DMG MORI offers LASERTEC 65 3D, a hybrid machine built to incorporate generative laser deposition welding into a 5-axis milling machine. "In times of shorter product life cycles and increasingly complex and more individualized components, generative manufacturing processes can help companies produce new and innovative products more quickly," said a company spokesperson. "Generative manufacturing processes enable the production of complex geometries and workpieces. With the LASERTEC 65 3D, DMG MORI offers a hybrid solution for combined laser deposition welding and 5-axis milling. The machine uses a deposition process by means of a powder nozzle.
"The market for additive processes has been growing rapidly, but up to now, these processes have been restricted to the production of prototypes and small parts which could not otherwise have been manufactured using conventional methods. With the combination of the two processes, metal deposition / additive manufacturing (AM) and metal removal / subtractive manufacturing (SM), on one machine, additive technology complements and enhances traditional machining methods."
To enable generative manufacturing, the LASERTEC 65 3D is equipped with a 2 kW diode laser for laser deposition welding. The 5-axis milling machine in monoBLOCK design is built to carry out accurate milling operations. "Due to the fully automatic changeover between milling and laser operation, the LASERTEC 65 3D is suitable for the complete machining of complex components with undercuts as well as for repair work and the application of partial or complete coatings for moldmaking and mechanical engineering or even medical engineering," said Friedemann Lell, Sales Director at SAUER LASERTEC.
Producing Large Parts
In contrast to laser melting in a powder bed, laser deposition welding enables large parts to be manufactured using a metal powder nozzle, according to the company. "With a deposition rate of up to 1 kg/h / 2.2 lbs./h, this process is up to 10 times faster than the laser generation of parts in a powder bed," said the spokesperson. "The combination with milling opens up new applications. The component can be built up in several steps, whereby milling can be interspersed with deposition welding in order to allow areas which the cutter would no longer be able to reach when the component is finished due to component geometry to be machined to final accuracy."
According to the company, the hybrid machine combines the advantages of milling, such as high precision and surface quality, with the flexibility and high deposition rate of powder deposition welding. "In the case of integral components, where today 95% of the material is removed by milling, with additive processes material is only built up where it is needed," said Lell. "This leads to significant savings in raw materials and costs."
The laser, complete with powder deposition head, is fitted into the HSK toolholder of the milling spindle. It is designed to be automatically parked in a secure docking station while milling operations are being carried out on the machine. The machine and process are operated and controlled with the new 21.5" ERGOline control with CELOS and Operate 4.5 on SIEMENS 840D solution line.
Producing 3D Contours
Using a laser diode, the metal powder is deposited in layers onto a base material and fused without pores or cracks, according to the company. The metal powder is intended to form a high-strength welded bond with the surface. A coaxial inert gas should prevent oxidation during the build-up process. After cooling, a layer of metal forms which can then be mechanically machined.
"As laser deposition welding has long been established as a stand-alone technology, it is ideal for incorporation into DMG MORI's CNC machines," said the spokesperson. "The combination of chip-removal and additive processes will become more important in the future as it opens up so many new options and advantages for the user," said Lell.
According to the company, one strength of this process is the option of successively building up layers of different materials. "Wall thicknesses of 0.1-5 mm / 0.004-0.2 inches are possible depending on the laser and nozzle geometry," said the spokesperson. "Even complex 3D contours can be generated without any support structures."
The company stated that the individual layers can then be accurately machined before the areas become inaccessible to a cutter or other tools due to component geometry. "The combination of the two processes is a sensible choice for repair work and the production of tools and molds," said the spokesperson. "However, it also offers many interesting options for lightweight components, prototypes or small series production, particularly in the large-part manufacturing sector where other additive manufacturing processes cannot be used due to space limitations."
Cutting Costs
According to the company, large machines - such as those used for machining bulky components in the energy or aerospace industries - tend to be expensive. "The possibility of carrying out roughing, deposition and finishing on a single machine presents a financially advantageous solution for the customer," said the spokesperson. "Another example is the energy and oil industry where components often must be coated with corrosion-resistant alloys to protect them against wear. Deposition welding provides protection for products such as pipes, fittings, flanges and special constructions which are used in aggressive environments. With a hybrid solution, machining of the base material, coating and finishing can be carried out on one machine. This results in cost savings and a reduction in throughput times."
Technical Data
Features of the LASERTEC 65 3D include the following:
Feasibility of complete 3D components with diameters up to 500 mm / 19.7 inches without supporting geometry
Travels (X / Y / Z, mm / inches): 650 / 650 / 560 // 25.6 / 25.6 / 22.0
Max. speed (RPM): 10,000 / 24,000 optional
Drive power (40 / 100% DC, kW / HP): 13 / 9 // 17.4 / 12.1
Torque (40 / 100% DC, Nm / ft-lbs.): 83 / 57 // 61.2 / 42.0
Rapid traverse (m/minute / IPM): 24 / 944.9
Feed force maximum (kN / lbf.): 6 / 1,348.9
Clamping surface (mm / inches): 650 mm / 25.6
Table load maximum (kg / lbs.): 600 / 1,000 optional // 1,322.8 / 2,204.6
B-axis swivel range: +120° / -120°
Maximum number of tools: 120.
