CTX beta 1250 TC
Turn & Mill complete machining with the new ultra-compact patented turn-mill spindle compactMASTER
Highlights
Complex turning and milling operations with ultra-compact turning/milling spindle and up to 20,000 rpm
- Turning and milling spindle compactMASTER with 12,000 rpm, 22 kW and 120 Nm
- ± 120 mm Y-stroke for external machining
- Swivel range of B-axis ± 110° for maximum flexibility
Tool magazine as a disk or chain magazine for shorter set-up and idle times
- Disk magazine for 24 tools in standard
- Chain magazine with 48 or 80 stations as option
- Tools up to 400 mm length and Ø 120 mm
6-sided complete machining by main spindle up to 700 Nm and optional counter spindle
- Integrated spindle drives with up to 700 Nm for maximum cutting performance
- Counter spindles up to 360 Nm and 65 mm bar capacity as option
- Optional with complete package for bar machining with automatic workpiece pickup device
Accuracy
- Precision in μm range
- Positioning accuracy up to <6 μm and repeatability up to <2 μm
- Linear scales in the linear axes of the traveling column (X1 / Y1 / Z1)
- Liquid-cooled spindles and cooling of the X- / Y- / Z-motors
Application Examples
Automation
Standard automation and customised solutions in the VERTICO design
Automation is a key element of digital production. Every DMG MORI machine can be upgraded with standard automation or with a customised automation solution for flexible manufacturing systems:
Robo2Go Turning
Flexible workpiece handling for small to medium batch sizes
- One app for uniform control of all Robo2Go variants, setting up a new workpiece < 5 minutes
- Robo2Go Turning, robot payload 12, 25 or 35 kg
- Rapid changeover from chuck to shaft parts
- Robo2Go Vision, robot payload 35 kg
- Robust 3D camera recognition, ideal for multi-job function
Highlights
One app for uniform control of all Robo2Go variants.
- Integrated in the machine control operation via CELOS APP: No need to change your NC programs!
- Intuitive usability thanks to dialog-guided software
- Creation of the process through predefined program modules via drag & drop: No robot programming knowledge necessary
- Setting up a new workpiece < 5 minutes
Robo2Go Turning
- Rapid changeover from chuck to shaft part storage
- Handling of shafts ø 20 – 170 mm and chuck parts ø 20 – 175 mm
- Three versions for all requirements: Robot payload 12 / 25 / 35 kg
- Stacking magazine
Robo2Go Drawer Storage
The storage expantion for your Robo2Go Turning
- 300 % higher capacity compared to standard
- Main time-parallel setup of the workpiece storage
- Multijob per drawer and within a drawer possible in the standard system
- Job management of all jobs via the Robo2Go Jobs app
Robo2Go Vision
- Robust 3D camera recognition, ideal for multijob function
- Infeed and outfeed of raw and finished parts by pallet
- Cylindrical chuck parts of ø 25 – 175 mm
Details
Robo2Go Turning – Load capacity 12, 25 and 35 kg
Standard automation but flexible to suit your workpieces
MATRIS Light
Highly flexible and collaborative automation for workpieces up to 5 kg
- Freely movable workpiece handling, incl. robot and storage area on a trolley
- Workpieces up to 5 kg, or 2 × 2 kg with double gripper
- No infrastructure changes
- No safety fence necessary
- 600 × 900 mm footprint
- Collaborative robots, setup time <5 minutes
- Direct teaching without robot knowledge
- Easy connection via Ethernet
- Expansion (option)
- Storage for up to 108 workpieces (2-position storage for max. 36 workpieces as standard)
- Blow-off device
- Measuring system and quality check
Videos
MATRIS
Flexible modular robot system for ≥ 1 machine
- Modular concept with standardized peripheral devices, e. g. washing, measuring or marking
- 80 % shorter setup time due to modular and standardized peripherals and robot programs
- Flexible adaptation to system changes including after installation
- Simple and easy operation via the MATRIS control system without programming
Highlights
Highlights - Workpiece Handling
- Handling of workpieces up to ø 200 × 200 mm, 1 × 20 kg or 2 × 10 kg
- Stacking magazine:
- 14, 20 and 26 pallets: ø 150 × 120 mm, max. 35 kg per pallet
- 10 and 20 pallets: ø 200 × 200 mm, max. 75 kg per pallet
- Loading of oversized tooling in case of vertical machining center
- Available for 13 series, e. g. NLX, NTX, NHX, DMU, NMV, eVo, etc.
