DMG MORI held its annual open house at its Pfronten, Germany facility, to debut advances in machining technologies, including the introduction of six new machine tools and Industry 4.0 enabling technologies.
Thousands from Europe and North America attend the annual event in Pfronten to see latest in machine tool technologies. This year’s event included the world premier of six new machines: the CTX gamma 3000 TC second generation turn-mill machine, the DMU 160 P duoBlock and DMU 210 P universal milling machines, the DMU 600 gantry linear for large part machining, and the Ultrasonic 20 linear machine.
Two highlights at the event were Celos, DMG MORI’s machine user interface that networks all machines within a shop to create an Industry 4.0 enabling solution, and its additive manufacturing technologies, two hybrid machines, Lasertec 65 3D and Lasertec 4300 3D.
A key building block in DMG MORI’s digitalisation strategy is the app-based Celos system, which the machine tool manufacturer first presented around three years ago and which it has consistently continued to develop. Using this uniform user interface for machine and office PC, employees in shop floor and job scheduling can manage, document and visualise job order, process and machine data.
Thanks to its open architecture Celos allows the exchange of information with higher-level structures in addition to its effects in the shop floor area, offering customers complete integration of their machines. The benefits include 30 per cent time saving in tooling times and 50 per cent lower time and effort for the calculation of technology values or the search for important information.
Additive manufacturing technologies
DMG MORI uses powder deposition welding with laser, as it has long been used in principle for repair work in the tool making or engine technology branches. In this process, the powder is melted onto the base material by the laser beam. It differs from other laser-based processes in additive manufacture that work according to the layer principle, whereby a component is built-up layer by layer from powder material.
“We also build up layer by layer, but we only use the powder where it is actually needed”, says Friedemann Lell, sales manager at SAUER GmbH, pointing out the significantly lower quantity of powder used. Other advantages include the around ten times faster build-up of the material and simple integra-tion into existing machine tools. “This allows the integral combination of additive and machining manufacturing in a single setup, so we can offer our customers the best of both worlds.”
By the best of both worlds Friedemann Lell means that additive manufacturing on its own still has its limits with regard to speed, accuracy and surface quality. But proven five axis machining can compensate these limits. He goes on to explain: “The combination of additive manufacturing and machining brings us the geometric freedom, while machining guarantees the precision and quality of the component.” The time-saving benefit derives from the fact that no sequential production necessitating a machine changeover is necessary.
In practice this combination of the two technologies allows completely new complexities. Friedemann Lell sees examples of this in the free formed geometric elements in turbine and engine construction and in the internal cooling channels of injection moulds.
“In the case of sequential manufacturing it would not be possible to reach many of the contour areas with turning, milling or grinding tools after additive manufacture.” In the final analysis, every component can first be built up to a specific height and then certain areas machined. “Large components in particular can be manufactured cost-effectively in this way.”
Debuting new machines
The CTX gamma 3000 TC is a second generation turn-mill machine offering turning lengths of 3,050 mm, making it the largest turn-mill machining centre in the company’s CTX series. The machine is equipped with DMG MORI’s compactMaster mill-turn spindle, deisgn with 220 nM to achieve what the company says is 120 per cent higher torque. At the core of the machine is the B axis with a swivel angle of +/- 120°. The machine features an integrated bed cooling system as well as cooling of the linear guides of the travelling column. The machine is equipped with 36 tool pockets as standard with an option to go with 80, 120 or 180 tools.
The DMU 160 P duoBlock universal milling machine features a 15,000 rpm speedMaster spindle with 35 kW and 130 Nm in the standard version. A key feature is quick toolchange. It offers a 0.5 second tool changeover tim and holds up to 453 tools, despite being a small footprint machine.
Its cousin, the DMU 210 P second generation universal milling machine, has a work area measuring 2,100 x 2,100 x 1,250 mm and a tool magazine that can accommodate up to 303 SK50 tools. A range of spindles are available, inlcuding the speedMaster, the powerMaster and the torqueMaster.
One of the largest machines on display this year was the DMU 600 gantry linear, part of the XXL machining range. The construction of the is based on a single-piece EN-GJS-600-3 (GGG60) cast iron Y crossbeam and X traverse. The side walls are part of the foundation and are made of reinforced concrete. The standard version of the gantry machine is designed for workpieces weighing up to 150,000 kg, with a point load of 15,000 kg/m². The table measures 5,000 x 3,000 mm in a work area of 6,000 x 3,500 x 1,500 mm in the standard configuration. The plunger with optimised interference contour enables travel of optionally up to 2,000 mm in the Z direction, the Y axis crossbeam of 4,500 mm and the X-axis can be lengthened as desired.