Machining Transformation (MX) by Process Integration, Automation, Digitization and Sustainability
Every 10 years, social needs change fundamentally. DMG MORI has always been evolving its business model to meet these needs with new products and services. Now, DMG MORI has matured into a provider of Machining Transformation (MX) to drive Green Transformation (GX) through process integration and automation of machine tools.
The three areas of Process Integration, Automation and Digital Transformation (DX) have an impact on Green Transformation. The social contribution consists of the resulting sustainability but also includes the solution to the shortage of skilled staff through automation as well as the development of top talent. This can be ensured through an extensive training program as part of digitalization. The goal is to focus on the qualifications of all types of employees – from engineer to machine operator.
Machining Transformation
Process Integration
5-axis opens opportunities in process integration
Workpieces that were sequentially processed by multiple machines can now be manufactured in one technology-integrated machine in a single set-up, such as a 5-axis machine or a mill-turn center to achieve higher accuracy. Following such complex technology integration, automation leads to further resource optimization, such as compensating for a lack of operators and elimination of intermediate work-in-process after each operation, which previously occupied shop floor space and costs. Digitization has helped optimize the machining process by visualizing and providing feedback from areas where operators cannot be involved due to automation.
Process Integration
High utilization of one machining center instead of partial utilization of several simple machines.
Technology Integration means that several processes such as turning, milling, grinding and measurement functions are combined in one machine tool for higher productivity. This integration reduces the number of operators needed, frees them from having to carry out multiple setups and contributes to a rewarding working environment within a company. More time can be devoted to high value-added operations, making work more rewarding for staff.
The integration of several technologies like Turn-Mill, Mill-Turn (FD), ULTRASONIC, LASERTEC and ADDITIVE MANUFACTURING (DED / DED hybrid) in a single machine tool ensures higher productivity, saves resources and reduces CO2 emissions.
NTX 500
42,000 rpm compactMASTER TURN & MILL Spindle for high speed and micro machining
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6-sided complete machining
- at main and sub spindle with 8,000 rpm
- 4-axis machining by lower 16-station turret BMT 42 / 64 with 12,000 rpm
- 60 mm Y-axis for the lower turret
Workpieces up to ø 350 mm and 580 mm long
- Machining of flange parts with 350 mm diameter.
- Bar machining up to ø 65 mm
- Workpieces up to ø 90 mm and 580 mm turning length: when machining with lower turret
High-speed turn & mill spindle compactMASTER
- up to 42,000 rpm (30,000 rpm as standard), incl. 150 mm Y-axis
38-pocket tool magazine
- Capto C4 / HSK-T40 / KM40, optional 76 or 114
NTX 1000
Covering Extensive Range of Machining Across All Fields
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Simultaneous 5-axis machining
- Simultaneous 5-axis machining of complex parts with the direct drive motor (DDM) installed in the B axis
- The B-axis rotation range of 240° and rotation speed of 100 min–1, the X-axis travel of 455 mm (17.9 in.)
- Equipped with a Capto C5 tool spindle as standard, max. spindle speed of 12,000 min-1, 20,000 min–1 (Option)
High precision
- Thoroughly controlled thermal displacement by cooling oil circulation in the body
High rigidity
- High-rigidity bed and linear motion guide achieve high rigidity
Peripheral equipment
- Full range of optional equipment for automation, including an in-machine travelling robot and workpiece unloader
NTX 1000 – Shoulder Implant
NTX 2000
Covering Extensive Range of Machining Across All Fields
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High productivity
- The compactMASTER, the world’s shortest tool spindle in its class (350 mm), ensures a wide machining envelop to increase productivity
- Wide range of machining area with the X-axis stroke of 675 mm (-125 - ＋550 mm) and the Y-axis 300 mm (±150 mm)
- Y-axis stroke of ±40 mm of Turret 2 expands the machining range
Simultaneous 5-axis machining
- Simultaneous 5-axis machining with the Direct Drive Motor (DDM) on the B-axis
- 6-face machining is available with Spindle 2 to complete the machining of components on one machine
High precision
- Cooling oil circulation in spindle motors and ball screws controls thermal displacement and achieves highly accurate machining
Energy-saving
- Energy-saving Setting and Visualization of Energy-saving Effect
NTX 2500
6-sided machining with Turn & Mill Spindle compactMASTER
