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09/19/2017|EMO 2017 - DMG MORI Technology Excellence: Automotive

As a global full-liner to comprehensive competence partnership

Integral portfolio in milling and turning – DMG MORI offers optimum solutions for flexible and efficient production in the automotive sector

  • More than 1,500 DMG MORI machines annually for the automotive industry
  • Everything from a single source: Turning, Milling, ULTRASONIC, LASERTEC Shape, ADDITIVE MANUFACTURING, and Automation
  • The 3rd generation CTV with the 85 Nm torqueDRIVE turret
  • CTV 250 DF: vertical 5-axis production turning and milling
  • NEW: CTX beta 1250 CS, unique machine concept for crankshaft production
  • NEW: MULTISPRINT, Multi-spindle automatic turning machines for SWISSTYPE machining up to 180 mm turning length
  • NEW: DMU 200 Gantry and DMU 340 Gantry with up to 0.5 g
  • DMC H linear: economical production of engine blocks and powerchains
  • i-series: Mass production of cylinder blocks or cylinder heads
  • NRX: Highly productive dual-spindle turning centre for serial production
DMG MORI presents integral complete solutions comprising high-performance machine tools, technologies, automation solutions and intelligent software for the automotive sector.

Rising sales figures in both the traditional North American and European markets as well as in high-growth China characterise the automotive sector. Manufacturers in this branch and their suppliers are confronted with the challenge of how to come up with a fast and economical production solution that will give them the edge in this fiercely competitive market: low unit costs, automated processes and a high level of flexibility are the key factors here. As a long-standing competence partner in automobile manufacture DMG MORI sells 1,500 machines a year for the automotive industry and is called upon to meet the high demands with state-of-the-art CNC technologies. The turnkey solutions from the leader of technology have long developed into integral modular systems consisting of high-performance machining centres and intelligent software. This guarantees top availability and maximum process reliability.

The change taking place in automobile manufacture is quite evident: hybrid technology and electromobility are on the rise. Digitisation within the branch is expanding progressively as the result of the growth in autonomously-driven vehicles and the networking of vehicles. At the same time more and more cars are being built with conventional engines. This has an impact on car production – in particular in the area of mechanical manufacturing. A high hybrid percentage gives rise to a demand for machining solutions, while flexible manufacturing solutions are more important where electromobility is concerned. After all comparatively small batch sizes for powertrains have to be produced just as economically as is the case in mass production. Added to this are the diverse range of extras for vehicles and continuously changing design features aimed at encouraging customers to make a purchase. This fast-moving pace is reflected especially in the automotive tool and mould sector.

DMC H linear and i-series:
Efficient manufacture of engine blocks and powertrains

Thanks to its wide and diverse range of products DMG MORI is in a position to meet the high demands on production in automobile construction – both in demanding milling and highly productive turning and turn-mill operations. Machining accuracy and productivity are always the focus of the different solutions, as the manufacture of gear and crankshaft housings show. As aluminium components with a high chip volume are usually concerned here, the horizontal machining centres in the DMC H linear series come into their own in this area. Their steeply angled interior covers and open-bottom machine beds enable chip fall directly into the chip conveyor. This results in a higher level of process stability, longer tool life as well as better heat dissipation and surface qualities of the machined parts. To ensure maximum productivity DMG MORI relies in this series on an innovative machine design: The machines can be automated simply with a single pallet changer or a rotary magazine with up to twelve pallets as well as ideally connected to a linear pallet system serving several machines. Linear drives in all axes with rapid traverses of up to 100 m/min and 10 m/s² acceleration ensure both the necessary dynamics and high precision. Positioning accuracy is 5 µm and repeat accuracy 3 µm.

With the i-series DMG MORI offers a highly productive concept for the mass production of cylinder blocks or cylinder heads. Equipped with patent-pending Z-axis kinematics, the spindle guarantees the i 50 and i 80L maximum stability with two lateral guides arranged at an angle to each other. This minimises vibrations during the high-precision machining while at the same time ensuring longer tool life. The linear axes are all located in the area of the spindle thus reducing moving masses in all axes to a minimum. In combination with the lightweight construction, this enables high-speed machining and enormous dynamics, so that the shortest possible chip-to-chip times can be achieved. The guideways are located outside of the work area thus preventing any temperature impact and contributing to the incomparable level of precision.

