ULTRASONIC 20 linear HSC 20 linear FLEXIBLE TECHNOLOGY INTEGRATION INTO DMG MORI MACHINES ECONOMICAL GRINDING, MILLING AND DRILLING OF ADVANCED MATERIALS ULTRASONIC DMGMORI.COM
Applications and parts Machine and technology Application areas Control technology Technical data ULTRASONIC ULTRASONIC grinding / milling and drilling. Reduced process forces for increased productivity The demands for workpieces made from Advanced Materials are very industry sector specific. Short cycle times and therewith a high productivity is indispensable for most companies. Exactly here is where ULTRASONIC-technology of DMG MORI can convince with versatile unique selling propositions. The kinematic overlapping of the tool rotation with an additional oscillation effects a reduction of the process forces by up to 40 % in comparison to conventional machining. Depending on the workpiece requirements, this allows higher feed and infeed, longer tool life or significantly better surface finishes of up to Ra < 0.1 µm. The number and depth of micro cracks in hard-brittle materials is reduced to a minimum. 02 FUNCTIONAL PRINCIPLE The tool rotation is superimposed via the HSK-E32 / HSK-E40 / HSK-E50 / HSK-A63 / HSK-A100 interface of the ULTRASONIC actuator tool holder with an additional oscillation in the axial direction (piezoelectric effect). HIGHLIGHTS + Economical grinding, milling and drilling of hard and brittle as well as hard to machine Advanced Materials + New, stiffer ULTRASONIC HSK actuating tool holder with increased amplitude power for a powerfull ULTRASONIC performance + Up to 40 % reduced process forces for highest productivity, surface quality, precision and longer tool life + Automatic detection and autotracking of ULTRASONIC frequency and amplitude CUSTOMER BENEFITS + Machining of complex part geometries in one setup + Machining of high tech materials like ceramics, corundum, tungsten carbide and composites + Higher productivity compared to conventional grinding due to ULTRASONIC ULTRASONIC Reduced process forces Perfect surfaces Optimal particle removal
Powerfull ULTRASONIC with optimised inductive transmission Reinforced actuator for more stiffness 03 Stronger ULTRASONIC- Booster for up to 3 times higher amplitudes Tools with undefined and defined cutting edge Oscillation- amplitude 0 – 15 µm / depending on tool an parameter
Applications and parts Machine and technology Application areas Control technology Technical data ULTRASONIC 1 ULTRASONIC grinding, milling and drilling. The ULTRASONIC technology from DMG MORI enables the economical machining of complex workpiece geometries in demanding high-tech materials like e. g. ceramics, glass, corundum, tungsten carbide or even composites. The kinematic overlapping of the tool rotation with an additional oscillation effects a reduction of the process forces by up to 40 % in comparison to conventional machining. ULTRASONIC GRINDING 04 ULTRASONIC machining of complex parts by tools with defined cutting edge + Face grinding + Outer / inner cylindrical grinding with MT-technology + Drilling with diamond drills + 3D-contours with ball nose or shaft milling cutters Optical industry Watch industry / fine mechanics High performance ceramic components Die & mould
1: ULTRASONIC grinding of a mirror support made from zirconium oxide 2 2: ULTRASONIC milling of Inconel blade Depending on the workpiece requirements, this allows higher feed and infeed, longer tool life or significantly better surface finishes of up to Ra < 0.1 μm. Based on a consequent development of the ULTRASONIC tech- nology according to the markets requirements, the ULTRASONIC now also is able to cover ULTRASONIC- assisted milling of hard to machine metal alloys or fibre reinforced materials with defined cutting edge. ULTRASONIC MILLING ULTRASONIC machining of complex parts by tools with defined cutting edge + Machining of complex geometries with ball nose or shaft milling cutters up to ø 20 mm + Deep hole drilling with aspect ratio 1:100 + Delamination free processing of fibre reinforced composites Aerospace Production of composite workpieces 05 Automotive MRO* of composite components * MRO = Maintenance, Repair, Overhaul
Applications and parts Machine and technology › Concept Application areas Control technology Technical data ULTRASONIC ULTRASONIC series for handsized up to ø 3,000 mm workpieces. Since 2001 SAUER represents the Advanced Technologies of DMG MORI and is a synonym for innovation power, technological foresight as well as highest know-how expertise for the economical machining of Advanced Materials. With a consistent ULTRASONIC product line, this innovative tech- nology offers machine solutions for almost every important branche, application field or workpiece size and parallelly serves an unrivalled large material spectrum. Starting with the SAUER own machining center ULTRASONIC 20 linear also the flexible technology integration into almost all high-tech machines of the DMG MORI portfolio is possible. 06 ULTRASONIC 20 linear ULTRASONIC 50 Available ULTRASONIC machine types linear Universal Series basic machine Option FD Max. traverse paths (X / Y / Z) Max. spindle speed milling Max. spindle speed ULTRASONIC ULTRASONIC HSK actuator system Max. workpiece size / clamping surface (5-axis) Max. table load (5-axis) available, – not available, * option mm rpm rpm mm kg HSC 20 linear ULTRASONIC 20 linear ULTRASONIC 50 SAUER – 200 / 220 / 280 42,000 / 60,000* – SAUER 200 / 220 / 280 42,000 / 60,000* 50.000 HSK-E32 (HSK-E40)* HSK-E32 (HSK-E40)* ø 250 15 ø 200 15 DMU – 500 / 450 / 400 18,000 18,000 HSK-A63 ø 630 × 500 200
