Machining Transformation (MX) by Process Integration, Automation, Digitization and Sustainability
Every 10 years, social needs change fundamentally. DMG MORI has constantly been evolving its business model to meet these needs with new products and services. Now, DMG MORI has matured into a Machining Transformation provider to drive Green Transformation (GX) through process integration and automation of machine tools.
The three areas of Process Integration, Automation and Digital Transformation (DX) have an impact on Green Transformation. The social contribution consists of the resulting sustainability but also includes the solution to the shortage of skilled staff through automation as well as the development of top talent. This can be ensured through an extensive training program as part of Digitization. The goal is to focus on the qualifications of all types of employees – from engineers to machine operators.
Machining Transformation
Process Integration
5-axis opens opportunities in process integration
Workpieces that were sequentially processed by multiple machines can now be manufactured in one technology-integrated machine in a single set-up, such as a 5-axis machine or a mill-turn center to achieve higher accuracy. Following such complex technology integration, automation leads to further resource optimization, such as compensation for lack of operators and eliminating intermediate work-in-process after each operation, which previously occupied shop floor space and costs. Digitization has helped optimize the machining process by visualizing and providing feedback from areas where operators cannot be involved due to automation.
Process Integration
High utilization of one machining center instead of partial utilization of several simple machines.
Technology Integration means that several processes such as turning, milling, grinding and measurement functions are combined in one machine tool for higher productivity. This integration reduces the number of operators needed, frees them from having to carry out multiple setups and contributes to a rewarding working environment within a company. More time can be devoted to high-value-added operations, making work more rewarding for staff.
The integration of several technologies like Turn-Mill, Mill-Turn (FD), ULTRASONIC, LASERTEC, and ADDITIVE MANUFACTURING (DED / DED hybrid) in a single machine tool ensures higher productivity, saves resources and reduces CO2 emissions.
NTX 500
42,000 rpm compactMASTER TURN & MILL Spindle for high speed and micro machining
NTX 1000
Covering Extensive Range of Machining Across All Fields
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Simultaneous 5-axis machining
- Simultaneous 5-axis machining of complex parts with the direct drive motor (DDM) installed in the B-axis
- The B-axis rotation range of 240° and rotation speed of 100 rpm, the X-axis travel of 17.9 in.
- Equipped with a Capto C5 tool spindle as standard, max. spindle speed of 12,000 rpm, 20,000 rpm (Option)
High precision
- Thoroughly controlled thermal displacement by cooling oil circulation in the body
High rigidity
- High-rigidity bed and linear motion guide achieve high rigidity
Peripheral equipment
- Full range of optional equipment for automation, including an in-machine travelling robot and workpiece unloader
NTX 1000 – Shoulder Implant
NTX 2000
Covering Extensive Range of Machining Across All Fields
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High productivity
- The compactMASTER, the world’s shortest tool spindle in its class (350 mm), ensures a wide machining envelop to increase productivity.
- Wide range of machining area with the X-axis stroke of 675 mm (-125 - ＋550 mm) and the Y-axis 300 mm (±150 mm)
- Y-axis stroke of ±40 mm of Turret 2 expands the machining range
Simultaneous 5-axis machining
- Simultaneous 5-axis machining with the Direct Drive Motor (DDM) on the B-axis.
- 6-face machining is available with Spindle 2 to complete the machining of components on one machine.
High precision
- Cooling oil circulation in spindle motors and ball screws controls thermal displacement and achieves highly accurate machining.
Energy-saving
- Energy-saving Setting and Visualization of Energy-saving Effect
NTX 2500
6-sided machining with Turn & Mill Spindle compactMASTER
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High productivity
- The compactMASTER, the world’s shortest tool spindle in its class (350 mm), ensures a wide machining envelop to increase productivity.
- Wide range of machining area with the X-axis stroke of 675 mm (-125 - ＋550 mm) and the Y-axis 300 mm (±150 mm)
- Y-axis stroke of ±40 mm of Turret 2 expands the machining range
Simultaneous 5-axis machining
- Simultaneous 5-axis machining with the Direct Drive Motor (DDM) on the B-axis.