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High productivity
- The compactMASTER, the world’s shortest tool spindle in its class (350 mm), ensures a wide machining envelop to increase productivity
- Wide range of machining area with the X-axis stroke of 675 mm (-125 - ＋550 mm) and the Y-axis 300 mm (±150 mm)
- Y-axis stroke of ±40 mm of Turret 2 expands the machining range
Simultaneous 5-axis machining
- Simultaneous 5-axis machining with the Direct Drive Motor (DDM) on the B-axis
- 6-face machining is available with Spindle 2 to complete the machining of components on one machine
High precision
- Cooling oil circulation in spindle motors and ball screws controls thermal displacement and achieves highly accurate machining
Energy-saving
- Energy-saving Setting and Visualization of Energy-saving Effect
NTX 3000
Overwhelming quality by perfect performance
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High productivity
- The compactMASTER, the world’s shortest tool spindle in its class (350 mm), ensures a wide machining envelop to increase productivity
- Wide range of machining area with the X-axis stroke of 675 mm (-125 - ＋550 mm) and the Y-axis 300 mm (±150 mm)
- Y-axis stroke of ±40 mm of Turret 2 expands the machining range
Simultaneous 5-axis machining
- Simultaneous 5-axis machining with the Direct Drive Motor (DDM) on the B-axis
- 6-face machining is available with Spindle 2 to complete the machining of components on one machine
High precision
- Cooling oil circulation in spindle motors and ball screws controls thermal displacement and achieves highly accurate machining
Energy-saving
- Energy-saving Setting and Visualization of Energy-saving Effect
ULTRASONIC 20 linear
Compact, precise, process reliable with >2 g acceleration and spindle speeds up to 60.000 1/min
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ULTRASONIC technology integration - reduced process forces for higher productivity
- Technology integration via HSK-E32 / HSK-E40 interface for ultrasonic superimposition of the tool rotation with amplitudes up to 15 µm
- Process forces reduced by up to 50% through ULTRASONIC enable, depending on requirements: higher feed rates, improved surface quality up to Ra <0.1 µm, longer tool life
- Specific coolant treatment systems with centrifuges, optimized for the ULTRASONIC processing of Advanced Materials
ULTRASONIC 3rd Generation - Optimal process control through intelligent controls
- Constant amplitude in the process to ensure reproducibility
- Automatic detection of the working frequency, significantly improved hardware for signal acquisition
- Frequency tracking and simultaneous power control in real time for optimal process stability
- Ensuring the ULTRASONIC advantages even with non-optimal tools
- Fully compatible with 2nd generation ULTRASONIC actuator
Compact 5-axis portal machine in gantry design with integrated NC swivelling / rotary table (A- / C-axis)
- Compact footprint of only 3.5 m2 and Gantry-design (Y-portal) for optimized chip-fall
- Optional NC-swivel-/ rotary table with -15° to 130° swivel range (A-axis), C-axis 360° infinite
- Ø 200 mm clamping surface and 15 kg table load (5-axis), rigid table 370 mm x 320 mm und 100 kg (3-axis)
All in one - ULTRASONIC hard machining of Advanced Materials and HSC machining on one machine
- Powerful, water-cooled spindle variants up to 60,000 rpm. with HSK-E32 / HSK-E40 tool holder
- HSC- with max. 60.000 1/min. As well as ULTRASONIC-machining with max. 42.000 1/min
- Rotary table with max. 1,500 rpm: Outer and inner cylindrical grinding of Advanced Materials for optimal surface qualities and rotation symmetries
Highest dynamic with >2g acceleration and absolute longterm stability
- Linear drives in X / Y / Z with > 2 g acceleration
- 50% stronger drives in the A-axis
- Stable, FEM-optimised, vibration-damping mineral composite column
Integrated linear magazine PH 10 | 100 with max. 99 pallet places (max. 10 kg handling weight)
- Compact footprint with only 6 m²
- Flexible integration of all available clamping systems
- Customer specific expansion modules available on request
LASERTEC 20 PrecisionTool
Diamond tool machining with up to 3 mm / min and up to 56% lower costs per part compared to eroding
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DMG MORI PrecisionTool technologies for high end tool manufacturing
NEW: High Speed Mode 3.0 – 210 % faster speed
and 56 % lower cost per part compared to EDM!
- Laser finishing of diamond tools with up to 3.0 mm/min
- Individual edge preparation: < 1 µm sharp edge
- 3, 6, 9, 12, 15 µm defined edge roundness as well as egative chamfersLonger tool life up to factor 2,5 due to laser machining
- 5-axis separation of cutting inserts out of blanks up to 10x faster than conventional wire EDM (machine version PreCut).
Established software features - the easiest switch from eroding to laser processing!