Powerfull control Uniform control philosophy with 3D path control SINUMERIK 840D solutionline, user friendly CELOS operator surface* as well as special ULTRASONIC software features. ULTRASONIC HSK actuator system of the 2nd Generation Flexible Integration into 5-axis milling centers of DMG MORI (HSK-32 / 40 / 50 / 63 / 100): ULTRASONIC milling, grin- ding and milling of Advanced Materials as well as conventional machining on one machine. CELOS App ULTRASONIC Special ULTRASONIC cycles for automatic adaption of the feed and CNC-programming as well as ULTRASONIC parameters for automatic frequency and amplitude detection and autotracking in the machining process. 0707 ULTRASONIC 40 eVo linear ULTRASONIC 85 ULTRASONIC 210 eVo monoBLOCK Portal ULTRASONIC 40 eVo linear ULTRASONIC 60 eVo linear ULTRASONIC 65 ULTRASONIC 85 ULTRASONIC 210 P eVo eVo DMU / DMC monoBLOCK DMU / DMC monoBLOCK DMU P Portal 400 / 400 / 375 600 / 500 / 500 18,000 18,000 HSK-A63 450 × 400 250 18,000 18,000 HSK-A63 600 × 500 400 735 / 650 / 560 18,000 / 24,000* 18,000 935 / 850 / 650 18,000 / 24,000* 18,000 1,800 / 2,100 / 1,250 18,000 (12,000) 18,000 (12,000) HSK-A63 (HSK-E50)* HSK-A63 (HSK-E50)* HSK-A63 (HSK-A100)* ø 840 × 500 600 ø 1,040 × 590 1,500 ø 1,850 × 1,250 4,000 / 8,000
Applications and parts Machine and technology › ULTRASONIC 20 linear Application areas Control technology Technical data ULTRASONIC 20 linear Multitalent in various disciplines – compact, precise, process reliable. Completely revised, the new ULTRASONIC 20 linear convinces with a new functional design and a reduced footprint of 3.5 m² with in parallel improved rigidity and dynamics. The versatile technical optimisations lead to higher spindle rpm of now up to 60,000 rpm for HSC applications, an optional mill-turn-table with max. 1,500 rpm for economical ULTRASONIC cylindrical grinding operations in Advanced Materials, in up to 50 % increased drive motors (A-axis), an increased table load of 15 kg and in the use of bigger tool diameters of now up to 50 mm. The new ULTRASONIC 20 linear is also equip- ped now with the powerful and innovative CELOS from DMG MORI and a new developed ULTRASONIC APPs for an intuitive ULTRASONIC machining. 08 Mineral fibre base Stable, most compact, vibration dampening mineral fiber base for optimal long-term-stability, accuracy at the workpiece as well as an optimised chip fall (Y-portal in gantry design).
CONTROL OF THE LATEST GENERATION + CELOS with SINUMERIK Operate 4.7 + Integration of ULTRASONIC CELOS APPs + Visualisation of the most important ULTRASONIC process parameters: frequency, amplitude, output power + Automatic process control + Optimal control of the ULTRASONIC process parameters INTEGRATED NC-SWIVEL- ROTARY TABLE OF THE LATEST GENERATION + Stronger drive motors in A, C and Z for optimal holding torque + Increased 5-axis table load: 15 kg + Highest dynamics and precision due to torque technology UNIQUE TECHNOLOGY INTEGRATION + ULTRASONIC grinding of Advanced Materials as well as HSC milling on one machine, with 42,000 rpm in the standard + Flexible change based on a standard HSK-E32 / HSK-E40 holder + HSC milling with up to 60,000 rpm / HSK-E32* *Option FOR OUTER AND INNER CYLINDRICAL GRINDING + Complete machining of rotation symmetrical workpieces: grinding and drilling incl. inner / peripheral machining in only one clamping + Rotary table with max. 1,500 rpm: inner and outer cylindrical grinding of Advanced Materials for optimal surface qualities 09
Applications and parts Machine and technology › ULTRASONIC 20 linear Application areas Control technology Technical data 1 2 1: Integration of almost all available clamping systems 2: Linear handling in 3 axes – positioning of a pallet with tooth crown ULTRASONIC 20 linear Automation solution with linear magazine PH 10 | 100. With the integrated automation solution PH 10 | 100 up to 99 workpieces can be loaded from the top into the working area of the ULTRASONIC 20 linear. Thereby all available clamping systems in the market are flexibly integrable. A pallet change is completed in ≤ 30 seconds. The compact, integrated design guarantees an optimal accessibility to the working area and the PH 10 | 100. 10 HIGHLIGHTS + Integrated linear magazine PH 10 | 100 with max. 99 pallet places (max. 10 kg handling weight) + Dynamic and stabile pallet change ≤ 30 seconds (workpiece handlingfrom the top) + Flexibility: integration of most available clamping systems + Six layers in the standard, optional five additional layers + Pallet layers are application oriented and can be configured with 3, 5, 7 or 9 pallet places + Optimal accessibility to machine and PH 10 | 100 + Compact and integrated design with only 6 m² footprint
11 LINEAR MAGAZINE AUTOMATION PH 10 | 100 The integrated automation solution with linear magazine PH 10 | 100 offers the best conditions for the automa- ted production in multi-shift operation. Thanks to the optional prepe- ration fot this automation, the upgrade is also possible to a later time.