Efficient turning technology for demanding serial production

With the compact and easily accessible turning centres in the NZX-S series DMG MORI has the right solution available for the serial production of crankshafts and camshafts. Their space-saving design make these machines ideally suited for production lines. Short travel paths and optimised spindle power and feed ensure maximum performance and short throughput times. The high machining accuracy of the NZX-S models derives from a thermo-symmetric design in relation to the spindle centre. The vertical design guarantees optimum chip fall.

With its third tool mount and turning unit with integrated steady rest, the CTX beta 1250 CS is the only model in its class that offers turning and milling operations for crankshafts on one machine.

DMG MORI has revolutionised crankshaft production

The newly developed CTX beta 1250 CS is a first in the field of automotive crankshaft production and was designed specifically for such workpieces. It is equipped with two powerful milling units each with a torque of 3,750 Nm. Glass scales in the X and Z-axes ensure maximum precision. The special feature of the CTX beta 1250 CS is the third tool mount: a turning unit with integrated steady rest. “Thanks to the three tool mounts and the patented, integrated steady rest we are the only machine tool manufacture in a position to offer turning and milling operations for crankshafts on one machine”, says Managing Director Harry Junger about the advantages of this machine. With this concept customers save up to 50 percent machining time for turning and milling operations and they do so on a considerably smaller footprint.

The third generation CTV – stable, fast, accurate

With the new generation of the CTV series it has been possible to perfect the core arguments of the machine: automation, stability and productivity. “Over 15 years of experience in vertical production turning coupled with consistent customer-orientated further development have helped us develop the best CTV ever”, explains Harry Junger. They have also optimised the series with regard to technology: “Thanks to new process integrations, such as grinding and gearSKIVING on the CTV 250 DF, the series now offers manufacturing solutions for an even greater circle of customers.”

DMG MORI enables the productive serial production of constant velocity joints with the CTV 250 DF. Instead of a turret, the CTV 250 DF is equipped with a turn-mill swivelling tool carrier with a swivel range of + 105° to- 45°. With a speed of 90 rpm the Direct Drive ensures maximum dynamics. The machine is designed for up to two milling spindles with maximum 6,000 rpm, 14.5 kW and 46 Nm. Due to its high thermal stability the CTV 250 DF combines shortest machining times of just 33 seconds for constant velocity joints with consistently high accuracy.

DMG MORI will be showcasing another highlight of the CTV series at the EMO with a production cell consisting of two linked CTV 250 machines. The two machines are connected by a portal automation and four accumulating conveyor belts. The attractively priced DUO automation has proved to be an extremely productive manufacturing solution with a high level of stability. CELOS and an Industry 4.0 sensor package help users with the documentation of production that is so important in the automotive sector.

With the new automatic multi-spindle turning machines DMG MORI has developed a highly flexible machine concept that can efficiently manufacture complex components such as shafts for automobile construction by means of both chuck and bar machining.

DMG MORI rounds off its portfolio in highly productive turning with the NRX series. The dual-spindle turning centres are designed for diameters of up to ø 180 mm, and ø 150 mm with a milling specification. Workpiece loading takes just 5.6 seconds with a spindle working on uninterrupted while the other is being loaded. With two 8-station turrets – ten stations in the milling version – the NRX guarantees optimum chip fall.

Unique diversity for the automotive process chain

Markus Piber, Managing Director of DECKEL MAHO Pfronten GmbH, stresses the importance of a comprehensive range of services for customers in the automotive industry: “Under the motto ‘A full Automotive Technology Integration’ we present complete solutions or integral modular systems comprising high-performance machine tools, integral technologies, automation solutions and intelligent software. This guarantees our customers in the automotive industry top availability and maximum process reliability.”

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