Highlights - Pallet Handling
- Ideal for the flexible production of 50 to 200 workpieces / day
- Space-saving pallet handling for up to 40 pallets
- 400 × 400 mm pallet size
- 150 kg transfer weight (workpiece and pallet)
- Integration of secondary processes such as deburring or marking possible
- Available for the CMX 50 U, CMX 70 U, DMU 50, DMU 65 monoBLOCK, CMX 600 V, CMX 800 V, CMX 1100 V
AMR 2000
Holistic automation on the shop floor
- Collaborative automation solution with free layout design
- Omnidirectional movement for minimal space requirements (turning radius 0m)
- Basis for additional tasks, e.g. B. tool handling, chip disposal, etc.
- Material transport from Euro pallets 1,200 x 800 mm
- Maximum transport weight of up to 2,000 kg
- Security based on Sick and Siemens technology
Highlights
AMR 2000 Material
- Autonomous transport of material pallets
- Load capacity up to 2000 kg
- Compact and manoeuvrable
- Integration into existing processes
AMR 2000 chips
- Autonomous transport of chip trolleys
- Automatic pick-up order from the DMGMORI master computer
- Integration into existing material processes
- Extension of machine tool autonomy over the night or weekend
- Fleet ready
AMR 2000 tool handling
- Tool identification in the standard
- Quick installation of the automation system
- Reliable technology with proven components
- Integration into existing production possible
- Max. tool dimensions ø 280 / 400 mm
- Max. tool weight 30 kg
- Transport weight 720 kg (24× 30 kg)
- Maximum number of tools: 24 pcs
Control & Software
FreeTurn
- For shop-floor programming with easier integration in the NC-program.
- Easy tool definition in for the NC-program due to the integrated tool library
- Possibility to define the adjusting angle (kappa) for each cutting edge and each operation to achieve the best machining results
* Simultaneous movement of Kappa must be programmed with CAM
Highlights
AAC – Automatic Approaching Cycle
- Approach to the workpiece with contact detection by means of motor current evaluation of the grinding spindle*.
- Measuring sensitivity adjustable via user interface
- Individual setting of oversize possible after contact detection
*Available as an extension of the grinding package
Highlights
Customer Benefits
- Significant reduction of air cuts, so that the grinding process starts directly at the actual dimension of the workpiece
- Extension of the handling capability, especially when the structure-borne noise on the part cannot be determined clearly
- Full integration in the grinding cycle package
Tool Balance Assistant
- Residual unbalance-based calculation of the permissible tool speed limit in the HMI
- Continuous monitoring and automatic registration of all limit value violations during machining
- Export function of all registered events in tabular form
Highlights
Customer benefits
- High transparency and sensitivity with regard to tool balancing due to simple operation
- Improved dimensional accuracy, surface quality and reduced tool wear due to the consistent use of balanced tools
Polygon- / Oval-Grinding
- Producing high precision oval and und polygon geometries with grinding – tolerance class IT5*
- Easy parametrized definition of the geometries based on DIN 32711
- Perfect complement to technology cycle Polygon- / Oval-Turning
* as extension of the grinding technology cycle
Highlights
Customer Benefits
- New machining opportunities for more innovations on the part – e.g. shaft-hub connections.
- Position-oriented polygon and oval geometries due to 6-sided complete machining advantages
cCLAMP – the clamping force calculator
- Integrated clamping force calculator according to VDI 3306
- Intuitive calculation of the minimum and clamping forces based on the used machining parameters
- Comprehensive package for internal and external clamping with 3 to 8 jaws for turning, milling and drilling
Highlights
Customer benefits
- Avoidance of component deformation due to unknowingly excessive clamping force
- Increased clamping safety
- Faster set-up and safe clamping in combination with iJAW (DMQP RÖHM)
iJAW – Smarter clamping!
- Sensitive clamping force with quick-change jaws
- Controlled clamping force during the machining process
- LIVE measurement of the actual clamping forces
Highlights
Customer benefits
- Optimum clamping force monitoring for process-specific applications
- No component deformation due to unknown clamping force
- Indicator for chuck maintenance, in case of clamping force decrease
crownHOBBING
- Production of hirth serrations by impact milling on turn-mill machines
- Automatic calculation of the tool path movement
- Position-oriented tooth pairings by determining the angular position of the toothing on the component
Highlights
gearSHAPING
- For straight external and internal gears with shoulder (interference contours)
- Toothing modules between 0.3 – 1.5 with quality 8 according to DIN 3961
- Up to module 2 on CTX gamma TC*
*Quality and machining time depending on tool and workpiece
Highlights
safeRETREAT
- Safe decoupling of mold and component at the push of a button (emergency stop).
- Protection of tool and component against damage, in case of an unexpected event.
