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Grace Engineering - Mazak Integrex 100-IV ST Dual Turret Post Processor

License Version Status Phase

A custom Autodesk Autodesk Fusion post processor for the Mazak Integrex 100-IV ST dual turret mill-turn machine with Matrix (Nexus) control.

🎯 Overview

This post processor is specifically designed for:

  • Machine: Mazak Integrex 100-IV ST (Model IN1004ST)
  • Serial Number: 195369
  • Control: Mazak Matrix (Matrix Nexus)
  • Owner: Grace Engineering Corp
  • Configuration: Dual turret, Y-axes on both turrets, B-axis on upper turret, sub-spindle

Key Features

  • ✅ Dual turret support with G109 L1/L2 turret selection
  • ✅ Matrix control M-codes (M901/M902, M200/M300, M950, M562/M563)
  • ✅ Y-axis on both upper and lower turrets (±105mm travel)
  • ✅ B-axis on upper turret (0-90°, programmable) - output pending
  • ✅ Sub-spindle support
  • ✅ Diameter mode for turning operations
  • ✅ Complete motion control (G0, G1, G2, G3)
  • ✅ Drilling cycles (G81-G89)
  • ✅ Tapping cycles (G74/G84)
  • ✅ Boring cycles (G85-G89)
  • ✅ Threading cycles (G76/G92) - NEW in v0.5.0!
  • ✅ Milling and turning operations
  • ✅ Work offset management (G54-G59)
  • ✅ Spindle speed limiting per spindle type

📋 Machine Specifications

Axis Configuration

Axis Travel Notes
X-axis -50mm min (radius) No maximum limit check
Y-axis ±105mm Both turrets
Z-axis Software limits ±100,000mm for calculations
B-axis 0° to 90° Upper turret only, programmable
C-axis 0° to 360° Both spindles, cyclic

Spindle Specifications

Spindle Max RPM Notes
Main 5,060 Kitagawa 6" 3-jaw chuck limitation
Sub 6,000 Standard chuck
Live Tooling 12,000 Both turrets

Turret Configuration

Turret Y-Axis B-Axis C-Axis Live Tools
Upper (TR1/HD1) ✅ ±105mm ✅ 0-90° ✅ ✅ 12k RPM
Lower (TR2/HD2) ✅ ±105mm ❌ ✅ ✅ 12k RPM

🚀 Installation

Prerequisites

  • Autodesk Fusion
  • Access to CAM workspace
  • Basic understanding of mill-turn programming

Installation Steps

  1. Download the Post Processor:

    git clone https://github.com/your-username/grace-integrex-post.git
cd grace-integrex-post

  2. Copy to Autodesk Fusion Post Library:

    Windows:

    Copy grace_integrex_100iv_dual_turret.cps to:
%LOCALAPPDATA%\Autodesk\webdeploy\production\<version>\Fusion\Server\CAM\cache\posts\

    macOS:

    Copy grace_integrex_100iv_dual_turret.cps to:
~/Library/Application Support/Autodesk/webdeploy/production/<version>/Fusion360.app/Contents/Libraries/Applications/CAM/cache/posts/

  3. Select in Autodesk Fusion:

    • Open CAM workspace
    • Right-click on Setup → Post Process
    • Click "Select" next to "Post Configuration"
    • Choose "grace_integrex_100iv_dual_turret" from library
    • Click "Post"

📖 Usage

Basic Workflow

  1. Setup Your Part in Autodesk Fusion

    • Create manufacturing setup for mill-turn
    • Assign operations to correct turret (1=Upper, 2=Lower)
    • Set spindle (Primary=Main, Secondary=Sub)
    • Define work coordinate system (G54-G59)

  2. Tool Assignment

    • Turret 1 (Upper): Tools with Y-axis and B-axis capability
    • Turret 2 (Lower): Tools with Y-axis, no B-axis
    • Enter Tool ID Code in Product ID field if required

  3. Post Process

    • Select this post processor
    • Configure properties (see below)
    • Generate G-code
    • Review output for correctness

Post Processor Properties

Property Default Options Description
Controller Type Matrix Matrix, Smooth Control type
Max Spindle Speed (Main) 5060 0-10000 Main spindle RPM limit
Max Spindle Speed (Sub) 6000 0-10000 Sub-spindle RPM limit
Max Spindle Speed (Live) 12000 0-20000 Live tooling RPM limit
Use Sequence Numbers Tool Change Yes, No, Tool Change N-code output
Use Radius Arcs true true, false R vs IJK for arcs
Use Canned Cycles true true, false Drilling cycles
Optional Stop true true, false M01 output

Example Program Structure

%
(PROGRAM: SAMPLE-PART)
(Grace Engineering - Integrex 100-IV ST)
(Serial: 195369)

G21 G18 G90 G94 G49 G54

(======================================)
(UPPER TURRET - MILLING WITH DRILLING)
(======================================)
G109 L1
M901
M200
M203 S5000
T0101
G54
M8

(Contour milling)
G17
G0 X25.0 Y0.0 Z5.0
G1 Z-5.0 F500
G3 X25.0 Y0.0 I-25.0 J0.0 F800

(Drilling pattern - NEW!)
G0 X30.0 Y10.0
G98 G90 G83 X30.0 Y10.0 Z-20.0 R5.0 Q5.0 F100
X40.0 Y10.0
X50.0 Y10.0
G80

G0 Z50.0
M205
M202
M9
M950
M30

(======================================)
(LOWER TURRET - TURNING)
(======================================)
G109 L2
M901
M202
T0201
M3 S1200
G0 X52.0 Z5.0
G1 Z-25.0 F0.25
X50.0
G0 X100.0 Z50.0
M9 M5
M950
M30