For more information contact:
DMG MORI USA
2400 Huntington Blvd.
Hoffman Estates, IL 60192
847-593-5400
www.us.dmgmori.com
Southwest
DMG MORI - Dallas
9001 Currency Street #200
Irving, TX 75063
972-929-8321
www.us.dmgmori.com
TX, LA
DMG MORI Ellison Technologies - Dallas
9001 Currency Street #200
Irving, TX 75063
972-812-5500
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Houston
3403 N. Sam Houston Pkwy. West #100
Houston, TX 77086
713-365-9500
www.ellisontechnologies.com
OK
DMG MORI - Tulsa
7633 E 63rd Place, Suite 300
Tulsa, OK 74133
918-932-2893
www.us.dmgmori.com
Southeast
DMG MORI - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-940-3380
www.us.dmgmori.com
VA, NC, SC
DMG MORI Ellison Technologies - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-545-7362
www.ellisontechnologies.com
S. AL, GA, MS, TN
DMG MORI Ellison Technologies - Nashville
7118 Crossroads Blvd.
Brentwood, TN 37027
615-661-6800
www.ellisontechnologies.com
FL
DMG MORI - Clearwater
4585 140th Ave. North, Suite H1008
Clearwater, FL 33762
727-530-1490
www.us.dmgmori.com
Northeast
DMG MORI - Newark
1160 Parsippany Blvd, Suite 103
Parsippany, NJ 07054
973-257-9620
www.us.dmgmori.com
DMG MORI Tyler Machine Tool
111 Ledge Rd.
Seabrook, NH 03874
603-474-7730
www.us.dmgmori.com
DMG MORI Tyler Machine Tool
68 Nutmeg Road South
South Windsor, CT 06074
860-528-4010
www.us.dmgmori.com
Boldt Machinery, Inc.
4803 Pittsburgh Ave.
Erie, PA 16509
814-833-9836
www.boldtmachinery.com
Boldt Machinery, Inc.
104 Boss Rd.
Mattydale, NY 13211
315-463-5754
www.boldtmachinery.com
MD, DE
DMG MORI - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-940-3380
www.us.dmgmori.com
DMG MORI Ellison Technologies - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-545-7362
www.ellisontechnologies.com
Midwest
DMG MORI - Chicago
2400 Huntington Boulevard
Hoffman Estates, IL 60192
847-593-5400
www.us.dmgmori.com
DMG MORI Ellison Technologies - Chicago
4630 Weaver Parkway
Warrenville, IL 60555
630-393-8900
www.ellisontechnologies.com
DMG MORI - Cincinnati
5333 Mulhauser Road
Hamilton, OH 45011
513-874-2736
www.us.dmgmori.com
DMG MORI Ellison Technologies - Cincinnati
5333 Mulhauser Road
Hamilton, OH 45011
513-874-2736
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Cleveland
6955 Treeline Drive
Brecksville, OH 44141
440-546-1920
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Davenport
145 West 76th Street
Davenport, IA 52806
563-388-0800
www.ellisontechnologies.com
DMG MORI Ellison Technologies - St. Louis
16 MB Corporate Park Ct.
St. Charles, MO 63301
636-946-7077
www.ellisontechnologies.com
DMG MORI - Detroit
29050 Cabot Drive
Novi, MI 48377
248-324-1928
www.us.dmgmori.com
DMG MORI Ellison Technologies - Detroit
29050 Cabot Drive
Novi, MI 48377
248-324-1928
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Grand Rapids
1550 Gezon Parkway SW, Suite B
Wyoming, MI 49509
616-261-8665
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Indianapolis
8930 Bash Road, Suite A
Indianapolis, IN 46256
317-577-3723
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Milwaukee
N29 W23825 Woodgate Court West
Suite 100
Pewaukee, WI 53072
262-523-3400
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Minneapolis
13400 10th Avenue North
Plymouth, MN 55441
763-545-9699
www.ellisontechnologies.com
DMG MORI - Kansas City
7500 College Blvd, 5th Floor
Suites 520/521/522/524
Overland Park, KS 66210
913-871-1373
www.us.dmgmori.com
DMG MORI - Wichita
3450 N Rock Rd
Building 500, Suite 505
Wichita, KS 67266
316-425-7993
www.us.dmgmori.com
West
DMG MORI - Los Angeles
5740 Warland Drive
Cypress, CA 90630
562-430-3800
www.us.dmgmori.com
Southern CA
DMG MORI Ellison Technologies - Los Angeles
9890 Pioneer Blvd.
Santa Fe Springs, CA 90670
562-949-8311
www.ellisontechnologies.com
Northern CA
DMG MORI Ellison Technologies - San Francisco
2607 7th St. Suite C
Berkeley, CA 94710
866-814-7238
www.ellisontechnologies.com
WA, ID, MT
DMG MORI Ellison Technologies - Seattle
19625 62nd Ave. South, Suite A109
Kent, WA 98032
253-872-1661
www.ellisontechnologies.com
OR
DMG MORI Ellison Technologies - Portland
10159 SW Commerce Circle #K
Wilsonville, OR 97070
503-682-3280
www.ellisontechnologies.com
AZ
Ellison Machinery
1610 S. Priest Dr. #101
Tempe, AZ 85281
480-968-5335
www.ellisonaz.com
CO
Triad Machine Tool Co., Inc.
7885 West 48th Avenue
Wheat Ridge, CO 80033
303-424-0268
www.triadmt.com
UT, ID, MT, WY
New West Machine Tool Technologies
7990 South 1530 West
West Jordan, UT 84088
801-561-2001
www.newwestmachine.com