- Available as an additional option for the technology cycles gearSKIVING 2.0 and Multi threading 2.0
Highlights
Excentric Grinding
- Production of high precision eccentric cylinders by means of grinding* – Tolerance class IT5
- Simple parametric definition of diameter and eccentricity
- The perfect addition to the machining cycle Excentric turning and milling*.
*Can be ordered as an extension of the grinding package
Highlights
gearBROACHING
- Broaching of internal and external splines with dialogue guided programming
- One-Tooth up to 4-theeth cutting tools with clear tool definition for easy setup.
- Compensation parameters for tool holder deviation in X-direction
Highlights
5-axis simultaneous machining
- Free form surfaces by 5-axis interpolation on the main and counter spindle
- Turning and milling with interpolated B-axis
- Programming the 5-axis movements via customer CAD / CAM systems
- An intellegent Look-ahead function for a continuous process
Highlights
gearHONING
- Technology available for the first time on turn-mill machines, as the perfect complement to gear skiving
- Fully integrated operation on the control including automatic probing of the tooth space
- Full technological support from the DMQP partner for tool support for tool design and for start-up
Highlights
Customer Benefits
- Smoothing of the profile line and straightening of the flank lines.
- Improvement of the grading due to smoothed feed marking
- Improvement of concentricity
- Improved overall quality*
*By one quality level, depending on the quality of the previous hobbing process.
Tool sort cycle
- Shorter non-productive times thanks to sorting of tools in the tool magazine according to the sequence of the tools in the program
- Time-optimized sorting in the chain magazine due to the use Of the tool shuttle instead of the spindle
* Optimization is not done in parallel to main time
Highlights
Customer Benefits
- Minimized tool changing times from lot sizes > 3
- Flexible tooling in the magazine depending on the NC program
Grinding
Turning
- Turning, milling and grinding in one clamping
- Grinding cycles for internal, external and face grinding as well as dressing cyclesn
- Body-borne sound sensors for start-up and dressing
- Full integration of measurement module for relative and absolute LIVE-Measuring – parallel to main time
Milling
- Better surface quality through integration of the grinding technology
- Grinding cycles for internal, external and face grinding as well as dressing cycles
- Body-borne sound sensors for start-up and dressingn
- 1,300 l Cooling system with integrated centrifugal filter for The filtration of particles > 10 μ
- AKZ nozzle unit optionally available for best possible Flushing of the grinding gap
Highlights
Easy Tool Monitor 2.0
- Prevention of damage due to tool breakage or tool overload
- Sensorless with automated learning of load limits
- For turning, milling and drilling (up to 3 mm diameter)
- NEW: User interface on CELOS SideScreen
- NEW: Powerful algorithm for efficient monitoring after the first workpiece
Highlights
Customer Benefits
- Protection Package: Perfect supplement to MPC Lathes. Price advantage (approx. 40%)
- Save the monitoring limits for each tool and every cutting edge in the program
Steady rest for turret
- Hydraulically operated steady rest to support long and slim components
- Expansion of the possibility of using multi-channel machines
- The cycle allows both approaching to and retraction from the steady rest
Highlights
Customer Benefits
- Hydraulically operated steady rest in the tool table
- Position-locking the turret leads to increased process safety
- Fix the steady rest position, to position and shape tolerances to comply with the program after reboot
Y-Axis Parting
- Higher stability due to optimal force transmission in thelongitudinal direction of the tool holder
- Generation of tool feed in the Y-direction for parting off components at a push of a button
- Compatible with the standard cycle CYCLE92 (Part off cycle), so that the operator can program as usual (ShopTurn and DIN / ISO)
Highlights
Customer Benefits
- Up to three times higher productivity possible (3x feed) with simultaneously improved chip control
- Reduced noise level and higher surface quality through more tool stability
- Less material loss due to reduction of the parting width
autoCHUCK 2.0
- Automatic optimization of servo drives parameters for Main- and Sub-Spindle
- Reduction of Setup time
- Optimization of machining result
Highlights
Customer Benefits
- Setup Time reduction
- Automatic determination of parameters independent from machine operator experience
- saving the setting in NC-program for more quality assurancet
Keyway Broaching
- Structured input parameters for the groove geometry, the tool and the machining strategy
- Inner and outer grooves in any position and number freely adjustable
- Easy compensation of tool displacement + Calculation of residual strokes based on selected machining strategy
Highlights
Polygon- / Oval-Turning
- Easy handling of non-circular parts
- Intuitive user interface for polygons / oval turning
Highlights
Customer Benefits
- Making the required geometries with possibilities of simple fine-tuning
- Possiblity of fine tuning of the geometric parameters (long / short Semi-axis and bearing angle)
- Machining can be combined with main spindle or counter spindle
Runtime Monitor
- Application especially for multi-channel machines for time analysis of the production process and as a basis for the cycle time optimization
- Individual zoom in to view minute details for cycle time optimization
Highlights
Customer Benefits
- Histogram up to three channels
- Provides the basis for cycle time optimization by graphical inputs
- Save / Load the recorded data to compare individual optimized steps
Excentric turning and milling
- Superposition of the turning movement by additional X- and Y-traverses
- Applicable for turning and milling
Highlights
Customer Benefits
- Eccentric geometries easy to manufacture
- Exact axis coupling and synchronization in the background
Multi Threading 2.0
- NEW: On-Point Threading - Position oriented thread production
- Free definition of contours, pitches and gears possible
- Creation of large transmission threads, which can not be manufactured by simple thread chasing
Highlights
Customer Benefits
- Trapezoidal, buttress and knuckle thread easily programmable at the machine
- Screw conveyor with any profile geometry
- Ball screw nut with cross holes simple to realize
Multi threading 2.0 Pro
Highlights
- Producing profiles with undercut due to the profile splitting option.
