A festival of technology

Despite a difficult year in 2009, 2010 has kicked off positively for the global machine tool manufacturer with an order intake value of €58.5 million and 282 machines sold. 

Situated around 150km from Munich, Pfronten is home to the Deckel Maho factory. The event is historically a big deal for DMG in terms of unveiling new machines and technologies and in this regard the 2010 Open House didn't disappoint, with 55 working machines on display of which 14 were new innovations. At €53.4 million, order intake was up on the previous year and 263 machines were sold during the duration of the event. Visitor attendance was claimed to be around the 4,000 mark.

As well as showcasing its new products, DMG also presented number of topical seminars covering subjects such as energy efficient machining and the benefits of holistically optimised process chains in aerospace, automotive and medical applications.

From a broad perspective, the Open House focused on six key areas: Energy Saving; the DMG Process Chain; the DMU 600 and CTX delta 6000 TC – the new heavyweights in the DMG machine tool range; the Great Wall Motors (GWM) project; Ultrasonic 10; and the Lasertec 50 PowerDrill. Energy saving

With the new software tools and service products available under the label ‘DMG ENERGYsaving', DMG claims it will increase energy efficiency in the development, manufacture and use of machine tools. This starts with energy optimised designs, through to the complete machining of components and parts in one clamping position and the energy orientated matching of machines, control systems, methods and sequences with intelligent software tools.
DMG's GREENmode for example, is reported to save up to 20% of energy consumption through intelligent control and performance data acquisition technology. The maximum cutting force per tool is stored by pressing a button during the first processing run of an NC program and for the remainder of the batch, based on these maximum values, the cutting forces are optimised by adaptive regulation, resulting in reduced machining times.

AUTOshutdown is an operator adjustable standby control system designed to optimise the energy balance sheet – allowing the user to set default times for the shutdown of various systems through the control interface, similar to the energy save options of a laptop computer. On a similar theme, DMG EnergySave is a manufacturer independent retrofit kit to reduce power consumption during machine idle time, however it differs from AUTOshutdown because the process is not instigated by a control function but rather by a separate hardware kit, which can be adapted to and used on any machine tool. 

Virtually sound

The new DMG Process Chain is a complete package comprising a CAM system and a DMG Virtual Machine as Rudolf Hahn, managing director of DMG Electronics explains: “The efficiency of a virtual process chain depends mainly on the quality of the data supplied to the workpiece, tool or clamping means, as well as on secure data receipt,” he says. “With the DMG Process Chain we are able to offer customers an optimal solution – starting with the NX CAM from Siemens PLM, the virtual CNC and PLC from Siemens in our DMG Virtual Machine, through to the actual CNC and PLC control systems from Siemens in our machines.”

In contrast to conventional simulation tools, the DMG Virtual Machine operates with ‘real' machine characteristics such as geometry, kinematics and dynamics as well as CNC, control, NC and PLC functionality. 

Bring on the heavyweights

With its DMU 600 and CTX delta TC machines, DMG consolidates its entry into large machine construction for automotive, power generation and plant engineering applications.

The new DMU 600 P gantry machine for example is designed for very large and heavy workpieces. Traversing paths of more than 6,000mm in the Y axis and 3,400mm in the X axis are complemented by a cross beam that can be moved by 2,000mm and the ram by an additional 800mm. The table can accommodate workpiece weights of up to 25,000kg on its 2,500mm by 4,500mm surface and also featured is a special torque spindle for roughing which reaches 7,000rpm and 1,000Nm. The finishing spindle rotates at 24,000rpm and 90Nm.

Dynamic machining allows high feed speeds of up to 30m/minute in the linear axes with acceleration values up to 3m/s². On the control side, the user friendly DMG ERGOline control desk with 19 inch display is utilised and users can choose between Heidenhain iTNC 530 or Siemens 840D solutionline control system.

On the turning front, the third quarter of the year will see DMG enter the large turn/mill machining centre market with its CTX delta 4000 TC and CTX delta 6000 TC.

With turning lengths of 4,150mm or 6,150mm respectively and a maximum turning diameter of up to 1,070 mm, the two machines are particularly suitable for the machining of large shafts. Both machines are equipped with DMG's ERGOline control and large 19 inch screens, complete with 3D high tech control system and ShopTurn 3G based on the Siemens Solutionline 840D.

Further features of the new turning/milling centres include tailstock and counter spindle, a sturdy moving column with solid slide guided centre sleeve, high precision gantry drives in the X and Z axes, and the B axis of the turn/mill spindle swivelling through ±120° with backlash free direct drive. A further aspect of the CTX delta TC series is the tool magazine with tool shuttle moving the tool to the spindle in the machining centre. 

Project Great Wall Motors

DMG claims that modified versions of its DMC 55 H duoBlock and DMC 75 H duoBlock machining centres have been used to good effect by one of its customers, Great Wall Motors (GWM) – the largest privately owned car manufacturer in China, on its crankcase production line. An order was subsequently secured for a total of 18 machining centres.

The modifications included DMG developing a special loading system to replace the conventional pallet changer. Motor spindles with 110Nm torque and 12,000rpm on the DMC 55 H and 288Nm and 10,000rpm on the DMC 75 H guarantee efficient and precise milling of the aluminium crankcases.

Both machine types are equipped with a dynamic vertical chain magazine holding up to 40 tools and a fast, cam controlled double gripper allows tool change times of less than one second. With nine machining steps per component, the machines reach average cycle times of 1.31 minutes. A chip affixed to the component supports the automatic work process and transmits the component type and the machining status to the control system.

Ultrasonic 10 - productivity in dental laboratories

The industrial manufacture of dentures is gaining in popularity and with ultrasonic chip removal, DMG has developed a milling method enabling the efficient machining of hard and brittle materials such as ceramics and synthetic materials. Designed specifically for small and medium sized dental laboratories, the system combines advanced production technology with a compact machine design.

Occupying just 2m² of floor space, the Ultrasonic 10 can easily fit through conventional doorways and in addition to its compact dimensions and ultrasonic chip removal, the machine can also handle the machining of hard and brittle materials such as glass ceramics and special synthetic materials. The high speed milling of difficult-to-machine metals such as titanium and chrome cobalt is also accommodated.

The flexibility of the Ultrasonic 10 is enhanced through its ability to produce complex geometries. The integrated rotary table swivelling through -15° and 120° effectively provides a fourth and fifth axis, thereby allowing extreme undercuts. Two optional automation solutions are available for the smallest Ultrasonic machine to permit unmanned production for several hours which yields valuable time for dental technicians to digitally model new dentures.

Looking to lasers Designed specifically for the machining of turbine blades, heat shields and similar parts for aerospace applications, Sauer Lasertec – a Gildemeister Group subsidiary – has recently complemented its product range with the Lasertec 50 PowerDrill.

With a footprint of just 4m² and polymer concrete base, the Lasertec 50 features a new optical system whereby the focus size can be changed without moving the focal point. Depending on its application, the machine is optionally equipped with high quality Nd:YAG, CO2 or fibre laser, allowing accuracy up to 8μm.

Dimensions of 500mm in the X and Y direction, and 700mm in the Z direction are more than generous for its range of applications, DMG claims. The swivel rotary axis can accommodate workpieces weighing up to 14kg and the linear drives with an acceleration rate of 1g permit rapid traverse speeds of up to 80m/minute in X and Y and 40m/minute in Z.

DMG
www.gildemeister.com