DMG MORI’s Innovation Days 2014 from May 6 to 9, 2014, will feature machining demonstrations, seminars and one-on-one application consultations aimed to help manufacturers remain productive and competitive. DMG MORI will be showcasing 38 machine demos, including four innovative U.S. premieres, the new common design and the new control platform CELOS – from the idea to the finished product.
CELOS offers a uniform interface for all new high-tech machines from DMG MORI. CELOS apps provide the user with integrated and digitized management, documentation and visualization of order, process and machine data. Visitors to the event can also experience the New Design at Innovation Days: new long life surfaces provide a higher scratch resistance and better protection against damages.
Among the U.S. premieres will be the new and improved universal turning machines NLX 3000Y/1250 and NLX 4000BY/1500, as well as the 4th Generation 5-axis machining center DMU 80 P duoBLOCK® and the recently released compact CTX 450 ecoline.
One highlight will certainly be the hybrid machine demonstrations, combining laser metal deposition and turn-mill processes in one machine. On show will be the NT 4300SZ turn-mill center from Iga, Japan. The unique combination of laser metal deposition via powder nozzle and subtractive machining accelerates the manufacturing process. Complete workpieces can be generated up to
20-times faster as compared to powder bed technology. Additionally, unique machining operations are possible – for instance the realization of geometric features with negative angles. Thanks to these characteristics, additive manufacturing opens up new perspectives in the machining of large workpieces as required by the aerospace sector and other industries.
Additionally, presentations on the many facets of today’s advanced manufacturing will include gear milling technology. Special software and newly developed processes have transformed the turn-mill centers of the NT and NTX series into perfect gear milling machines for small and medium-sized batches. The machines can accomplish virtually everything that special gear cutting machines can do. They are also more flexible, making cost-effective capacity planning far easier.
U.S. manufacturing at its best
Guests to DMG MORI Innovation Days can also inform themselves about the company’s Digital Technology Laboratory (DTL) and Manufacturing Factory, which make up the company’s Davis, CA campus. DTL provides much of DMG MORI’s engineering analysis capability and R&D to support machine tool design and manufacturing operations around the world. The building also houses a showroom of machine tools and related products. The Manufacturing Factory, opened in July 2012, covers 200,000 sq.ft. of manufacturing space and an expansive showroom. Here, DMG MORI manufactures and assembles the NHX series, as well as the DuraVertical 5100. In 2014, production of the DMU 50 and CTX 450 ecoline will start. Since U.S. manufacturing started to rebound in 2013, DMG MORI USA has seen increased interest in its high-end equipment, which can now be backed up by the viable resources available at the Davis, CA facilities.
The Manufacturing Factory of DMG MORI in Davis covers 200,000 sq.ft. of manufacturing space and an expansive showroom.
U.S. Premiere: DMU 80 P duoBLOCK® –
4th Generation duoBLOCK® for 30 % more performance, precision and efficiency
The 4th Generation DMU 80 P duoBLOCK® from DMG MORI provides 5-axis machining at the highest level with outstanding performance features. We have significantly improved the core properties of the DMU 80 P duoBLOCK®, namely precision, performance and efficiency by about 30 % compared to previous models. The duoBLOCK® design from DMG MORI has long been proven in industries such as aerospace, automotive engineering, mechanical engineering or tool and mold manufacturing. The highly stable design of the 5-axis universal machine, the long-term accuracy and highest precision with up to 5 μm (0.0002 in) positioning accuracy strengthen the worldwide market leadership in a complex production environment.
The high rigidity of the DMU 80 P duoBLOCK® provides the basis for heavy machining with the new powerMASTER 1000 motor spindle in the B-axis. Its maximum torque of 1,000 Nm (737.6 ft/lbs) corresponds to an increase of 130 %. The output is at 77 kW (103 hp), the maximum torque at 9,000 rpm. These properties provide a milling performance and chipping capacity in a new dimension: Compared to the competition, DMG MORI achieves a 75% higher chip removal volume.