- Applying standard tools and tool holder for left and right sided machining of the flanks
- Surface quality of Ra 0,3 an CrNi-Alloys possible
Retraction Cycle
- By pushing the associated key the X- axis and the Y-axis travel to the positive end-positions for external machining
- Ideally suited to prepare the work space for set-up and alternatively also as an emergency rescue function.
Highlights
Customer Benefits
- Easy operation when setting up multi - channel machinery
- Possibilty of a fast response during external machining as a rescue function
Tailstock for turret
- Centring tip mounted on the turret
- Centring tip data is saved directly in the tool memory
- For fixed and spring-loaded centring tips
Highlights
Customer Benefits
- Easy operation for positioning the centring tip
- Position-locking the turret leads to increased process safety
- Pressing force of the tip is variable, programmable and monitorable
Control of program status
- In combination with the Gildemeister structure programming, A safe and fast reboot of the machining program after an interruption
- Easy program operation especially with multiple spindles or tool magazine
- Displays the process status of the workpiece
Highlights
Customer Benefits
- Display of the detailed status on the controller
- Enter remarks automatically by the GILDEMEISTER structure programming.
- Safe re-entry into the program by the press of a button instead of searching for a specific block.
GILDEMEISTER Structural Program
- Structured approach with more than 20 standard programs and more than 200 processing variants incl. automation (bar processing, robot / portal loading, ...)
- Display of the program status with additional markers (EPS) for the sub-programs.
Multitool
- Efficient use of multi-tip turning tools with more than one cutting edge on turn & mill
- Several "sister tools" on one main tool holder
Highlights
Customer Benefits
- Reduction of tool change times
- Saves tool magazine space
Interpolation turning 2.0 – turning recessing cycle
- With interpolation turning, the tool cutter follows a circular movement, where the cutter is always oriented towards the center Of the circle.
- Possible for external and internal machining
- Synchronization and tool path controlled by the cycle
- NEW: in version 2.0 complex turning contours are possible (currently only available on the DMU 50, other machine types will follow)
Highlights
Customer benefits
- Easy manufacturing of sealing surfaces where milling operation might not be possible.
- Complete component processing in one clamping possible
- Reduced investment costs for tools
gearSKIVING 2.0
- Straight and helical external or internal spur gears and splines
- Arrow teeth with tooth offset Turn-mill machines
- Ball-shaped toothing by mathematical transformation of the 6th virtual axis
Highlights
MPC 2.0 – Machine Protection Control
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
Highlights
Customer Benefits
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
Application Tuning Cycle
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight
Highlights
gearHOBBING
- Programming of the gearing parameters via dialog input
- For spur gear, helical gear and worm gear
- Gear cutters and disk cutters can be used
- Maximized tool life by shifting of the cutter
- Achievable quality ≤ DIN 7
Highlights
Alternating speed
- Easy to operate through three parameters and without additional sensors
- Avoiding vibrations by means adaptation of the speed
- Application for the main spindle and counter spindle, or for milling machines with FD tables with Direct Drive
Highlights
Customer Benefits
- No manual intervention by the operator
- Identical repeatability for all components
- Increased process safety for special applications by avoiding vibrations. example, When using long thin drills or for milling parts with critical clamping
DMG MORI gearMILL
- Productive complete processing
- Cost-effective gear cutting on standard machine with standard tools
- Flexible for different gear geometries
- Quality inspection in the process
Highlights
Customer Benefits
- Program creation based on blank drawings and gear data
- Optimization of workpiece orientation e.g. after heat treatment
- Interface for coordinate measuring device (Klingenberg, Leitz, Zeiss)
3D quickSET
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
Highlights
Turning Customer Benefits
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
Milling Customer Benefits
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation