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Precision Machining of Complex Geometries in Advanced Materials

April 1, 2014

The ULTRASONIC 30 linear features a gantry design with linear technology and integral temperature control.

With the ULTRASONIC, forces during the machining process are reduced by up to 40%, according to the company. As a result, tool life is increased and surface qualities improved with up to Ra <0.1 um in hard-brittle high-performance materials (Zerodur shown).

Work area of the ULTRASONIC 30 linear with integrated swivel rotary table and 19 kW motor 40,000 RPM spindle.

According to DMG MORI, superposition of the tool rotation with additional oscillating kinematics results in significantly reduced process forces.

Finish machining of a watch case from blue zirconium oxide in pendulum grinding with Ra <0.1 um.

ULTRASONIC machining of CFK with double feed rates, avoidance of pulling out of fibers, delamination and built-up edges.

The ULTRASONIC 30 linear from DMG MORI features a stable gantry design with integral temperature control concept designed to open up new possibilities in 5-axis precision machining of advanced materials. "The application focus here is on highest dimensional accuracy, contour accuracy as well as surface qualities of Ra <0.1 um for ULTRASONIC grinding of complex geometries in high performance materials for the optical, watch and medical industries as well as precision mold manufacturing," said a company spokesperson.

The dynamic, actively cooled linear drives in X, Y and Z provide up to > 1.2 g acceleration and 50 m/min rapid traverse. A 40,000 RPM spindle is standard. An optional swivel range of +/- 120° in the B-axis is available. The tool changer features a double gripper; the chain magazine offers 30 tools standard and is optionally available for 60 or 120 tools.

Based on a standardized HSK-40 spindle holder, the ULTRASONIC actuator holders can be exchanged automatically in the milling spindle. These include piezo elements, which are activated with an inductive system via the spindle with a high frequency between 20 and 50 kHz. "The actual tool rotation is superimposed with additional kinematics in longitudinal direction," said ULTRASONIC Sales Manager Benedikt Brocks. "At the cutting edge an amplitude as high as about 10 um is generated. This oscillating contact interruption achieves better lubrication and cooling of the cutting edge as well as optimum removal of particles from the active zone. This ULTRASONIC superimposition of vibrations at the cutting edge of the diamond tool thus reduces the process forces by up to 40%, depending on the material."

"This results in longer tool service life as well as excellent surface qualities of up to Ra <0.1 um for hard-brittle high-performance materials such as glass, ceramics, corundum and other materials that are difficult to machine, such as hard metal or fiber composites," said the spokesperson. "The ULTRASONIC 30 linear thus uniquely combines high-speed cutting and highly efficient ULTRASONIC grinding of advanced materials in one machine. This means a large range of materials can be machined.

"The aim is to achieve component precision in the <5 um range as well as surface qualities of Ra <0.1 um. These are ensured by the highly precise, long-term stable gantry design in particular - highly compact on just 4.6 m floor space with dual drive in the Y-axis and integral temperature control concept. The drives, guides, spindle, machine bed, control cabinet as well as all media are temperature controlled."

The ULTRASONIC 30 linear is equipped with the Operate 4.5 Siemens 840D solutionline. Operate 4.5 is the new system platform from DMG MORI for all machines with Siemens control, from entry level to high-end. Operate 4.5 comprises the entire automation technology of a machine tool, from the drives to the CNC control. Furthermore, Operate 4.5 provides users with a standard user interface for all technologies.

"Due to the up to 40% reduced process forces in ULTRASONIC machining, double feed rates as well as excellent component quality can be achieved," said the spokesperson. ULTRASONIC avoids the pulling out of fibers or delamination as well as formation of built-up edges."

For more information contact:

DMG MORI

2400 Huntington Blvd.

Hoffman Estates, IL 60192

847-593-5400

www.dmgmori-usa.com

Southwest

Mori Seiki Dallas

9001 Currency Street #200

Irving, TX 75063

972-929-8321

TX, LA

DMG MORI

Ellison Technologies - Dallas

9001 Currency Street #200

Irving, TX 75063

972-812-5500

April 2014

Precision Machining of Complex Geometries in Advanced Materials

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