- 6-face machining is available with Spindle 2 to complete the machining of components on one machine.
High precision
- Cooling oil circulation in spindle motors and ball screws controls thermal displacement and achieves highly accurate machining.
Energy-saving
- Energy-saving Setting and Visualization of Energy-saving Effect
NTX 3000
Overwhelming quality by perfect performance
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High productivity
- The compactMASTER, the world’s shortest tool spindle in its class (350 mm), ensures a wide machining envelop to increase productivity.
- Wide range of machining area with the X-axis stroke of 675 mm (-125 - ＋550 mm) and the Y-axis 300 mm (±150 mm)
- Y-axis stroke of ±40 mm of Turret 2 expands the machining range
Simultaneous 5-axis machining
- Simultaneous 5-axis machining with the Direct Drive Motor (DDM) on the B-axis.
- 6-face machining is available with Spindle 2 to complete the machining of components on one machine.
High precision
- Cooling oil circulation in spindle motors and ball screws controls thermal displacement and achieves highly accurate machining.
Energy-saving
- Energy-saving Setting and Visualization of Energy-saving Effect
ULTRASONIC 20 linear
Compact, precise, reliable process with >2 g acceleration and spindle speeds up to 60,000 rpm
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ULTRASONIC technology integration for an expanded machining portfolio
- Technology integration via HSK-E32 / HSK-E40 actuator system
- ULTRASONIC superimposition of the tool rotation with amplitudes up to > 0.254 µin
- Automatic frequency detection -adaption, amplitude regulation and automatic feed adjustment
- Up to 50% reduced process forces due to ULTRASONIC allow for higher feeds, better surface finishes up to Ra < 0.00254 µin, and longer tool life
All in one - ULTRASONIC hard machining of Advanced Materials and HSC machining on one machine
- Powerful, water-cooled spindle variants from 42,000 rpm to 60,000 rpm
- HSC- with max. 60,000 rpm and ULTRASONIC-machining with max. 50,000 rpm
Compact 5-axis portal machine in gantry design with integrated NC swivelling / rotary table (A- / C-axis)
- Compact footprint of only 37.3 ft2 and gantry design (Y-portal) for optimized chip fall
- Optional NC-swivel-/ rotary table with -15° to 130° swivel range (A-axis), C-axis 360° infinite
- Ø 7.9 in clamping surface and 33.1 lb table load (5-axis), rigid table 14.6 in x 12.6 in and 220.5 lb, (3-axis)
Highest dynamic with > 2g acceleration and absolute longterm stability
- Linear drives in X / Y / Z with > 2 g acceleration
- 50% stronger drives in the A-axis
- Stable, FEM-optimized, vibration-damping mineral
- composite column
Integrated linear magazine PH 10 | 100 with max. 99 pallet places (max. 22 lb handling weight)
- Compact footprint with only 64.6 ft²
- Flexible integration of all available clamping systems
- Customer specific expansion modules available on request
LASERTEC 20 PrecisionTool
Diamond tool manufacturing up to 0,008 ft/min with 30% lower cost per part compared to EDM
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DMG MORI PrecisionTool technologies for high end tool manufacturing
Using laser technology to enter into a new dimension of precision tool machining
- Contact-free machining without need of electrodes and without tool wear
- Chip free cutting edges, relief angles and chip breakers in PCD, CVD-D and CBN
- Longer tool life up to factor 2,5 due to laser machining
- Highly dynamic 5-axis separation of cutting inserts out of blanks (Version PreCut)
- Separation is up to 10x faster than conventional wire EDM (version PreCut)
Highly dynamic 5-axis precision machine in the portal design with 0.127 µin positioning accuracy, compact with a 37.7 ft² footprint
- Highly dynamic due to linear drives in the X-, Y-, Z-axis with > 2 g
- Integrated swivel rotary table (4th / 5th axis come as standard) with torque technology, –10° / +130°
- Precision cooling in all axis
State-of-the-art CNC-control
- Siemens 840D solutionline with Operate 4.7 on CELOS from DMG MORI for simple operation and complete integration into the company organization
- LASERSOFT software packages for processing shank and HSK tools, ISO and special cutting inserts, chip breakers
Automation solution with integrated linear magazine PH 10 | 100
- Compact and integrated design with a 64.6 ft² footprint
- Handling of cutting discs, shaft tools and tools with HSK-holder (combination of different tool types possible)
- Customized expansion or combination with additional LASERTEC 20 machines possible on request.