The machine is available with CELOS from DMG MORI with 21.5” ERGOline® and SIEMENS or with Operate 4.5 on SIEMENS 840D solutionline or with HEIDENHAIN TNC 640.
U.S. Premiere: CTX 450 ecoline –
Sophisticated turning in the entry-level class
The new CTX 450 ecoline follows the course that ECOLINE has been promoting for years: top technology with proven components at the best price. The ECOLINE machines built by DMG MORI are high-quality machines that can be used by everyone. The basis of the powerful, dynamic and high-precision machine is an extremely stable construction that allows accurate machining even under difficult conditions. The generously dimensioned ball-screw spindles and wide roller guides of the
CTX 450 ecoline are unbeatable in this class and set the machine clearly apart from the competition. They achieve best rigidity values and positioning accuracies of at least 0.00031 in and less – even under 0.00024 in with a direct measuring system.
Despite its compact footprint of just 52.7 sq.ft., the CTX 450 ecoline offers a generously dimensioned work area for maximum workpiece machining processes that is unique in this segment. The rear chip conveyor available as an option reduces the front machine width by up to 35 %, so the production area can be used far more efficiently and flexibly.
The machine comes with an automatic tailstock to aid exact machining of long shaft parts and a turret for 12 tools as standard, or a servo turret
with 12 driven VDI and six block tool stations. There is also a real C-axis available to allow highly efficient turn-mill operations. The CTX 450 ecoline is available with 15” SLIMline® with Operate 4.5 on SIEMENS 840D solutionline, 15” SLIMline® with HEIDENHAIN CNC PILOT 640 or 10.4” TFT screen with MAPPS IV and MITSUBISHI.
U.S. Premieres: NLX 3000Y/1250 | NLX 4000BY/1500 / NLX 2500SY/700
Three new models complement the successful NLX series
No less than three new models in the new DMG MORI design complement the successful NLX series since EMO 2013. Every year, more than 1,200 NLX machines are sold. The NLX series provides its users with a maximum of performance, flexibility and reliability. The integrated cooling system in the machine bed ensures better thermal stability. The flat guides in all axes serve as optimum basis for efficient turning.
U.S. Premiere NLX 3000Y/1250: Accurate efficient turning and milling with BMT® turret up to 1,250 mm (49.2 in) turning length
Next to the general advantages of the NLX series from DMG MORI, the new NLX 3000Y/1250 provides the additional highlight of a Y-axis with turning lengths up to 1,250 mm (49.2 in) and a bar capacity of 111 mm (4.4 in). BMT® (“Built-In Motor Turret”) refers to the integrated direct tool drive, which provides optimum conditions also for heavy milling operations with up to 10,000 rpm and the high torque of up to 54 Nm (39.8 ft/lbs). Even large threads up to M4 x P3.0 can be optimally machined.
The wide flat guides provide ideal machining conditions for complex turn-mill complete machining. The coolant circuit of the NLX 3000Y/1250 through the machine body and machine bed also guarantees high precision, ensuring a consistent temperature of the whole machine.
U.S. Premiere NLX 4000 BY/1500: Efficient complete machining of large workpieces of up to 500 mm (19.7 in) diameter and 1,500 mm (59.1 in) turning length
Characteristic highlights of the NLX 4000BY/1500 are the large traverse path in the X-axis of 1,500 mm (59.1 in) on the one hand and, on the other hand, steady rests of up to 310 mm (12.2) diameter can be mounted for supporting workpieces. The maximum turning diameter is 600 mm (23.6 in) for the version with driven tools (MC). For the model with integrated Y-axis, the turning diameter measures
a maximum of 500 mm (19.7 in), and the Y-axis in turn provides a traverse path of 120 mm (4.7 in). The machine is optionally available with a 145 mm (5.7 in) or 185 mm (7.3 in) Y-axis, depending on the bar capacity. This U.S. premiere also impresses with the BMT® turret.
