The future of machine tool manufacturing

Holistic digitisation and productive complete machining with innovative CNC technology will be presented by DMG MORI on its 700 sq metre stand, H20-490, during MACH 2018.

Twelve of the company's latest machine tools including the DMC 80 FD duoBLOCK, the CTX 2500|700, the NHX 5000 2nd Generation and the DMU 50 3rd Generation with PH 150 pallet handling system will be on display. The latter is an example of one of the focus topics at the show, namely automation solutions. The joint venture DMG MORI HEITEC supplies standard and customised automation solutions for all machine tools from DMG MORI.

The aerospace industry is a second focus. The DMG MORI Aerospace Excellence Centre supports OEMs and suppliers with productive manufacturing processes by being involved in the future projects of customers at an ever-earlier stage. As a third focus, DMG MORI will promote digital workflows as a fundamental step towards the digital factory.

End-to-end solutions for the digital factory

First presented at EMO 2017, digital workflows for data-supported production planning and automated tool management have since undergone fine-tuning. They will be available for customers as CELOS apps as early as the first half of this year. Other digital themes include continuous expansion of monitoring possibilities for optimising processes and production as well as digital products and services. Embedded in the new manufacturer-neutral IIoT (industrial internet of things) platform, ADAMOS, DMG MORI offers its customers and suppliers integrated and open end-to-end digitisation solutions.

DMC 80 FD duoBLOCK: Maximum productivity and top surface quality

5-axis simultaneous machining is increasingly being developed as a key technology. Furthermore, automation and combined milling and turning are becoming more important. With about 4,500 duoBLOCK machines successfully sold, DMG MORI has been at the forefront of this development. One of these models is the DMC 80 FD duoBLOCK universal machining centre equipped with a pallet changer, demonstrating enhanced flexibility and productivity with improvements of 30 percent in their core characteristics of precision, performance and efficiency.

The extremely rigid machine is capable of heavy-duty cutting of rotational parts – for instance in aerospace applications – with its HSK 100 B-axis interface and powerMASTER 1000 spindle. It has a power of 77 kW, maximum speed is 9,000 rpm and the torque achieved is 1,000 Nm. Additionally, DMG MORI offers the integration of grinding technology for the DMC 80 FD duoBLOCK, guaranteeing surface qualities to Ra < 0.3 µm.

CTX 2500|700: Universal high-performance turning

The CTX 2500|700 from DMG MORI, combining the precision, performance and stability of two successful CNC lathes, represents the new standard in universal turning. The rigid machine bed and stable guideway arrangement is based on that of the NLX 2500|700, of which 10,000 have been sold, while the VDI turret and the SIEMENS 840D solutionline control were adapted from the CTX beta 800.

When it comes to performance, the CTX 2500|700 excels with its turnMASTER spindles. A 10″ chuck model with 4,000 rpm, 26 kW and 525 Nm or optionally a 12″ chuck version with 3,500 rpm, 30 kW and 1194 Nm are available. The counter spindle has a 6″ chuck as standard and achieves 7,000 rpm, up to 11 kW as well as 70 Nm. An 8″ chuck with 5,000 rpm, 32 kW and 360 Nm is offered as an alternative.

With a maximum turning diameter of 366 mm and 705 mm turning length in the case of the CTX 2500|700, the new lathe offers enough capacity for a broad range of jobs. The chuck size for the standard model is 250 mm with a bar capacity of 76 mm. Travels in the X-, Y- and Z-axis are 260 x 100 x 795 mm. The user-friendliness and digital intelligence of the APP-based control and operation interface, CELOS, as well as an ergonomic design, round off the CTX 2500|700 and are teamed with customer-orientated automation options.

NHX 5000: Horizontal machining with high speed and high precision

The NHX 5000 2nd Generation is a general-purpose, horizontal-spindle machining centre enabling high-efficiency, continuous machining and efficient production in areas such as the automotive sector. The machine’s robust bed provides stable, high-quality machining. The X- and Z-axis guideways are positioned to maximise the rigidity of the bed, column and spindle. The entire structure is optimised for increased static and dynamic rigidity.

As a result, the machine achieves the highest levels of speed and accuracy. The NHX 5000 2nd Generation is equipped with the latest spindle technology, speedMASTER, ensuring high-speed, stable, high-precision machining in combination with the rigid bed. Designed with a 40 taper spindle and equipped with CELOS, the NHX 5000 2nd Generation is suitable for mass production of medium-sized workpieces. It offers a pallet size of 500 × 500 mm and a maximum table load capacity of 500 kg as standard, or up to 700 kg as an option.

DMU 50 3rd Generation: High-quality equipment for price-conscious users

The compact DMU 50 3rd Generation sets new standards in 5-sided to 5-axis simultaneous machining. With its extended swivel range, more powerful spindle and its innovative cooling, it provides a competitive edge in a multitude of sectors. Areas of application range from training, to general mechanical engineering, fixture production and on to include work in demanding industries such as aerospace, medical and automotive.

Travels of 650 x 520 x 475 mm and workpiece weights of up to 300 kg mean the DMU 50 3rd generation covers a wide range of components. Its swivelling rotary table with an enlarged swivel range of -35°/+110° boosts this versatility. Rapid traverse of 42 m/min in the linear axes and 30 rpm in the rotary axes ensure high dynamics for 5-axis machining.

Instead of the 15,000 rpm SpeedMASTER motor spindle, the user can choose between motor spindles of up to a 20,000 rpm. During MACH, DMG MORI will show the DMU 50 3rd Generation in automated version with the PH 150 pallet handling system, underlining the philosophy of offering automation solutions for the manufacturer's whole machine tool portfolio.