LASERTEC 65 DED hybrid
Hybrid Complete Machining: Additive Manufacturing and Milling in one machine
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Flexibility by utilizing combination of additive and milling machining process for 3D-parts in finished quality
- The laser head is handled by a fully automatic shuttle - without manual intervention
- 5-axis material deposition by coaxial nozzle for homogeneous powder distribution, independent from direction of laser deposition welding
- Full 5-axis milling machine in rigid monoBLOCK-design with < 129.2 ft² footprint
- Process monitoring and adaptive process-control (Closed Loop)
- User friendly and specifically developed software with operator-orientated user interface and CELOS integration
Process monitoring for highest process safety and quality management
- Continuous measuring and monitoring of the laser buildup process as well as automatic regulation of the laser power in real-time for homogeneous part qualities
Siemens NX: Complete Hybrid CAD / CAM – Module for additive and subtractive programming
- One software package for the complete process chain (design, additive process, substractive machining, finishing)
- Exclusive LASERTEC build-up strategies - fully integrated in the CAD / CAM software incl. 3D-simulation of machine and movements for collision prevention
- Shorter time-to-market due to completeted integrated PLM software integration
Completely new product design potential
- 5-axis controlled laser deposition welding in machining centers makes new products possible
- New part features possible due to alternating material deposition and machining strategies
- Improved part performance by utilizing new material combinations (e.g. Copper + Inconel)
- Parts with inner channels for innovative, improved cooling
ADDITIVE MANUFACTURING
LASERTEC 125 DED hybrid
Hybrid Additive Manufacturing: Building, repairing and coating of high value metal parts up to 4,409 lbs.
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LASERTEC 125 DED hybrid - Additive Manufacturing
High flexibility of manufacturing processes by combining welding and milling on one machine for additive manufacture and repair
- The laser deposition head is handled by a fully automatic shuttle without manual intervention
- 5 axis material deposition by coaxial nozzle for homogeneous powder distribution, independent of direction of laser deposition welding
- Full 5-axis milling capability based on the monoBLOCK machine
AM Assistant for the best process reliability and comprehensive traceability
- Integrated thermal imaging camera for observation of the whole working area, adapive process control and constant monitoring of the working distance
- Powder feed rate sensor as well as automatic powder calibration.
- AM Evaluator for visualisation of the relevant process data (e. g. meltpool size, powder mass flow) as a digital 3D-model as well as in the chronological sequence
Siemens NX: Complete Hybrid CAD / CAM – Module for additive and subtractive programming
- One software package for the complete process chain (design, additive process, substractive machining, finishing)
- Exclusive LASERTEC build-up strategies - fully integrated in the CAD / CAM software incl. 3D-simulation of machine movements for collision prevention
- Change between additive and machining programming strategies all within one programming environment.
Using Multi-Materials and Gradient Materials for Improved Part Performance
- Selectively adding materials with more than 60 Rockwell to avoid heat treatment processes
- Improving cooling performance by using bronze material in the mould core
- Better materials and improved reliability in the repair process for increased service life
- Improved performance of exisitng tool designs by adding wear resistant coating
- Material gradients between hard and soft, magnetic and non-magnetic, etc.