Applications and parts Machine and technology › HSC 20 linear Application areas Control technology Technical data HSC 20 linear High-Speed-Cutting with up to 60,000 rpm and > 2 g acceleration. Apart from the ULTRASONIC integration, the HSC 20 linear is equipped with all machine features and automation solutions of the ULTRASONIC 20 linear. It offers the best conditions for all require- ments of High Speed Cutting. Two control systems, CELOS with SIEMENS SINUMERIK Operate 4.7 as well as HEIDENHAIN TNC 640 are available. With a max. acceleration of > 2 g. The HSC 20 linear keeps the position of the most dynamic 5-axis precision machine of DMG MORI. 12
1 2 3 4 5 6 1: PET bottom mould, aluminum 2: 14-parted implant bridge, CoCr 3: Impeller, aluminum 4: Bone plate, titanium 5: Watch plate, brass 6: Electrode, graphite CELOS WITH SINUMERIK OPERATE 4.7 CELOS WITH HEIDENHAIN TNC 640 + Integration of ULTRASONIC CELOS Apps + Shopfloor or DIN-ISO programming + Visualisation of the most important ULTRASONIC process parameters: frequency, amplitude, output-power + Automatic process control + Perfect management of the ULTRASONIC parameters + 3D workpiece simulation + Graphical programming + Coordinate transformation + Rapid program creation with visual programming + Convenient thanks to the comprehensive selection of cycles 13
Applications and parts Machine and technology › ULTRASONIC Application areas Control technology Technical data ULTRASONIC Flexible ULTRASONIC integration into 5-axis milling machines of DMG MORI. In all hightech branches there is a constant demand for new technology solutions and economical machining procedures for hard to machine future materials. Exactly here, SAUER is positioned with its ULTRASONIC technology and underscores with a consistent product line its technological expertise as an innovative pioneer in the ULTRASONIC-assisted hard machining of Advanced Mate- rials. Based on a standard HSK-32 / 40 / 50 / 63 / 100 tool holder, the patented ULTRASONIC actuator system can be integrated flexible in almost all 5-axis milling machines of DMG MORI. 14 HIGHLIGHTS + Flexible ULTRASONIC technology integration based on a standard HSK-40 / 50 / 63 / 100 tool holder + Combination of conventional HSK tool holders and ULTRASONIC actuating tool holders in one magazine + Flexible change possible (HSC-) Milling and ULTRASONIC machining on one machine + ULTRASONIC integration into following DMG MORI series: – HSC-series – monoBLOCK series – DMF series – eVo linear series – duoBLOCK series – Portal series
15 1 2 3 1: Machining of a diffusor-cage made from Inconel 718 on an ULTRASONIC 125 FD 2: Outer and inner cylindrical grinding of a pump housing made from mineral cast on an ULTRASONIC 125 FD 3: ULTRASONIC complete machining of an mirror support made from Zerodur on an ULTRASONIC 65
Applications and parts Machine and technology › ULTRASONIC Grinding Application areas Control technology Technical data 1616 ULTRASONIC GRINDING ULTRASONIC represents a future-oriented technology for new markets with signi- ficantly increasing demand and rising workpiece requi- rements. Due to the kine- matic overlapping of the tool rotation with an oscillation (in axial direction), conventi- onally hard to machine high performance materials can be machined economical in highest quality.
APPLICATION AREAS Economical ULTRASONIC grinding of Advanced Materials with reduced process forces. ULTRASONIC grinding enables an economical machining of complex workpiece geometries in demanding high-tech materials like e. g. ceramics, glass, corundum, carbide or composites. Due to the kinematic overlapping of the tool rotation with an additional oscillation, ULTRASONIC leads to a reduction of the process forces by up to 40 % compared to conventional machining. Depending on the material properties, this allows outstanding surface finishes of Ra < 0.1 μm, the production of thin-walled lightweight structures, longer tool service life and significantly reduced micro-cracks in the material. 1717 BENEFITS ULTRASONIC GRINDING + Reduced process forces by up to 40 %* + Higher stock removal rate* + Excellent surface quality of Ra < 0.1 μm* + Feasibility of thin walls < 0.5 mm wall thickness* + Reduced Sub-Surface-Damaging* + Longer tool life, reduction of the tool temperature* + Economical, formative machining of sintered, and even hipped technical ceramics (e. g.: Si3N4, SiC, hip-ZrO2) + Workpiece precision < 10 μm possible* + Optimal particle removal from the working zone + Reduced delamination with fibre reinforced composites * depending on the material and process properties ULTRASONIC
Applications and parts Machine and technology › ULTRASONIC Grinding Application areas Control technology Technical data ULTRASONIC GRINDING ULTRASONIC grinding and drilling with unique selling propositions. The demand for best possible surface qualities, longer tool life, increase in productivity and work- piece quality in the machining of future materials is unbroken. Especially the request for more and more complex geometrical shapes needs efficient and economical machining methods. Exactly here is where the patented ULTRASONIC technology of the market leader DMG MORI can convince with versatile unique selling propositions. For each material and every machining task, the perfect machining strategy is beeing developed and made easily operable by the right ULTRASONIC cycle. 18 ULTRASONIC machining strategies ULTRASONIC DRILLING with longitudinal movement kinematics ULTRASONIC GRINDING ULTRASONIC FACE GRINDING of a pocket with undercut with cross-side vibration with tilted cup grinding wheel with cross-side vibration
