XXL-machining to within tens of microns
Founded in 1946, Baltic Metalltechnik GmbH, a subsidiary of the Hauni Group, specialises in modern manufacturing technologies. At the Hamburg factory, 248 employees are responsible for the production of complex mechanical components and assemblies. Machining of the high-precision components is carried out on versatile machine tools on the company’s shopfloor, which include around 45 models from DMG MORI. Since January 2019, Baltic Metalltechnik has been using a DMC 340 U for machining its large part in addition to several 5-axis machining centers and CTX beta TC turn-mill centers.
Hauni Group's machines produce up to 20,000 cigarettes per minute. “The quality of every one of these is inspected by an optical process and where necessary recycled”, adds Thorsten Deumlich, Head of Large Part Machining. All individual elements of the sophisticated machines must interact perfectly if such high speeds are to be achieved. “This calls for many years of experience in both the development and design as well as in machining.” This also explains the high demands on quality: “We work entirely to accuracies within tens of microns and we do it with components that are over three meters long.”
Optimum project management from design through to commissioning
This first criterion defined the investment in a new machining center for large components – frames and housings for example. The second criterion was a time-driven, according to Thorsten Deumlich: “We had to complete the entire project within a year and a half.” DMG MORI proved an all-round and extremely reliable partner during this period. “Everything went smoothly, from the design of the system to testing in Pfronten right though to final acceptance at our premises.”
DMC 340 U – accuracy to within tens of microns over a length of three meters
The DMC 340 U was technologically convincing even in the early testing phases. Thanks to the expertise of all those involved and the precision package with which the machine is equipped, the XXL model achieved all drawing tolerances. “We are talking here about a few hundredths of a millimeter over three meters”, says Thorsten Deumlich, clearly impressed.
Perfectly coordinated equipment
The portal machine with its extensive equipment was installed at the beginning of 2019 after Baltic Metalltechnik had excavated a pit in the factory floor so the DMC 340 U could be installed at a user-friendly height. The 5-wheel tool magazine with space for 303 HSK-A100 tools reduced idle times, as did the laser system that establishes the contours of the part or the position of the workholding devices and table supports. “A monitor simultaneously displays which tools are required”, explains Thorsten Deumlich. This means employees can set up new pallets in the shortest possible time during production. “The customized table also has special slots that simplify the process even further.”
CELOS – future-oriented functions for the digital future
In the case of the DMC 340 U the process optimization goes a step further, because the CELOS Performance Package is also installed. This includes the CONDITION ANALYZER for the analysis of machine and process signals as well as the PERFORMANCE MONITOR for maximum transparency and monitoring of machining parameters. The SERVICEcamera providing a fast and simple remote solution for service queries rounds off the groundbreaking specification of the machine.
Experience has proved that the machine was a sound investment for the future. Thorsten Deumlich says in this respect: “We have boosted our efficiency sustainably where large part machining is concerned and in so doing have created further capacity. ”As Baltic Metalltechnik is planning further growth: “Our core business remains production within the Hauni Group, but our manufacturing competence and machining portfolio are also available for external customers.”
