Summary

The Mazak INTEGREX i-500 AG is a hybrid multi-tasking machining center designed for complete gear manufacturing, integrating gear cutting, 5-axis milling, turning, and in-machine measurement. The system supports gear skiving, hobbing, and endmilling within a single setup, streamlining both high-mix, low-volume and mass production of precision gear components. Notable technical capabilities include synchronized rotational control for high-accuracy gear skiving and automated part measurement with phase angle identification, enabling ISO class 5 gear accuracy with correction functions.

Key Capabilities

• Combines 5-axis milling, turning, and gear cutting (skiving, hobbing, endmilling) in a single machine
• In-process gear measurement with scanning probe and automatic phase angle detection (0.005° accuracy)
• Conversational programming and automatic G-code generation for cutting and measuring
• Supports machining with both specialized hob cutters and standard end mills
• Tool life extension and micro-geometry correction functions in integrated gear software
• Automated workflow up to keyway machining, drilling, and deburring based on measured gear features

Key Specifications