LASERTEC 3000 DED hybrid
Hybrid Machining: Additive Manufacturing and Turning / Milling in one Machine
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Flexibility, due to the combination of additive and turning machine process for 3D-parts in finished quality
- Large parts up to ø 670 × 932 mm (at B-axis 180°) or up to ø 400 × 1,321 mm (at B-axis 90°)
- 5-axis material deposition by coaxial nozzle for homogeneous powder distribution, independent from direction of laser deposition welding
- Additive Manufacturing of metals and reactive materials such as Ti-6Al-4V (optional)
AM Assistant supports you during additive manufacturing (Option)
- Monitors melt pool size and temperature and controls laser output by feedbacking the monitored values for a stable build
Melt Pool Monitoring: Continuously monitors melt pool conditions
Working distance monitoring: Measures and monitors the distance between nozzle and melt pool
Automatic Powder Calibration: Automatically measures the powder flow rate
Completely new product design potential
- 5-axis controlled laser deposition welding in machining centers makes new products possible
- New part features possible due to alternating material deposition and machining strategies
- Improved part performance through new material combinations (e.g. Copper + Inconel)
- Parts with inner channels for innovative, improved cooling
LASERTEC 6600 DED hybrid
Laser Metal Deposition & 5-axis machine
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Large Build Area
- Up to 1,040 mm on the X-axis, -280 mm to +330 mm on the Y-axis, 3,890 mm on the Z-axis
- Largest workpiece size: Φ1,010 mm × 3,702 mm
- Suited for large workpieces including rocket engine parts for the aerospace industry, oil-well pipes for the energy industry and shafts for transport aircrafts
Hybrid of metal additive manufacturing technology and subtractive machining
- Efficient additive manufacturing and subtractive manufacturing on one machine with the linear axes (X-, Y-, and Z-axis), B-axis (turn-mill spindle), C-axis (Left spindle and Right spindle)
- Synchronized operation of Left spindle and Right spindle that transfers workpieces between the two spindles to achieve streamlined additive manufacturing processes
- Turn-Mill spindle equipped with the AM head and AM nozzle to carry out metal powder injection and laser irradiation simultaneously
- Laser output - 2,000 W(standard), <4,000/6,000/8,000 W(option)>
Extensive maintenance functions
- Movable and high-performance dust collection duct to prevent dust powder from scattering
- Zero Sludge Coolant Tank that effectively collects fine sludge inside the coolant tank as standard
- Laser sensor installed on the machine cover and window to detect laser before it penetrates the cover and stop it
Process Integration for Enhanced Efficiency: Revolutionizing Manufacturing with DMG MORI
Automation
Automation systems for minimally attended or lights-out and / or weekend shifts
DMG MORI's range of automation systems includes workpiece handling and transport systems, pallet handling systems that transport pallets with fixtured workpieces and tool handling systems that transport cutters to the machines. The company offers a wide range, from small automation systems for single machines to automation for large production lines.
Benefits of automation
- Easy to use: Automation is not rocket science
- Proven technology: You are already using automation
- Night shifts and weekends: Let the machine work over night
- Become more competitive: Reduce your cost per part
- Flexibility: No mass production? – no problem!
- Sustainability: Often 1 automated system can replace 3 stand-alone machines
Digital Transformation (DX)
From CAD-CAM solutions and post-processors to simulation
Establishing a competitive advantage by improving workflows, creating new opportunities, and reducing power consumption.
The integrated Digitization approach is more than just an effective method to raise productivity. The applications reduce energy consumption and CO2 emissions, including increasing the productive spindle hours due to faster programming at or near the machine.
Digital transformation models automatically promote green transformation: The customer can improve productivity and reduce unnecessary energy consumption by working on Digitization. This also reduces CO2 emissions. In other words, embracing Digitization will also lead to Green Transformation.
Green Transformation (GX)
Sustainability
Technology integration saves resources and reduces CO2 emissions, automation leads to longer machine runtimes and Digitization reduces power consumption for customers.
The GX approach is more than the mere reduction of CO2 emissions. It also aims to cut unnecessary work-in-progress and intermediate inventory to realize lean production anywhere in the world. GX has the potential to conserve global resources as well as transform people and the environment.
Social Contribution
The three areas of Technology Integration, Automation, and Digital Transformation impact on Green Transformation. In addition, they thrive on the cycle of constant learning and further development. The result is a social contribution by the organization:
- Technology Integration maximizes management resources and minimizes environmental impact
- Automation helps to solve a shortage of operators
- Digital Transformation supports the development of talent through extensive training programs