DMG MORI Innovation Days May 6 - 9

DMG MORI's Innovation Days 2014 will take place May 6 - 9, 2014, in Hoffman Estates, IL. It 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 U.S. premieres, the new common design and the new control platform CELOS.

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, according to the company.

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.

Hybrid machine demonstrations will combine laser metal deposition and turn-mill processes in one machine. On show will be the NT 4300SZ turn-mill center from Iga, Japan. The combination of laser metal deposition via powder nozzle and subtractive machining is intended to accelerate the manufacturing process. "Complete workpieces can be generated up to 20 times faster as compared to powder bed technology," said a company spokesperson. "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 possibilities 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."

Guests to DMG MORI Innovation Days can also learn more 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.

U.S. premieres include:

• DMU 80 P duoBLOCK - "The 4th Generation DMU 80 P duoBLOCK from DMG MORI features improved core properties, namely precision, performance and efficiency, by about 30% compared to previous models," said the spokesperson. The duoBLOCK 5-axis universal machine is intended to provide long-term accuracy and high precision with up to 5 um (0.0002") positioning accuracy.

The DMU 80 P duoBLOCK features the new powerMASTER 1000 motor spindle in the B-axis. According to the company, 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," said the spokesperson.

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.

• CTX 450 ecoline - "The basis of the high-precision machine is a stable construction that allows accurate machining even under difficult conditions," said the spokesperson. "The generously dimensioned ballscrew spindles and wide roller guides achieve best rigidity values and positioning accuracies of at least 0.00031 inches and less - even under 0.00024 inches with a direct measuring system.

"Despite its compact footprint of just 52.7 sq. ft., the CTX 450 ecoline offers a work area for maximum workpiece machining processes. The rear chip conveyor available as an option reduces the front machine width by up to 35%."

The machine comes with an automatic tailstock to aid 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 C-axis available to allow 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.

• NLX 3000Y/1250 - The new NLX 3000Y/1250 features a Y-axis with turning lengths up to 1,250 mm (49.2") and a bar capacity of 111 mm (4.4"). Built-In Motor Turret (BMT) refers to the integrated direct tool drive, which provides enhanced conditions 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," said the spokesperson. "The coolant circuit of the NLX 3000Y/1250 through the machine body and machine bed guarantees high precision, ensuring a consistent temperature of the whole machine.

• U.S. premiere NLX 4000 BY/1500 - Highlights of the NLX 4000BY/1500 are the large traverse path in the X-axis of 1,500 mm (59.1") and steady rests of up to 310 mm (12.2") diameter that can be mounted for supporting workpieces. The maximum turning diameter is 600 mm (23.6") 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"), and the Y-axis in turn provides a traverse path of 120 mm (4.7").

The machine is optionally available with a 145 mm (5.7") or 185 mm (7.3") Y-axis, depending on the bar capacity. This U.S. premiere also features the BMT turret.

• NLX 2500SY/700 - As well as the main and counter spindles, 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"). The turret is also optionally available in VDI design with the TRIFIX high-speed clamping system.

The turning length is 705 mm (27.8") and the maximum turning diameter is 366 mm (14.4"). A turning diameter of 460 mm (18.1") is possible if the Y-axis is omitted. In addition, a clearance of 80 mm (3.1") allows larger diameter bars to be machined. For enhanced temperature management, the coolant floods through the machine body and the machine bed in a circuit, ensuring a constant temperature of the whole machine.

• MAX 3000 - 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 rigidity and agility. The machine was developed for high-precision, high-speed machining of small workpieces.

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" x 11.8"), 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 rapid traverse rate of 62 m/min (2,440.9 IPM) 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, according to the company. Roller guides are used for the guideways to offer better repeatability. The MAX3000 comes with the MAPPS IV high-performance operating system.

Additive Manufacturing

DMG MORI's 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 accurate SM operations to be carried out.

According to the company, 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" to 0.2") 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," said the spokesperson. "Additionally, it offers many interesting options for lightweight components, prototypes or small batch production.

"For integral parts that 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.

For more information contact:

DMG MORI

2400 Huntington Blvd.

Hoffman Estates, IL 60192

847-593-5400

www.dmgmori-usa.com