- Industry standard (GTR) as a programming solution allows the import of existing EDM projects
- Minimal training required when switching from eroding to lasers
- EndMill software - programming of rotary tools
- TurningTools software - programming of fixed tools
- ChipBreaker Software - programming of chip breakers and negative chamfers
Highly dynamic 5-axis precision machine in the portal design with 5 µm positioning accuracy, compact with a 3.5 m² footprint
- Highly dynamic through linear drives in the X-, Y-, Z-axis with > 2 g
- Integrated swivel rotary table (4th / 5th axis come standard) with torque technology, –10° / +130°
- Precision cooling in all axis
State-of-the-art CNC-control
- Siemens 840D solutionline with Operate 4.7 on CELOS from DMG MORI for simple operation and complete integration into the company organisation
- LASERSOFT software packages for machining shank and HSK tools, ISO and special cutting inserts, chip breakers
Automation solution with integrated linear magazine PH 10 | 100
- Compact and integrated design with a 6 m² footprint
- Handling of cutting discs, shaft tools and tools with HSK-holder (combination of different tool types possible)
- Up to 12 tools ø 200 mm / l = 260 mm or up to 54 tools ø 85 mm / l = 140 mm
LASERTEC 65 DED hybrid
Hybrid Complete Machining: Additive Manufacturing and Milling in one Machine
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Flexibility through combination of additive and milling machining process for 3D-parts in finished quality
- The laser head is handled by a fully automatic shuttle - without manual intervention
- 5-axis material deposition by coaxial nozzle for homogeneous powder distribution, independent from direction of laser deposition welding
- Full 5-axis milling machine in rigid monoBLOCK-design with < 12 m² footprint
AM Assistant for the best process reliability and comprehensive traceability
- Integrated thermal imaging camera for observation of the whole working area, adapive process control and constant monitoring of the working distance
- Powder feed rate sensor as well as automatic powder calibration.
- AM Evaluator for visualisation of the relevant process data (e. g. meltpool size, powder mass flow) as a digital 3D-model as well as in the chronological sequence
Siemens NX: Complete Hybrid CAD / CAM – Module for additive and subtractive programming
- One software package for the complete process chain (design, additive process, substractive machining, finishing)
- Exclusive LASERTEC build-up strategies - fully integrated in the CAD / CAM software incl. 3D-simulation of machine and movements for collision prevention
- Shorter time-to-market due to completete integrated PLM software integration
Using Multi-Materials and Gradient Materials for Improved Part Performance
- Selectively adding materials with more than 60 Rockwell to avoid heat treatment processes
- Improving cooling performance by using bronze material in the mould core
- Better materials and improved reliability in the repair process for increased service life
- Improved performance of exisitng tool designs by adding wear resistant coating
- Material gradients between hard and soft, magnetic and non-magnetic, etc.
ADDITIVE MANUFACTURING
LASERTEC 125 DED hybrid
Directed energy deposition combined with 5-axis milling, for building and repairing of high-value metal parts
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LASERTEC 125 DED hybrid - Additive Manufacturing
Proven monoBLOCK design for the best machine performance
- Fiber-guided diode laser with 3,000 W power and 600 µm fiber diameter
- Powerful motor spindles up to a maximum of 20,000 rpm
- NC swivel rotary table with swivel range A-axis: + 120 ° / -120, C-axis 360 ° endless, for up to 2,000 kg component weight
- Large door opening of 1,900 mm and unique access to the work area with minimal space requirements
- Comprehensive cooling measures, powerful cooling unit and multi-sensor compensation as standard
High flexibility of manufacturing processes by combining welding and milling on one machine for additive manufacture and repair
- The laser deposition head is handled by a fully automatic shuttle without manual intervention
- 5 axis material deposition by coaxial nozzle for homogeneous powder distribution, independent of direction of laser deposition welding
- Full 5-axis milling capability based on the monoBLOCK machine
AM Assistant for the best process reliability and comprehensive traceability
- Integrated thermal imaging camera for observation of the whole working area, adapive process control and constant monitoring of the working distance
- Powder feed rate sensor as well as automatic powder calibration.
- AM Evaluator for visualisation of the relevant process data (e. g. meltpool size, powder mass flow) as a digital 3D-model as well as in the chronological sequence
Siemens NX: Complete Hybrid CAD / CAM – Module for additive and subtractive programming
- One software package for the complete process chain (design, additive process, substractive machining, finishing)
- Exclusive LASERTEC build-up strategies - fully integrated in the CAD / CAM software incl. 3D-simulation of machine movements for collision prevention
- Change between additive and machining programming strategies all within one programming environment.
Using Multi-Materials and Gradient Materials for Improved Part Performance
- Selectively adding materials with more than 60 Rockwell to avoid heat treatment processes
- Improving cooling performance by using bronze material in the mould core
- Better materials and improved reliability in the repair process for increased service life
- Improved performance of exisitng tool designs by adding wear resistant coating
- Material gradients between hard and soft, magnetic and non-magnetic, etc.