NLX 2500SY/700: Efficient complete machining
One of the top models in the NLX range is the NLX 2500SY/700. As well as the main and counter spindles, which are obligatory in this performance class, the standard BMT® turret provides space for 12 driven tools, which can cut material at speeds of up to 10,000 rpm (10 or 20-station turrets are available as an option). The Y-axis travel is 100 mm (3.9 in). The turret is also optionally available in VDI design with the TRIFIX® high-speed clamping system.
The NLX2500 SY/700 has been designed with generous traverse distances in order to cover a wide spectrum of parts. The turning length is 705 mm (27.8 in), and the maximum turning diameter is 366 mm (14.4 in). A turning diameter of 460 mm (18.1 in) is possible if the Y-axis is omitted. In addition, a clearance of 80 mm (3.1 in) allows larger diameter bars to be machined.
Finally, an important feature for machining accuracy is the excellent temperature management. For this purpose, the coolant floods through the machine body and the machine bed in a circuit, ensuring a constant temperature of the whole machine.
MAX 3000 – High-speed 30-tape vertical machining center revolutionizes the shop floor
Made for the demands of the automotive industry, the MAX 3000 30-taper vertical machining center comes standard with a high-speed, 2-station automatic pallet changer (APC) and offers both superior rigidity and agility.
The machine was developed aiming at high-precision, high-speed machining of small workpieces, with the first priority on enhancement of customers’ productivity and efficiency.
The compact MAX 3000 features a footprint of only 4.6 m2 (49.5 sq.ft.) despite employing a two-station APC. The table working surface of 600 mm x 300 mm (23.6 in x 11.8 in), which is suitable for machining small automotive parts, allows a round table to be installed, enabling the machine to offer a broad range of machining from small part machining using high-speed feed to complex machining requiring simultaneous 4-axis control.
The MAX 3000 achieves the fastest rapid traverse rate of 62 m/min (2,440.9 ipm) in its class on all axes. In order to suppress pitching, the MAX 3000 has reduced the weights of the column and other moving parts without losing its rigidity, and minimized the distance between the center of gravity of the moving parts and the guideways. Roller guides are used for the guideways to offer even better repeatability. The MAX3000 comes with the MAPPS IV high-performance operating system.
Additive Manufacturing – Additive and subtractive machining in one setup
Additive manufacturing offers new possibilities for high complexity and individuality and the market for additive technologies is growing quickly.
DMG MORI’s unique hybrid solutions combine subtractive machining (SM)
and laser metal deposition processes for additive manufacturing. The LASERTEC 65 3D is based on a DMU 65 monoBLOCK® machine and has been developed by SAUER LASERTEC in Pfronten, Germany, in collaboration with DMG MORI USA. The LASERTEC 4300 3D is based on the turn-mill center NT4300SZ from Iga, Japan. Both machines are equipped with powerful diode lasers for deposition of the metal, while the 5-axis and turn-mill machine platforms enable highly accurate SM operations to be carried out.
The metal deposition process via powder nozzle is up to 20 times faster than laser sintering in a powder bed. All common metal powders can be processed, including steel, nickel and cobalt alloys, brass or titanium. Wear protection layers can also be applied on the base material.
One strength of this process is the option to successively build up layers of different materials. Wall thicknesses of 0.5 mm to 5 mm (0.02 in to 0.2 in) are possible depending on the laser and the nozzle geometry. Complex 3D contours can also be generated in layers without supports.
The individual layers can then be accurately machined before the areas become inaccessible to a cutter or other tools due to interference with subsequently deposited component geometry. The combination of the two processes is a sensible choice for repair work and the production of mold tools. Additionally, it offers many interesting options for lightweight components,
prototypes or small batch production.
For integral parts which are traditionally milled with a material waste rate of 95% and more, significant cost savings can be achieved and the rate of waste can be reduced to about 5%. Series production is planned for fall 2014.