Application sample Grinding of pockets and slots in a Zerodur-glass block with and without ULTRASONIC OPERATIONS Setup Machine Tool Machining 1 ULTRASONIC 20 linear ULTRASONIC actuator HSK-E32-ER11; GVD-mill with MES3-binding D76H, ø 6 mm 3 circular pockets each (ø 11 mm × 10 mm) Spindle speed Feed Infeed Cycle time Machining 2 N 8,000 rpm vf 800 mm/min. ap 0.25 mm contour helix; ae 5.5 mm 92 % 85 sec. / pocket 3 slots each (B: 6 mm, T: 10 mm, L: 60 mm) Spindle speed Feed Infeed Cycle time N 8,000 rpm vf 800 mm/min. ap 0.4 mm; ae 6 mm 100 % 141 sec./slot RESULT: FORCE MEASUREMENT Examination of the 3 pockets Conventional ULTRASONIC Fx / N Fy / N Fz / N Fx, US / N Fy, US / N Fz, US / N 25 25 26 23 22 23 75 66 70 12 13 14 11 12 13 54 60 61 Pocket Nr. 1 2 3 RESULTS + Force reduction in the pockets up to 50 % + Force reduction in the slots up to 50 % + Up to 60 % better surface quality + Reduced micro cracks up to 40 % RESULT: SURFACES (MICROSCOPE) 1 mm 1 mm with ULTRASONIC without ULTRASONIC 19 100-fold: bottom face of the slot ULTRASONIC Conventional Deviation Ra / μm Rz / μm Rq / μm Rp / μm 0.74 3.6 0.92 1.0 1.28 7.7 1.65 2.4 –42 % –53 % –44 % –58 % 1 mm 1 mm Examination of the 3 slots Conventional ULTRASONIC 100-fold: side face of the slot mit ULTRASONIC without ULTRASONIC Slot Nr. 1 2 3 Fx / N Fy / N Fz / N Fx, US / N Fy, US / N Fz, US / N 10 10 10 50 50 45 95 95 95 5 5 5 25 35 30 65 75 65 ULTRASONIC Conventional Deviation Ra / μm Rz / μm Rq / μm Rp / μm 1.15 6.4 1.48 1.8 1.34 8.0 1.72 3.4 –14 % –20 % –14 % –47 %
Applications and parts Machine and technology › ULTRASONIC Grinding Application areas Control technology Technical data ULTRASONIC GRINDING Combined ULTRASONIC cylindrical grinding and drilling on one machine. The production of high precise and complex workpieces requires flexible machine solutions. Due to the patented ULTRASONIC technology integration into 5-axis milling centres from DMG MORI, complex workpieces can be machined economically in only a few clampings. For the machining of rotation symmetrical workpieces, several machine series are also available with mill-turn-option. Special ULTRASONIC cycles are available to assist the operator at demanding outer / inner cylindrical grinding operations. 20 Machining Special Nr. of tools Machine Clamping 1 Step 1* Step 2 Step 3* Step 4 Clamping 2 Step 5* Step 6 Complete machining of a SiC sealing ring ø 160 × 30 mm Use of ULTRASONIC-MT-grinding cycles for outer / inner cylindrical grinding with rotating tool 6 diamond grinding / drilling tools ULTRASONIC 65 FD Roughing of the plane surface and outer contour with ø 100 mm 1A1 grinding discs Drilling of the ø 2 mm thru holes from outside Finishing of the outer and inner contour with radius Grinding of the outer radial slots Roughing and finishing of the inner contour and plane surface Grinding of the face side slots * with ULTRASONIC MT grinding cycle for outer / inner cylindrical grinding
Applications and parts Machine and technology Application areas › Optical industry Control technology Technical data OPTICAL INDUSTRY Mirror supports with thin-walled webs and other complex geometries in Zerodur, high precision deep hole drilling in gyroscopes or rod lenses of corundum / optical glass for scan- ner systems / endoscopy are typical ULTRASONIC applications. In this way the ULTRASONIC series has successfully entered the fields of projectionand measurement optics, satellite construction and optical component manufacturing. 2222
APPLICATION AREAS Optical industry. Materials: optical glass, quartz glass, glass ceramics, corundum Application examples: (rod) lenses, mirror supports, technical parts with thin walls, long holes, slots, pockets, spheres ULTRASONIC 100 P duoBLOCK Complete machining of light weight structures for mirror supports of Zerodur Industry Material Tools Machining Satellite construction / telescopes Zerodur (glass ceramics) Diverse diamond drill / grinding tools Creating pockets with undercut and thin walls (light weight structures) ULTRASONIC 125 P duoBLOCK Grinding of spheres / aspheres in optical components Industry Material Tools Machining Optics Zerodur (glass ceramics) Diverse diamond coated cup wheels Feasibility of spheres / aspheres with surface qualities of Ra ≤ 0.2 μm ULTRASONIC 20 linear Gyroscope for gyro compass Industry Material Tools Machining Optics Quartz glass 7 diamond tools Complete machining with Ra < 0.1 µm as well as 5 µm fitting accuracy and 2 µm roundness ULTRASONIC 50 Complete machining in one clamping in 2 h 51 min. Industry Material Tools Machining Optics Zerodur (optical glass) 5 (diamond hollow drill / grinding pins) Feasibility of threads and thin webs with wall thickness < 0.5 mm ULTRASONIC 20 linear Miniature mirror support made from Zerodur Industry Material Tools Machining Optics Zerodur 5 diamond tools Complete machining in 17 machining steps in 70 min. 2323
Applications and parts Machine and technology Application areas › High performance ceramics Control technology Technical data HIGH PERFORMANCE CERAMICS The demand for longer tool service life, increased productivity and component quality makes the use of advanced materials una- voidable. Ceramic high-perfor- mance materials, like SiC, silicon nitride (Si3N4) or hipped zirconium oxide (hip-ZrO2) as well as the demand for ever more complex geometrical shapes, require high performance and economical machining procedures. This is exactly where the ULTRASONIC technology offers a competitive advantage. 2424
APPLICATION AREAS High performance ceramics. Aerospace Materials: silicon nitride / carbide, composites (e. g.: CMC = Ceramic Matrix Compounds) Application examples: casings, wear parts, armatures, blades ULTRASONIC 20 linear ULTRASONIC grinding of a mounting plate Industry Material Tools Machining Aerospace Silicon carbide Various diamond drills, grinding- and special-tools Complete machining of pockets, slots, holes and chamfers in one setup Pump- and armature industry Materials: all wear resistant high-performance ceramics, glass Application examples: examples: spinnerets, pump wheels, sealing / bearing rings, housings ULTRASONIC 65 monoBLOCK Pump housing made from Si-Quartz Industry Material Tools Machining Pump industry PME-Si-Quarz 1 diamondcup wheel Part machining (face grinding) of the semi-finished part 2525 Medical / Dental Materials: all high-performance ceramics, including hipped ZrO2, glass-ceramics Application examples: dentures, implants, prosthetics, technical medical optics components ULTRASONIC 20 linear Complete machining of an orthopaedic implant Industry Material Tools Medical Hipped zirconium oxide 5 diamond toroidal grinding points Machining Complete machining in 4.5 hours ULTRASONIC 20 linear Complete machining of an implant made of zirconium oxide Industry Material Tools Machining Dental Zirconium oxide 7 (diamond ball cutters / grinding points) In < 30 minutes (cylindrical contour, inner / outer thread, abutment connection)
