Mazak MegaStir Tools & Tool Holders
FSW Tools
An FSW tool consists of a protruding pin that plunges into workpieces and a larger concentric shoulder that remains on the surface of the joint. When tools rotate in contact with the base workpiece material, the action creates frictional heat that produces a plasticized region around the tool.
With extensive FSW tooling experience, Mazak MegaStir is an industry leader in the development of advanced FSW tooling produced from ultrahard materials for specific part material applications. We are the current patent holders for using diamond tool material in FSW joining of aluminum and cooper applications and the original inventors of PCBN tools for steel part applications. Additionally, we currently hold a patent for tools made from our special blend of PCBN.
Diamond FSW Tooling
High-performance diamond tools for full-rate production.
Specifications
- Tips: polycrystalline diamond
- Shank/Shoulder: 1 inch, 25 mm, 38 mm, 50 mm
- Shoulder Diameter: 25 mm, 38 mm, 50 mm
- Threading: C4 or MM
- Custom Pin: Contact Mazak MegaStir
Standard FSW Tooling
Standard tools for joining soft metals.
Specifications
- Tips: H13 tool steel
- Shank/Shoulder: 1 inch, 25 mm, 38 mm, 50 mm
- Shoulder Diameter: 25 mm, 38 mm, 50 mm
- Threading: C4 or MM
- Custom Pin: Contact Mazak MegaStir
High Temp CBN FSW Tooling
Robust tool for various high-strength metals.
Specifications
- Tips: PCBN with tungsten-rhenium binder
- Shank/Shoulder: 1 inch, 25 mm, 38 mm, 50 mm
- Shoulder Diameter: 25 mm, 38 mm, 50 mm
- Threading: C4 or MM
- Custom Pin: Contact Mazak MegaStir
FSW Tool Holders
With all aspects of effective FSW in mind, Mazak MegaStir continues to lead in the advancement of tool holding technology for the process. Within that technology are the company’s patent Intelligent Tool Holders that allow Mazak machines to seamlessly switch from conventional machining processes to FSW operations with the speed and simplicity of an automated tool change.
Intelligent Liquid-Cooled Tool Holder
For even greater accuracy and process security, the FSW Intelligent Tool Holder is also available with a liquid-cooled variant that provides all the same integrated features with the addition of advanced temperature-control capabilities. Liquid cooling ensures the longest tool life and the strongest possible welds, especially in high-temperature applications or those performed with softer FSW pin materials.
Specifications
Maximum load capability | 20,000 Ibf (88.9kN) |
Maximum spindle speed | 1,000 rpm |
Wireless frequency | 2.4 GHz IEEE |
Analog output | 8 channel analog outputs (0-3vDC) |
Temperature sample rates | 64 hertz |
Load sample rates | 512 hertz |
Tool shank size | 25/38/50 mm diameter |
Intelligent Tool Holder
The FSW Intelligent Tool Holder is an all-in-one tool holder and telemetry system that collects tool temperature, Z-axis load and data wirelessly for fine-tuning the FSW process. Analog outputs enable holder integration with Mazak’s MAZATROL Smooth machine controls for temperature or force-based algorithmic control of the process.
Features and Specifications
Features
· Wireless telemetry system with load, temperature and torque measurement capability.
· Works as a stand-alone device or simultaneously with a PC using USB interface for added utility.
· Easy to use “nodes” are fully rechargeable and connect wirelessly to a USB receiver.
· Up to 8 analog outputs for PID control (including output replicates).
Specifications
Spindle taper | CAT 40, CAT 50, HSK |
Load capability | 6,000 lbf (26.6kN) max |
Maximum spindle speed | 4,000 RPM |
Wireless frequency | 2.4 GHz IEEE 802.14.4-compliant |
Analog output | 8 channel analog outputs (0-3vDC) |
Temperature sample rates | 64 hertz |
Load sample rates | 512 hertz |
Tool shank size | 25 mm diameter |