ULTRASONIC: Innovative ultrasonic machining for hard and brittle materials
Short processing times, high productivity and accuracy for the production and machining of brittle and hard materials (advanced materials), such as ceramics, glass, corundum, carbide and fibre-reinforced materials (composites): all of this is now possible with ultrasound-assisted grinding, milling and drilling using machines from DMG MORI’s ULTRASONIC series.
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ULTRASONIC Machining: Advantages of ultrasonic technology
Superimposing a longitudinal ultrasonic vibration on the rotating tool reduces the process forces by up to 50 percent during machining. Depending on the requirements, this could make it possible to increase feed rates, improve surface quality, minimise wear and tear of the tool and consequently achieve the production of high-precision materials. Microscopic cracks inside the material (also referred to as SSD or sub-surface damages) are reduced to a minimum, which significantly shortens the time required for subsequent polishing processes.
All of these properties make ultrasonic technology a highly productive and reliable method that is particularly well suited for the production of components in the optics and semiconductor industries. Whether you need 5-axis grinding of ceramics, drilling of glass, insertion of micro-holes in workpieces or a combination of all of these – the ULTRASONIC series offers the right machine for every application.
- Ideal for machining of complex workpiece geometries in hard-brittle advanced materials like e.g. ceramics, glass, corundum, carbide or composites
- Up to 50% reduced process forces due to ULTRASONIC
- Up to 40 % reduces sub surface damages (SSD)
- Up to 3-times higher productivity
- Surface qualities of up to Ra ≤ 0,1 µm are possible
- Integration via HSK-Interface, all standard machine features for milling / turning are still possible.
- Flexible configuration
- ULTRASONIC drilling
- ULTRASONIC-grinding of ceramics, glass, etc.
- ULTRASONIC 3rd Generation – optimal process control by intelligent control
- Automatic frequency detection and tracking ULTRASONIC complete (in standard)
- Individual optimization of the machining strategies by amplitude regulation (ULTRASASONIC Programming cycle) or automatic feed adaption ULTRASASONIC feed control (option)
- Adaptive spindle with max. 32.000 min-1
- Use of hollow- or spiral-drills starting from ø 0,1 mm
- Automatic drilling force regulation (< 1 N)
- ICS with up to 40 bar and precise volume flow monitoring (<1ml)
- Automatic ejector for drill cores (with hollow drills) to avoid tool breakage
Overview
Series with the highest quality in ultrasonic machining
With the ULTASONIC series, DMG MORI has created a range of innovative solutions for grinding, drilling, milling and mill-turning, which, in combination with ultrasonic machining, are capable of handling even the most demanding materials. The users of DMG MORI machines benefit not only from excellent component quality, but above all from enhanced process reliability and an extended service life.
ULTRASONIC 20 linear
The ULTRASONIC 20 linear is your best choice for ultrasound-assisted grinding, milling and drilling of most components up to hand size! The ULTRASONIC 20 linear is compact and enables high-performance and reliable ultrasonic machining. The pure HSC version of the machine (HSC 20 linear) allows HSC processing at up to 60,000 rpm.
ULTRASONIC Universal / monoBLOCK
The ULTRASONIC Universal and monoBLOCK machines from DMG MORI are a long-established machine concept with integrated ultrasonic technology. The ULTRASONIC models are used by companies from a variety of industries for many different tasks, from 5-axis simultaneous milling to mill-turning with bench speeds of up to 1,200 rpm, all the way to high-performance machining with torques that may reach up to 430 Nm. One thing holds true for all processes: ULTRASONIC machining turns every machined component into a masterpiece.
Ultrasound-assisted grinding, milling and drilling with the ULTRASONIC eVo series
The machining centres of the ULTRASONIC eVo series offer a wide range of machining options, from highly dynamic simultaneous 5-axis machining to mill-turning operations. The optimised gantry design combines maximum stability with minimum space requirements and excellent accessibility to the work area. In their dynamic versions, the ULTRASONIC eVo models are equipped with linear drives in the X and Y axes. Rapid traverses up to 80 m/min particularly enable economical production.
ULTRASONIC Gantry / Portal
The machines of the ULTRASONIC gantry / portal series feature a highly stable gantry design. This design is the basis for maximum precision with a positioning uncertainty being reduced down to 8 µm. At the same time, the machines offer a highly dynamic performance with a feed speed of up to 60,000 mm/min. In addition to drilling and milling, the 5-axis ULTRASONIC machines can also be used to carry out turning operations using the same setup. Other key features of the ULTRASONIC Gantry/Portal series include large travel distances of up to 6,000 mm and high bench load capacities of up to 25 tons. Variants with pallet changers, as found on DMC machining centres, enable set-up to be carried out in parallel for maximum productivity in production.
ULTRASONIC MicroDrill
ULTRASONIC MicroDrill offers the highest degree of process reliability when drilling micro-holes in hard and brittle materials. With ultrasonic support and up to 35,000 rpm, the motor spindle is the ideal choice for highly productive drilling operations. For the reliable detection of tool wear, the ULTRASONIC MicroDrill monitors the feed force down to 1N and, for tools with internal cooling, also monitors the coolant flow with high precision. This makes it possible to avoid tool breakage and ensure consistently high component quality.
Important questions about ultrasound technology
How does ultrasonic machining work?
An ultrasound generator produces high-frequency alternating voltage, which is transferred without physical contact to the rotating tool holder – also referred to as an actuator – using patented inductive energy transmission. Piezo elements in the actuator convert the alternating voltage into mechanical ultrasound oscillation. The vibration that is generated in this way is transferred to the tool.
The ultrasound generator is operated with intelligent control algorithms to ensure that the optimal process parameters are maintained at all times during the machining process. Depending on the type of machining, the tool may oscillate up to 65,000 times per second with an amplitude of up to 15µm. This enables the tool to remove even the smallest particles from the surface of the material. At the same time, the diamond tool removes the removed material with additional rotation.
What strategies and processes are used?
The perfect machining strategy is developed specifically for each material and each machining task and can be implemented easily through selected ULTRASONIC cycles. Based on a HSKE32 / HSK-E 40 / HSK-A63 / HSK-A100 tool holder, the patented ULTRASONIC actuator system can be integrated flexibly into almost all 5-axis milling machines from DMG MORI.
The machine concepts range from standard 3-axis machining to 4-axis and 5-axis simultaneous machining. Optional high-speed direct-drive C-axes and mill-turn packages provide additional machining capabilities, e.g., for external cylindrical grinding / internal cylindrical grinding of hard/brittle advanced materials.
What is the difference from ultrasonic vibration lapping?
Ultrasonic vibration lapping is a highly precise metal-cutting manufacturing technique. According to the DIN 8589 standard, ultrasonic vibration lapping is classified as lapping. Unlike other lapping processes, however, it is only used for drilling and cutting. The tool vibrates at ultrasonic frequency in the longitudinal direction. Unlike ultrasonic machining with machines from the ULTRASONIC series, the diamond grain is not on the tool, but in the lapping material.