Applications and parts Machine and technology Application areas › Watch industry / fine mechanics Control technology Technical data WATCH INDUSTRY FINE MECHANICS The use of the innovative ULTRASONIC technology for watch components made of zirconium oxide, sapphire or glass ceramics is crucial. Numerous renowned manu- facturers of luxury watches manufacture intricate com- ponents on ULTRASONIC machines from DMG MORI. 2626
APPLICATION AREAS Watch industry / fine mechanics. Materials: zirconium oxide, corundum (sapphire), agate, ruby Application examples: watch housing, boards, clock components, bearings ULTRASONIC 20 linear Complete machining of a CFRP watch housing Industry Material Tools Watch industry CFRP 9 diamond coated carbide milling cutters Machining Complete machining from the raw material block ULTRASONIC 20 linear Complete machining of a clock face Industry Material Tools Watch industry Agate 8 diamond drilling / grinding points Machining Complete machining from the raw block ULTRASONIC 20 linear Complete machining of a lunette Industry Material Tools Watch industry Zirconium oxide 6 diamond drilling / grinding points Machining Complete machining from the raw block ULTRASONIC 20 linear Watch housing made from ceramics Industry Material Tools Machining Watch industry Zirconium / aluminum oxide 9 diamond tools Complete machining of an AI2O2 clock housing from the raw block in 15 machining steps ULTRASONIC 20 linear Watch plate made from sapphire Industry Material Tools Watch industry / Feinmechanik Sapphire (corundum) 8 diamond tools Machining Complete machining in 8 machining steps 2727
Applications and parts Machine and technology Application areas › Die & mould Control technology Technical data DIE & MOULD Where conventional materials quickly reach their limits, where enormous burdens through chemicals, high temperatu- res, friction forces or electricity prevail, wear-resistant Advanced Materials are used in. If there are highest demands on mould contour, materials and surface quality, youare spot on with the ULTRASONIC series. Especially in the case that quality should not suffer because of production costs or most complex forms should be manufactured through grinding and drilling in the shortest time. 2828
APPLICATION AREAS Die & mould. Materials: carbide, wear-resistant high-performance ceramics Application examples: dies, press tools, moulding dies, matrices, guiding elements, valves 2929 ULTRASONIC 20 linear Complete grinding of a tungsten carbide insert Industry Material Tools Machining Mould-making Carbide Diamond coated 6A9 cup wheel Grinding of the outer contour (bevels and radii) by hard machining ULTRASONIC 20 linear Complete machining of ceramic gear wheel Industry Material Tools Machining Tool and mould making Hipped zirconium oxide 2 diamond grinding points, 1 ball cutter Complete machining from the raw block in 24 minutes / tooth ULTRASONIC 20 linear Grinding of a M6 thread Industry Material Tools Machining Tool and mould making Tungsten carbide 1 diamond thread grinding point Grinding of a M6 thread in 4.5 minutes ULTRASONIC 20 linear Surface grinding of guiding elements for measuring machines Industry Material Tools Machining Machine construction Silicon carbide Various diamond cup grinding wheels Face grinding and grinding of recessed grooves with Ra < 0.1 μm ULTRASONIC 20 linear Complete machining of deep drawing tools Industry Material Tools Machining Tool and mould making Tungsten carbide 3 diamond tools Complete machining with 4 µm fitting accuracy
Applications and parts Machine and technology Application areas › Tool Bodies Control technology Technical data TOOL BODIES More and more, the ULTRASONIC-assisted grinding gets in place for the machining of tungsten carbide tool bodies. The ULTRASONIC technology allows an economical ULTRASONIC complete machining of tool bodies with chip flutes, plate seats and cooling channels / holes in one single setup. The machine integrated CAM software allows a parameterised programming. 3030 1 2 3 4 1: Basic parameters of tool geometries 2: Parameter setup of the plate seats 3: Parameter setup of the chip flutes 4: Simulation of the NC-programmes
APPLICATION AREAS Tool Bodies Materials: Tungsten carbide Application examples: Tool bodies with plate seats, chip flutes, cooling channels, straight or twisted, multi edges etc. ULTRASONIC 20 linear Step drill with plate seats and cooling channels Industry Material Tools Precision Tools Tungsten carbide 4 (cup wheel / hollow / twist-drill) Machining ULTRASONIC complete machining in one setup ULTRASONIC 20 linear Twisted milling cutter (3 edges) with plate seats, chip flutes and cooling channels Industry Material Tools Precision Tools Tungsten carbide 3 (cup wheel / hollow / twist-drill) Machining ULTRASONIC complete machining in one setup ULTRASONIC 20 linear Milling cutter (3 edges), straight fluted, with plate seats Industry Material Tools Precision Tools Tungsten carbide 2 (cup wheel / hollow / twist-drill) Machining ULTRASONIC complete machining in one setup ULTRASONIC 20 linear Roughing milling cutter with plate seats and cooling channels Industry Material Tools Precision Tools Tungsten carbide 2 (cup wheel / hollow / twist-drill) Machining ULTRASONIC complete machining in one setup ULTRASONIC 20 linear Milling cutter (4 edges), straight fluted, with plate seats Industry Material Tools Precision Tools Tungsten carbide 3 (cup wheel / hollow / twist-drill) Machining ULTRASONIC complete machining in one setup 3131
