a subcontract engineering company that isn’t short of space so this aspect dovetails well with the CV5-500’s target audience.

However compact footprints are all well and good but not at the expense of accessibility. Fortunately, the CV5-500’s design facilitates easy access both from the side and front: “In terms of work loading, the Y-axis/rotary axis configuration offers the flexibility to upgrade from a single pallet set-up to a more automated solution very easily,” Mr Mucklow advises.

“This can be specified at the time of purchase or as a retrofit later which offers a high degree of future-proofing. 5-axis machining can involve some pretty complex set-ups and the great benefit here is that work loading takes place from the side of the machine, leaving uninhibited front access for the operator. The best of both worlds.”

For optimum flexibility, the CV5-500 is available with a multitude of options. More about those in a minute, but as standard you get X, Y Z-axis travels of 730, 450 and 470mm respectively, 220° (±110°) B-axis table tilt and 360° of table rotation in the C-axis.

Rapid traverse rates of 36m/minute in all linear axes is also standard; as is a 500mm diameter table with 200kg load capacity, a 30 tool ATC, Mazatrol Smooth X control and 12,000rpm/18.5kW spindle.

Pick a package

With optional extras, things get interesting in terms of flexibility. Buyers must specify a production package at the time of ordering but there are five to choose from. These are primarily focused around coolant options: Production Package 1 for example comprises 0.5MPa flood coolant, bed wash coolant and a chip tank (lift out baskets).

Production Packages 2 & 3 are variants on this theme with 0.5MPa/1.5MPa through and flood coolant, bed wash coolant and chip conveyor.

Packages 4 & 5 are designed with automation in mind. Package 4, the basic automation option, comprises 1.5MPa through and flood coolant, bed wash and cover (Niagara) coolant and swarf management. Package 5, the advanced automation variant comes with mist extraction, swarf management, 7MPa through, 1.5MPa flood, cover (Niagara) and bed wash coolant.

Selection of one of the above is mandatory; however there are other measurement, automation, and 5-axis machining packages that are optional depending on the intended application. These include upgrades such as auto right hand side door, a robot interface and Mazacheck calibration software.

On the machine itself, options include a 48 tool ATC, 18,000rpm spindle and scale feedback on the linear axes. On the 18,000rpm high speed option, ballscrew core cooling on the X-, Y- and Z-axes keep things running smoothly.

“Based on many years’ experience designing, developing and selling 5-axis machines plus our in-depth knowledge of the subcontracting marketplace, we’ve designed the CV5-500 with complete flexibility and versatility in mind,” Mr Mucklow explains. “There’s a wide range of optional extras to suit just about every application and customers can specific exactly the functionality they need.”

Take control

Mazak has chosen the Mazatrol Smooth X CNC on the CV5-500 which takes full advantage of the machine’s full 5-axis capabilities. It’s a good choice: the 19 inch touchscreen interface is reassuringly similar to a smartphone or tablet and operationally it’s reported to be a breeze to use. Five highly interactive process home screens – programming, tool data, setup, machining and maintenance – make up the main working elements of the system.

In addition, there are a plethora of powerful features and modules that make the overall package even more attractive.

Functions like: Performance Spindle, which monitors a variety of performance parameters via sensors located in the spindle; Maintenance Support – useful information for preventive maintenance to prevent unexpected machine downtime; and also Thermal Shield – an automatic ambient temperature change compensation system.

These modules are designed not only to warn operators of potential problems and enhance productivity; they also help to optimise the inherent functions built into the machine itself. Variable Acceleration Control for example is a new function which exploits the rapid acceleration capabilities of the linear axes on the CV5-500.

Active Vibration Control is pretty self-explanatory; Smooth Corner Control on the other hand improves surface finishes and reduces cycle times through optimised acceleration/deceleration when machining corners.

Breaking new ground

It’s no secret that there are a number of established players in the entry-level 5-axis arena and without mentioning any names it’s a hotly contested marketplace. Alan Mucklow is more than aware of the challenges ahead, but Mazak’s national and indeed global reputation will certainly help in this regard.

Interest in Mazak machines is unquestionable. Year in year out, its open houses are phenomenally well-attended and its Worcester facility is something of a rare breed in the UK. There’s virtually nowhere else nationally where you can see machines being manufactured from start to finish. I’m always loathe to use the word unique, but Mazak is pretty much out on its own in this regard. This is its USP.

“We’re aware that this is a tough market but confident that the CV5-500 will do really well,” Mr Mucklow asserts. “The machine made its world debut at EMO in Hannover last year and was very well received. It was a similar story at our recent EMO Encore open house in December.

“We took a number of orders at the event but the really encouraging thing was that these were from both existing and new customers. What’s really appealing to clients is the technology inside the machine wrapped up in such a compact footprint.

“This is proving attractive not only to businesses taking their first steps into 5-axis machining, but also larger organisations needing more 5-axis capacity that simply don’t have the room to accommodate bigger machines. Also important is the fact that the CV5-500 was designed with automation in mind.”

The bottom line

I’ve saved arguably the most anticipated part until last – the price. It’s always supremely challenging to find that sweet spot between price and performance but I think Mazak is onto a winner here with the CV5-500.

Depending on specification, the price will range from £145,000 - £175,000. The machine can be seen up close and personal at the Southern Manufacturing show in February and MACH 2020 in April.

Yamazaki Mazak UK www.mazakeu.co.uk