LASERTEC 3000 DED hybrid
Hybrid Machining: Additive Manufacturing and Turning / Milling in one Machine
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Flexibility by the combination of additive and turning machining process for 3D-parts in finished quality
- Large parts up to ø 670 × 932 mm (at B-axis 180°) or up to ø 400 × 1,321 mm (at B-axis 90°)
- 5-axis material deposition by coaxial nozzle for homogeneous powder distribution, independent from direction of laser deposition welding
- Additive Manufacturing of metals and reactive materials such as Ti-6Al-4V (optional)
"AM Assistant" supports you during additive manufacturing (Option)
- Monitors melt pool size and temperature and controls laser output by feedbacking the monitored values for a stable build
- Melt Pool Monitoring: Continuously monitors melt pool conditions
- Working distance monitoring: Measures and monitors the distance between nozzle and melt pool
- Automatic Powder Calibration: Automatically measures the powder flow rate
Completely new product design potential
- 5-axis controlled laser deposition welding in machining centers makes new products possible
- New part features possible due to alternating material deposition and machining strategies
- Improved part performance through new material combinations (e.g. Copper + Inconel)
- Parts with inner channels for innovative, improved cooling
LASERTEC 6600 DED hybrid
Laser Metal Deposition & 5-axis machine
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Large Build Area
- Up to 1,040 mm on the X-axis, -280 mm to +330 mm on the Y-axis, 3,890 mm on the Z-axis
- Largest workpiece size: Φ1,010 mm × 3,702 mm
- Suited for large workpieces including rocket engine parts for the aerospace industry, oil-well pipes for the energy industry and shafts for transport aircrafts
Hybrid of metal additive manufacturing technology and subtractive machining
- Efficient additive manufacturing and subtractive manufacturing on one machine with the linear axes (X-, Y-, and Z-axis), B-axis (turn-mill spindle), C-axis (Left spindle and Right spindle)
- Synchronized operation of Left spindle and Right spindle that transfers workpieces between the two spindles to achieve streamlined additive manufacturing processes
- Turn-Mill spindle equipped with the AM head and AM nozzle to carry out metal powder injection and laser irradiation simultaneously
- Laser output - 2,000 W(standard), <4,000/6,000/8,000 W(option)>
Extensive maintenance functions
- Movable and high-performance dust collection duct to prevent dust powder from scattering
- Zero Sludge Coolant Tank that effectively collects fine sludge inside the coolant tank as standard
- Laser sensor installed on the machine cover and window to detect laser before it penetrates the cover and stop it
Process Integration for Enhanced Efficiency: Revolutionizing Manufacturing with DMG MORI
Automation
Automation systems for minimally attended or lights-out and / or weekend shifts
DMG MORI's range of automation systems includes workpiece handling and transport systems, pallet handling systems that transport pallets with fixtured workpieces and tool handling systems that transport cutters to the machines. The company offers a wide range, from small automation systems for single machines to automation for large production lines.
Benefits of automation
- Easier to use: Automation is not rocket science
- Proven technology: You are already using automation
- Night shifts and weekends: Let the machine work during the night
- Become more competitive: Reduce the cost per part
- Flexibility: No mass production – no problem
- Sustainability: Often 1 automated system can replace 3 stand-alone machines
Digital Transformation (DX)
From CAD-CAM solutions and post-processors to simulation
Use of digital technologies such as AI, IoT, Big Data and Digital Twin. It's about creating a competitive advantage by improving workflows and creating new business models.
The integrated Digitization approach is not only an effective method to raise productivity. The applications reduce energy consumption and therefore CO2 emissions as well, including by increasing the productive spindle hours due to faster programming at or near the machine.
Digital transformation models automatically promote green transformation: By working on Digitization, the customer can improve productivity and reduce unnecessary energy consumption. This also reduces CO2 emissions. In other words, embracing Digitization will also lead to Green Transformation.
Green Transformation (GX)
Sustainability
Technology integration saves resources and reduces CO2 emissions, automation leads to longer machine runtimes and digitization reduces power consumption for customers.
The GX approach is more than the mere reduction of CO2 emissions. It also aims to cut unnecessary work-in-progress and intermediate inventory to realize lean production anywhere in the world. GX has the potential to conserve global resources as well as transform people and the environment.
Social Contribution
The three areas of Technology Integration, Automation and Digital Transformation have an impact on Green Transformation. In addition, they thrive on the cycle of constant learning and further development. The result is a social contribution by the organization:
- Technology Integration maximizes management resources and minimizes environmental impact
- Automation helps to solve a shortage of operators
- Digital Transformation supports the development of talent through extensive training programs