Applications and parts Machine and technology Application areas › ULTRASONIC milling Control technology Technical data ULTRASONIC MILLING Due to a shortened and FEM optimized geometry design of the actuators which ensure a higher stiffness and enable due to the improved inductive transfer the use of amplitu- des to > 10 μm, also tools with geometrically defined cutting edges can be used now with complete utilisation of the exis- ting ULTRASONIC benefits. 3232
APPLICATION AREAS ULTRASONIC milling and drilling in hard- to-machine materials with geometrically defined cutting edge. The further development of the ULTRASONIC technology now as well facilitates its use in classic manu- facturing situations. From now on tools with geometrically defined cutting edge can be used securely because of reachable amplitudes of > 10 μm as well as the clearly improved stiffness of the actuators. So process forces during milling e. g. titanium alloys are up to 30 % lower. Feeds can be doubled in inconel and quintupled in other materials as magnesium. Enhanced surfaces, an obviously reduced tool wear and shorter breaking chips are additional advantages of ULTRASONIC-assisted machining. 3333 BENEFITS ULTRASONIC MILLING + Higher stock removal rates during finishing + Reduced process forces for optimised roughness values and lower polishing effort + Longer tool life + Optimised chip-flow reduced temperatureon the tool + Short-breaking chips + Avoidance of the formation of built-up edges during composite machining + Potential surface density + Avoidance of delamination and fibre tearing at composites ULTRASONIC
Applications and parts Machine and technology Application areas › Aerospace and Automotive Control technology Technical data AEROSPACE AND AUTOMOTIVE Representative ULTRASONIC applications can especially be found in the sector of aerospace and automotive. Compared to conventional milling, for example a two times longer tool life can be reached by use of ULTRASONIC e. g. milling a diffuser flange (Inconel) or two times faster cycle time for finishing of a turbine blade (Inconel). 3434
APPLICATION AREAS Aerospace and Automotive. Aerospace Materials:: Inconel 718, CMC Application examples: turbine components (casings, blades, ... ) ULTRASONIC 80 Complete machining of flange (diffusor cage) Industry Material Tools Machining Aerospace (turbines) Inconel 718 Ceramic tools Complete machining of the inner and outer contour with significantly increased tool life and optimal surface quality ULTRASONIC 65 Complete machining of a turbine blade made from the raw block Industry Material Tools Machining Aerospace (turbines) Inconel 718 1 carbide mill, 1 ceramic mill Complete machining with reduced machining time (23 minutes vs. 32 minutes) 3535 Automotive Materialien: cast, MnCr, Al- / Mg-alloys, hardened steel Application examples: engine- / cylinder blocks, gear components, rims ULTRASONIC 85 Deep hole drilling in a cylinder head Industry Material Tools Machining Automotive (motor production) Cast 1 carbide tools (ø 10 mm pilot drill, ø 10 mm step drill) Machining of fuel drillings with improvement of the straightness in the channel and optimised surface finish ULTRASONIC 85 Deep hole drilling in gear shaft Industry Material Tools Machining Automotive (gear manufacturing) MnCr 1 carbide twist drill Machining of a ø 2 mm × 260 mm deep hole drilling with improvement of the straightness in the channel, short-breaking chips and increased feed in 60 sec.
Applications and parts Machine and technology Application areas › ULTRASONIC Composites Control technology Technical data ULTRASONIC COMPOSITES The directed overlapping with ULTRASONIC in cutting direction enables a higher cutting speed to get a clean fibre cut and therewith meets the high requirements concerning productivity and workpiece quality. The reduc- tion of the process forces by up tu 40 % allows clean edges and prevents from fibre tea- ring as well as delamination on the part. 3636
APPLICATION AREAS ULTRASONIC composites. Aerospace Materials: CFRP, GFRP, AFRP, stacks, other composites (e. g. CMC = Ceramic Matrix Compounds) Application examples: housings, rotor parts, armatures ULTRASONIC 85 Four stepped scarfing in a rotor segment Industry Material Tools Machining Aerospace CFRP 1 VHM / carbide mill Clean exposure of the single laminate layers without fibre tearing or delamination in < 1 minute ULTRASONIC 360 Edge trimming and drilling of a Spoiler / Flap Industry Material Tools Machining Aerospace (MRO) CFRP + titanium Carbide milling cutter Complete machining: Edge trimming of the complete outer contour and drilling of the connectors through CFRP and titanium with > 50 % time benefit compared to the prior process 3737 Automotive / Lifestyle Materials: CFRP, GFRP, AFRP, stacks, other composites (e. g. CMC = Ceramic Matrix Compounds) Application examples: interiors, rims, watch-components, sports-components ULTRASONIC 85 Edge trimming, machining of holes and pockets in a center console Industry Material Tools Machining Automotive (interiors) CFRP 1 carbide mill / 1 carbide drill Complete machining with double feedrates and without fibre tearing in < 4 minutes ULTRASONIC 65 Edge trimming, machining of holes in a longboard Industry Material Tools Machining Lifestyle (sports) CFRP 1 carbide mill / 1 carbide drill Complete machining of the pre-laminated part with double feedrates and without fibre tearing in < 5 minutes
Applications and parts Machine and technology Application areas Control technology › CELOS Technical data Similar to a smartphone, operators can use the APP MENU to directly access all available applications. APP MENU Like on a smartphone, the operator has direct access to all available applications through the APP MENU. 3838 ERGOline CONTROL WITH A 21.5″ MULTI- TOUCH-SCREEN AND SIEMENS. Simple User-friendly machine operation for all new high-tech machines from DMG MORI. Consistent Consistent management, documentation and visualisation of order, process and machine data. Compatible Compatible with PPS and ERP systems. Can be networked with CAD / CAM products Open to trendsetting CELOS APP extensions. SMARTkey Personalised user authorisation: Individually adapted access rights for the control system and the machine.