M30
%

📊 Development Status

Current Version: 0.5.0
Status: Development - Cycles Complete (Drilling, Tapping, Threading)

Completed Phases (✅)

  • Phase 1: Foundation Setup

    • Machine configuration
    • Program structure
    • Header/footer generation

  • Phase 2: Matrix Control M-Codes

    • G109 turret selection
    • M901/M902 spindle selection
    • M200/M300 milling mode
    • M950 synchronization
    • Tool management

  • Phase 3: Motion Implementation

    • G0 rapid positioning
    • G1 linear interpolation
    • G2/G3 circular interpolation
    • Feed rate management
    • Y-axis per turret

  • Phase 4: Advanced Operations (40% Complete - IN PROGRESS)

    • ✅ G81-G89 Drilling/tapping/boring cycles
    • ✅ G76/G92 Threading cycles
    • ⏳ B-axis control (upper turret)
    • ⏳ C-axis positioning
    • ⏳ Sub-spindle operations

Pending Phases (🔄)

  • Phase 5: Compound Machining

    • Balanced cutting (M562/M563)
    • Parallel operations
    • Cross-machining (G110/G111)

  • Phase 6-8: Tool Management, Advanced WCS, Testing

See DEVELOPMENT_STATUS.md for detailed progress.

⚠️ Important Notes

Current Limitations

  • ❌ No B-axis output (upper turret B not implemented yet)
  • ❌ No C-axis indexing for live tools
  • ❌ No balanced cutting (M562/M563)
  • ❌ No sub-spindle part transfer
  • ❌ Not tested on actual machine yet

What Works (NEW in v0.5.0)

  • ✅ G76 Compound Threading - Multi-pass automatic threading with depth control
  • ✅ G92 Simple Threading - Single-pass threading
  • ✅ Thread parameters - Pitch, depth, taper, infeed angle, spring passes
  • ✅ All features from v0.4.5 (drilling, tapping, boring)

Safety Warnings

⚠️ DO NOT USE IN PRODUCTION

This post processor is under active development. Before using on the actual machine:

  1. ✅ Validate all G-code in Mazak simulator
  2. ✅ Perform dry run with no part/tools
  3. ✅ Verify all work offsets and tool offsets
  4. ✅ Check spindle speed limits
  5. ✅ Verify turret clearances
  6. ✅ Test with single-block execution first

The developers assume no liability for machine damage, tool breakage, or scrap parts.

🔧 Technical Details

Architecture

This is a standalone, definitive post processor:

  • All machine definitions contained in single file
  • No external machine definition files required
  • Single source of truth for this specific machine
  • Based on Mazak Integrex i-100S reference post

Key Technical Decisions

  1. Diameter Mode: X-axis uses scale:2 to output diameter values
  2. G109 Structure: Each turret section ends with M30
  3. M950 Synchronization: Automatic insertion between turret changes
  4. Modal Output: Efficient G-code with modal suppression

Code Structure

grace_integrex_100iv_dual_turret.cps
├── Header (Machine info, version, changelog)
├── Properties (User-configurable settings)
├── Format Definitions (Number formatting)
├── Global Variables (Machine state, flags)
├── M-Code Definitions (getCode function)
├── Machine Configuration (defineMachine)
├── Turret Activation (activateMachine)
├── Utility Functions (Helpers)
└── Main Callbacks (onOpen, onSection, onLinear, etc.)

📚 Documentation

🤝 Contributing

This is a custom post processor for a specific machine. Contributions are welcome but should maintain compatibility with the Grace Engineering Integrex 100-IV ST configuration.

How to Contribute

  1. Fork the repository
  2. Create a feature branch (git checkout -b feature/improvement)
  3. Make your changes
  4. Test thoroughly (simulator + dry run)
  5. Commit with clear messages (git commit -m 'Add feature: ...')
  6. Push to branch (git push origin feature/improvement)
  7. Create Pull Request

Coding Standards

  • Heavy commenting for clarity
  • Maintain existing code structure
  • Test all changes in simulator
  • Update documentation
  • Follow Autodesk post processor best practices

📝 License

Proprietary - Grace Engineering Corp

This post processor is custom-developed for Grace Engineering's specific machine configuration. Use on other machines may require modifications.

👥 Authors & Acknowledgments

Developed By:

  • Grace Engineering Corp
  • Claude AI (Anthropic)

Based On:

  • Autodesk Fusion mazak_integrex_i-100s.cps reference post
  • Mazak Matrix programming manual specifications
  • Grace Engineering machine parameters (Serial 195369)

Special Thanks:

  • Mazak for programming documentation
  • Autodesk for Fusion CAM platform
  • Mill-turn programming community

📞 Support

For Issues:

  • Open an issue on GitHub
  • Include Autodesk Fusion version
  • Attach generated G-code sample
  • Describe expected vs actual behavior

For Machine-Specific Questions:

  • Contact Grace Engineering directly
  • Refer to Mazak programming manual
  • Consult Mazak technical support

🔗 Resources

📅 Roadmap

Q1 2026

  • ✅ Phase 1-3 completion
  • ✅ Phase 4 started: Drilling cycles
  • 🔄 Phase 4 continuation: B-axis, threading
  • 🔄 Simulator testing

Q2 2026

  • Phase 5: Compound machining
  • First machine dry run
  • Documentation completion

Q3 2026

  • Phase 6-8: Final features
  • Production validation
  • v1.0 release

Last Updated: January 2026
Current Version: 0.4.5
Status: Active Development

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