05/15/2019|Chicago Innovation Days 2019 - 5-Axis Machining

Innovative Complete Machining for Every Application

DMG MORI specializes in the production of highly complex work pieces with a wide range of 5-axis solutions.

5-Axis Logo
  • Solution experience for 5-axis machining
  • DMU 50 3rd Generation with PH 150: Meeting the 5-axis requirements of tomorrow
  • DMU 75 monoBLOCK / DMU 95 monoBLOCK: Productive machining solutions with the monoBLOCK series
  • duoBLOCK series: Precision, performance, and efficiency
  • DMU 200 Gantry: 5-axis machining with up to 30,000 rpm and optional technology integration
  • ULTRASONC machining: Complete machining of advanced materials
  • LASERTEC 3D hybrid: Perfect additive and metal-cutting combination

5-axis machining was initially an answer to the trend towards increasingly complex work pieces. Today, it is increasingly becoming part of productive mass production in many industries, including Aerospace, Automotive, Medical, and Die & Mold making sectors. DMG MORI has been supporting these trend-setting industries with innovative manufacturing solutions for many years. The machine tool manufacturer will be showing a representative cross-section of its wide-ranging 5-axis portfolio during the Innovation Days in Chicago. DMG MORI will present a DMU 50 3rd Generation automated with a PH 150 pallet handling, two monoBLOCK machines and two models from the duoBLOCK series as well as the DMU 200 Gantry. The ULTRASONIC 20 linear and the LASERTEC 3D machines for additive manufacturing complete the 5-axis exhibits.

Solution experience for 5-axis machining

DMG MORI provides a 36-month MASTER spindle warranty – without any hourly limitation.

The 5-axis technology has proven to be an efficient machining solution for complex workpieces. It can manufacture parts in one clamping when 3-axis milling requires at least two or more process steps. With its experience in 5-axis machining DMG MORI consults customers specifically regarding their applications. This Solutions Experience includes technological aspects as well as economic challenges. Thus, customers are able to compare expected costs for machining complex parts using 5-axis or 3-axis machining. This work also involves looking at solutions for the financial investment into a 5-axis machining solution. During Innovation Days DMG MORI will have a special counter where experts will present the technological and economic advantages of 5-axis technology.

DMU 50 3rd Generation with PH 150: Meeting the 5-axis requirements of tomorrow

The PH 150 palette handling increases the productivity of the DMU 50 3rd and offers up to 24 pallets with a pallet size of 20 x 20 in.

While enhancing the DMU 50 3rd Generation, DMG MORI has managed to balance the modern appearance of the design with user-friendly operation. The large, smooth opening door to the work area, for example, with a width of 35 inches, ensures unrestricted access to the work zone from the front, even in combination with automation solutions. The table also has an ergonomic loading height of 32 inches, which gives optimum accessibility and the machine design encompasses maintenance friendly components such as the control cabinet, fluid box, oil mist separator, heat exchanger and cooling unit.

Axis Travels of 26 x 21 x 19 inches and work piece weights of up to 661 lbs. gives the DMU 50 3rd generation the ability to cover a wide range of components. Its new NC rotary table with an enlarged range of -35°/+110° enhances this versatility. A rapid traverse rate of 42 m/min and 30 rpm in the rotary axis ensure the dynamics for 5-axis positioning as well as 5-axis simultaneous machining. In addition to the 15,000-rpm speedMASTER spindle, the user can also choose spindles with up to 20,000-rpm. Uniting all of DMG MORI’s expertise the MASTER motor spindle series is characterised by high reliability and a significantly longer lifecycle compared to conventional spindles. With this increased reliability, DMG MORI provides a 36-month MASTER spindle warranty – without any hourly limitation. Also available as an option is an expanded tool magazine with up to 120 tools, with the 30 tool magazine being the standard version.

In addition to the expanded tool magazine capacity, the PH 150 palette handling system increases the productivity of the DMU 50 3rd Generation and offers up to 24 pallets with a pallet size of 20 x 20 inches and a work piece weight of up to 551 lbs.

DMU 75 monoBLOCK / DMU 95 monoBLOCK: Productive machining solutions with the monoBLOCK series

The DMU 75 monoBLOCK has a footprint of only 86 ft² and can be machining workpiece size up to 33 inches.

Die & Mold, aerospace, or energy – with a 20,000 rpm speedMASTER spindle (with a 36-month warranty without any hourly limitation) and a 60 tool magazine, the DMU 75 monoBLOCK and DMU 95 monoBLOCK machines offer top features from the ground up for many industries. With a footprint of only 86 ft² (DMU 75 mB) and 132.4 ft² (DMU 95 mB) and work piece size up to 33 inches (DMU 75 mB) and 41 inches (DMU 95 mB) in diameter can be machined. Two control systems and the integrated MPC (Machine Protection Control) complete this unique 5-axis solution.