ULTRASONIC SERIES – From the idea to the finished product. CELOS features a standard user interface for all new high-tech machines from DMG MORI. CELOS APPs enable the consistent administration, documentation and visualisation of order, process and machine data. They also simplify, standardise and automate the operation of the machine. 26 standard APPs help the machine operator prepare, optimise and systematically process production jobs. CELOS APPS – 3 EXAMPLES JOB MANAGER Systematic planning, administration and preparation of orders. + Machine-related creation and configuration of new orders + Structured storage of all production- related data and documents + Easy visualisation of orders, including NC program, equipment etc. JOB ASSISTANT Process-defined orders + Menu-guided set-up of the machine and processing of production orders + Reliable error prevention thanks to work instructions with mandatory acceptance function TOOL HANDLING Shorter tool setup times through assessments of the magazine configuration for subsequent orders. + Displays all tools required for a job, including automatic generation of a loading list + Generation of an unloading list through automatic detection of all tools not required for subsequent jobs 3939
Anwendungen und Teile Maschine und Technik Anwendungsgebiete Steuerungstechnologie Technische Daten ERGOline CONTROL Highend-CNCs for save process and maximum precision Intelligent control systems are todays basics to change over machine tool performance into a maximum of process efficiency, highest precision on the workpiece and an optimal user friendliness. SAUER with its ULTRASONIC product line exclusively trusts in the quality of world market leader SIEMENS and even increases its performance through own and holistic software solutions and special ULTRASONIC cycles as well as DMG MORI Virtual machine or DMG MORI process chain. 40 SIEMENS 840D SOLUTIONLINE ULTRASONIC CELOS APPS + The simplest interactive programming + Quick editing of large programs + Comprehensive 5-axis functionality + Quick view simulation of complex part programs + Direct spline processing of CAD data + Sophisticated tool handling + Visualisation of the most important ULTRASONIC process parameters: frequency, amplitude, output-power + Automatic process control: monitoring of the existing process parameters + Management of the ULTRASONIC specific tool parameters (easy handling also from demanding actuator-tool-combinations)
ULTRASONIC- parameterisation Special programming cycles ULTRASONIC PARAMETER DETECTION (UPD) ULTRASONIC PROGRAMMING CYCLE (UPC) + Automatic detection of the resonance frequency for all ULTRASONIC HSK-actuators for evaluation of the optimal working frequency / oscillation amplitude + No manual action of the operator neccessary + Simplified operator mask shows all functions and detects the parameters + Integration of ULTRASONIC specific cycles (e. g. use of different amplitudes within an operation task, other power restrictions) directly in the NC-programme + Optional available for all ULTRASONIC machines 41 ULTRASONIC AUTO TUNING (UAT) ULTRASONIC FEEDRATE CYCLE (UFC) + Autotracking of the ULTRASONIC frequency and amplitude within the machining process for compensation of the damping of the tool edge + Achievement of a stable, reliable ULTRASONIC processs + Automatic adaption of the feed rate in the machining process (analog to ACC = Adaptive Control Constraint) + Depending on the application, additional ULTRASONIC specific influencing factors (e. g. output power in W) can be used beside the standard values (e. g. torque in Nm) + Definition of a minimum and a maximum value
Applications and parts Machine and technology Application areas Control technology Technical data › Floor plans TECHNICAL DATA Floor plans Floor plans ULTRASONIC 20 linear Front view Top view 42
Floor plans ULTRASONIC 20 linear with automation PH 10 | 100 Front view Top view Automation Available for Automation Max. handling weight Workpiece change Integrable pallet types Erowa ITS 100 Max. number Erowa ITS 50 Max. number Other pallet types Max. number Floor plan data / basic machine and automation Floor space Dimensions L / W / H (incl. signal lamp) Footprint L / W / H Weight Handling of unpalleted material Job Management-System Type kg s m² mm mm kg 43 PH 10 | 100 HSC / ULTRASONIC 20 linear linear magazine 10 ≤ 30 yes 27 yes 99 yes depending on type < 6 2,020 / 3,250 / 3,400 4,400 / 5,200 / 3,700 4,900 no no
Applications and parts Machine and technology Application areas Control technology Technical data ULTRASONIC Technical Data Traverses X / Y / Z-axis A-axis C-axis Main drive Max. speed range ULTRASONIC to Max. speed range milling to Positioning accuracy in X / Y / Z Repeatability accuracy in X / Y / Z Feed Feed range up to Rapid traverse X / Y / Z Working table Clamping surface rigid table Max. table load Clamping surface NC swivel rotary table Max. table load Max. speed of rotational axes (A / C) Positioning accuracy (A / B / C-axis) 44 Tool Tool holder spindle Tool magazine (standard / option) Type – tool magazine (standard) Max. tool length at full capacity and max. speed Max. tool diameter at full capacity and max. speed Chip-to-chip time Options Work piece measurement Tool measurement Coolant treatment system Floor plan and