The monoBLOCK machine concept is the ideal basis for sophisticated applications in demanding industries and the ergonomic design ensures user-friendly operation. Work pieces can be loaded easily from the top by crane, and chips are discharged from the rear of the machine using a large chip chute. The machine’s 3-point-support design allows for easy installation and stainless-steel covers in the working area guarantee longevity. Several options like tool change capacities, tool and part measuring sensors, and production packages are available. There are two control options for the DMU 75 monoBLOCK as well as the DMU 95 monoBLOCK and both are equipped with DMG MORI’s CELOS HMI (Human Machine Interface) and customers can choose between Siemens Operate 4.7 on the SIEMENS 840D solution line or HEIDENHAIN TNC 640. Additionally, MPC (Machine Protection Control) is one of DMG MORI’s exclusive Technology Cycles that provide machine protection thanks to vibration sensors integrated into the spindle.

duoBLOCK series: Precision, performance, and efficiency

The DMC 80 FD duoBLOCK has a pallet changer, that allows new party during the process.

With an installation base of approximately 4,500 duoBLOCK series machines, DMG MORI has redefined 5-axis simultaneous machining. Over the years, the duoBLOCK concept has been continuously improved resulting in the fourth generation duoBLOCK, with further enhanced flexibility and productivity. With increased rigidity and innovative cooling systems, the accuracy has been increased by over 30% and the portfolio of MASTER spindles offers choices for high-performance manufacturing – either in high-speed machining with up to 20,000 rpm or heavy-duty milling with gear-driven torqueMASTER spindles which produce up to 1,328 ft./lbs of torque.

During Innovation Days, DMG MORI will be demonstrating the DMC 80 FD duoBLOCK and DMC 125 FD duoBLOCK showcasing complete machining solutions consolidating milling and turning operations in one production platform. Furthermore, both models have a pallet changer which allows users to setup new parts during the machining process to maximize spindle utilization.

DMU 200 Gantry: 5-axis machining with up to 30,000 rpm and optional technology integration

The DMU 200 Gantry has a footprint of 258.33 ft²

The DMU 200 Gantry from DMG MORI combines the machining of large components and maximum machine dynamics. Users benefit in the aerospace and automotive industry as well as in model making and the energy sector.

With 5-axis machining capability of up to 30,000 rpm and optional ULTRASONIC or LASERTEC technology integration, more complex components weighing up to 10,000 kg made of aluminium or composites as well as welded components can be machined economically. The machine can be easily loaded from the top with a crane.

The optimized gantry design of the DMU 200 Gantry enables maximum utilization of the work area. With a footprint of no more than 258.33 ft² the machine achieves travels of 78.74 x 78.74 x 47.24 in, which complements DMG MORI’s product range, between the DMF and the DMU P series. In addition, the ratio of the large work area of 6.5 x 6.5 ft to less than 258.33 ft² footprint impresses customers. The DMU 200 Gantry is an ideal complement of the DMG MORI product portfolio for the machining of large components. 

ULTRASONIC machining: Complete machining of advanced materials

The ULTRASONIC 20 linear relies a long-term stable gantry.

For many years, DMG MORI has been offering high-performance machining solutions with ULTRASONIC technology for 5-axis of complex workpieces made of advanced materials. With the ULTRASONIC 20 linear, visitors at Innovation Days will see examples of this innovative machining solution. The ULTRASONIC 20 linear is a gantry machine design, which meets the demands of ultrasonic 5-axis machining. Spindle speeds up to 60,000 rpm, powerful linear drive motors, and CELOS with applications specifically developed for the ULTRASONIC technology, are all features that users from the fields of optics, precision engineering, clocks, medical and high precision die & mold manufacturing will benefit from. In detail, the ULTRASONIC technology achieves a higher material removal volume, and up to 40 percent reduced process forces during machining of advanced materials like glass, ceramics, sapphire, hard metal and composite materials as well as carbide. The precision of the workpieces and reliability of the process is increased at the same time. The “oscillating” interruption of the tool contact with the workpiece results in improved cooling of the cutting edges and the optimum removal of particles from the work piece. The outcome is longer service life of the tools and excellent surface quality of up to <0.1 µ for hard-brittle high-performance materials.

LASERTEC 3D hybrid: Perfect additive and metal-cutting combination

The combination of laser deposition welding and machining on a single machine is used in the 5-axis LASERTEC 65 3D hybrid and the LASERTEC 4300 3D hybrid.

DMG MORI already revolutionized the additive manufacturing of metal components four years ago by combining laser deposition welding and machining on a single machine. This concept is used in both the 5-axis LASERTEC 65 3D hybrid and the LASERTEC 4300 3D hybrid. It combines laser deposition welding and 6-sided turn-mill machining. Both machines are designed for the manufacturing of comparatively large components such as complex turbine components. Work areas of ø 20 x 16 inches in the case of the LASERTEC 65 3D hybrid and ø 26 x 51 inches for the LASERTEC 4300 3D hybrid speak for themselves as do workpiece weights of up to 1323 lbs or 1984 lbs.

What is revolutionary about the machine concept of the LASERTEC 3D hybrid series is the diversity of the possible applications. Laser deposition welding and milling or turn-mill operations in a single set-up mean that work pieces can be produced in finished part quality. Whereby the powder nozzle and milling head can also be changed over at any time. Especially where complex geometries are concerned, areas can be machined that would no longer be accessible on the finished part. Such applications are particularly required in the aerospace, energy technology, and die & mold industries. Added to this is the option of producing innovative components from two or more materials and even graded materials by using different powder nozzles.

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