connection data / basic machine Floor space Dimensions L / W / H (incl. signal lamp) Footprint L / W / H (incl. access to all service doors) Weight Power rating Operating voltage / max. fuse rating Required compressed air connection Average air consumption Controls mm degree degree rpm rpm µm µm mm/min m/min mm kg mm kg rpm " type places type mm mm s type type type m² mm mm kg kVA V bar m3/h ULTRASONIC 20 linear 200 / 220 / 280 –15 ° to 130 ° 360 ° 50,000 60,000 P5 P3 20,000 40 370 × 320 100 ø 200 15 50 / 150 ±5 HSK-32 / HSK-40 24* (60 chain magazine)** changer wheel (horizontal) 200 50 10 DMG PP-400 Blum NT, RS NC-4 Toolsmart 3,5 1,884 / 1,920 / 2,427 3,500 / 3,100 / 2,500 3,750 40 400 (N/PE) / 80 A 6 15 ERGOline Control with 21.5″-multi-touch display CELOS und SIEMENS 840D solutionline Floor plans of the HSC linear / eVo linear / DMF / monoBLOCK / duoBLOCK / Portal machine versions in the relevant product brochures; * in combination with HSK-40: only 22 magazine places, **only every second magazine position can be used with an HSK-40 actuator
45 ULTRASONIC-HSK actuator systems HSK-E32 HSK-E40 HSK-E50 / HSK-A63 HSK-A100 Machine types Max. speed rpm Tool interface * HSK-E50 ULTRASONIC 20 linear ULTRASONIC 20 linear ULTRASONIC linear / monoBLOCK duoBLOCK 50,000 ER, 14 H 6, shrink 40,000 30,000* / 24,000 ER, 14 H 6, shrink ER, 20 H 7, shrink ULTRASONIC P / FD duoBLOCK 12,000 ER, 20 H 7, shrink
Applications and parts Machine and technology Application areas Control technology Technical data ULTRASONIC Market leader in the machining of Advanced Materials with > 1,000 installed machines worldwide. In all hightech branches there is a constant demand for new technology solutions and economical machining procedures for hard to machine future materials. Exactly here, SAUER is positioned with its ULTRASONIC technology and underscores with a consistent product line its technological expertise as an innovative pioneer in the ULTRASONIC-assisted hard machining of Advanced Materials. 46 2 3 1 4 1 America > 100 machines 2 Europe > 400 machines 3 Germany > 300 machines 4 Asia > 200 machines Breakdown by branches Dental / medical Ceramic components Die & mould Institutes / universities Breakdown by machines ULTRASONIC 10 HSC / ULTRASONIC 20 linear 25 % 20 % 15 % 15 % 12 % 53 % Watch industry / fine mechanics Optical industry Automotive Aerospace Flexible ULTRASONIC technology integration into DMG MORI machines 10 % 10 % 3 % 2 % 35 %
1: View of the ULTRASONIC showroom 2: SAUER ULTRASONIC in Stipshausen 3 + 4: ULTRASONICtechnology seminars in the showroom 1 2 ULTRASONIC EXCELLENCE + More than 30 years experience in machining hard-brittle and difficult to machine materials 3 + More than 1,000 installed ULTRASONIC machines (worldwide) + Strong, competent team of application engineers + Feasibility studies, process development / optimisation, complete turn-key solutions 4 5 5: The SAUER LASERTEC location in Pfronten represents itself with 5-axis laser precision machi- nes in the five technology fields: Shape (3D mach- ning, texturing), PrecisionTool (PCD / CVD-D / CBN precision tools), FineCutting (3D fine cutting parts), PowerDrill (turbine components) and Additive Manufacturing (3D laser deposition welding and milling on one machine) 47 ULTRASONIC Expert advantage in ULTRASONIC machining of advanced materials. Take advantage of the technical expertise of our competent team of application engineers and the numerous unique selling points of the ULTRASONIC series — visit SAUER ULTRASONIC in Stipshausen. Besides the actual production of machines, SAUER support their customers with feasibility studies, process optimisation and turn-key technology solutions by SAUER’s development and application department. In addition SAUER GmbH regularly organises ULTRASONIC technology seminars for customers and interested parties on the demonstration machines in a modern ULTRASONIC showroom.
DMG MORI LifeCycle Services DMGMORI.COM Customer First – Our service promise! Available for you around the clock: service-hutline.dmgmuri.cum “We have good news for you: Our service and spare parts prices have been completely revised. With our service commitments, we want to meet your high demands with the highest service quality.” Please contact us – your sales and service team is at your disposal! Top quality at fair prices. It's a promise! . s e v i t a n r e t l a C N C d n a Best Price Guarantee fur Original Spare Parts. Should you get Spindle service at best prices. The highest level of a spare part offered by us at least 20 % cheaper elsewhere, competence from the manufacturer at new and attractive we will refund the price difference up to 100 % *. prices – DMG MORI spindle service! Up tu 50 % luwer service custs. New Flat Call-Out Rate – Our prutective shield fur yuur pruductivity. Reduced operating without travel expenses or any additional costs! costs, highest machine availability and maximum precision – DMG MORI Service Plus! * All information and price advantages for Customer First are available at: customer-first.dmgmori.com t n e m p i u q e , s n o i t p o e m o s e d u l c n i y a m e r e h d e t c i p e d s e n i h c a m e h T . d e v r e s e r s t h g i r e t a d p u l a c i n h c e T . n o i t a c i f i d o m o t t c e j b u S K U _ 7 1 9 0 _ 6 6 3 0 7 1 0 2 P