Into the future of CNC manufacturing with local production
DMG MORI presents itself at this year’s CIMES in Beijing with 13 CNC machine tools and the focus topics Automotive, Aerospace and Medical.
Growth industries like automotive engineering, the aerospace sector and medical engineering determine the current trends in manufacturing in China as well. DMG MORI has always been providing innovative manufacturing solutions for these topics of the future. The worldwide leading machine tool manufacturer will present a cross-section of the range from 22 to 26 June 2016 at the upcoming CIMES in Beijing. 13 machines will be presented live in operation at a 600 m² stand – among them the WASINO J1 and the ecoMill 1100 V as Chinese premieres. Furthermore, DMG MORI is demonstrating the importance of local production.
CELOS and DMG MORI Software Solutions
DMG MORI is pushing forward intelligent software solutions as the elementary basis of the digital transformation of manufacturing process chains. In the age of „Industry 4.0“ it is very important to build-up a customer-oriented strategy of digital manufacturing. As a part of this strategy, DMG MORI supports customers on the way to digital transformation by offering the APP-based CELOS system and DMG MORI Technology Cycles.
CELOS was first presented three years ago and as for today, the system is still being developed. The holistic user interface from DMG MORI is as easy to use as smartphone. Thanks to its open architecture, CELOS allows the exchange of information with higher-level structures in addition to its effects in the shop floor area. So CELOS offers customers complete integration of their machines in the company organisation while simultaneously creating today the interface of metal cutting production in the cyber-physical production system of the future. The benefits in day-to-day operation are convincing: a 30 % time saving in tooling times and 50 % lower time and effort for the calculation of technology values or the search for important information are just a few of the effects that can be achieved with CELOS. In addition, CELOS offers smooth entry into the future of metal cutting production, because this takes place gradually. Customers who decide for CELOS today receive firstly unlimited access to the existing 16 CELOS APPs and secondly the chance to benefit from future applications – because CELOS is and will remain upwardly compatible.
Workshop-oriented programming is still of great importance especially in single item production and the production of small and medium-sized quantities – and it will remain just as important for a long time to come. Whereby working with cycles is now state-of-the-art and standard cycles for turning, milling and drilling have long been included in the performance range of modern controls. Based on its decades of application experience DMG MORI has gone far beyond the standard and currently has 24 exclusive DMG MORI Technology Cycles for the fields of turning / turning-milling or rather milling / milling-turning in its portfolio. These enable the operator in the workshop to programme complex machining him/herself up to 60 % faster directly on the machine via a dialog using parameterised context menus.
CTX gamma 2000 TC – complex complete machining with compact turning-milling spindle
DMG MORI now producing the smaller CTX beta TC already in its second generation, the larger sister model CTX gamma 2000 TC was also further developed. The outstanding features of these two models are the X-travel, which has increased by 150 mm to now 800 mm, and the compactMASTER spindle of the B-axis, developed together with the Japanese engineers as a cooperation project. Its unique selling point above all is the torque increased by 120 percent to 220 Nm. With 450 mm, the length of the compactMASTER spindle has been reduced by 70 mm – and this with a 120 percent higher torque. The interplay of the 150-mm larger X-axis (-25 / +775 mm) and the 20-mm longer Y-travel of ± 210 mm brings an enormous gain in freedom for users. It means, for example, that radial machining of workpieces with maximum diameters of 700 mm is possible with 170-mm long tools (with the B-axis in a vertical position). The 2nd generation of the CTX gamma TC also has advantages where horizontal machining is concerned: Workpieces measuring up to a good 300 mm in length can now be drilled completely out horizontally or hollow turned with no problem at all on the CTX gamma 2000 TC. The respective turning lengths is 2,000 mm.
The core element of the new CTX gamma TC model is still the B-axis with its swivel angle of ±120°, which is mounted on a highly stable travelling column and ensures milling performance right through to the field of 5-axis simultaneous machining. The machine concept has been radically revised with just such stability and precision in mind. The CTX gamma 2000 TC now has an integral thermal concept. This includes among other things integrated bed cooling as well as cooling of the linear guides of the travelling column, the spindle motors and the drive of the B-axis. Combined with the MAGNESCALE magnetic measuring systems, the thermal displacement of the machine is now ≤ 10 µm.
WASINO J1 – turning center for complex precision parts
With a more than 75-year-long tradition, the popular and successful models of WASINO have gained an excellent reputation with regard to compact and high-precision turning centers for production, among others in the car manufacturing and optical industries. With integration into the global sales and service network, DMG MORI intends to use this tailwind from Japan and lead the WASINO portfolio to success on an international basis as well. As an example for the series, the machine tool manufacturer will present the WASINO J1 at the CIMES 2016.
The WASINO J1 with 8-pocket turret is particularly suitable for the soft and hard machining of simple to complex workpieces. The areas of application of the precision turning center are rough machining and finishing in sequential production processes, where a tailstock can optionally be integrated for shaft machining. A sturdy machine bed with low centre of gravity forms the solid basis. The cover made of stainless steel has a low thermal conductivity, which prevents sudden temperature fluctuations in the machine bed. With this, the WASINO J1 achieves a precision of 4 µm for cold starts. Circularity is at an impressive 0.5 µm.
ecoMill V series – highest precision and 12,000 rpm milling spindle in standard
DMG MORI has been successfully defining the standard for users of powerful entry-level machines for many years with the ECOLINE product range. This especially applies to the new generation of ecoMill V vertical machining centres. The ecoMill 1100 V – with 1,100 mm X-axis traverse the biggest member of the series – will be presented as a China premiere at the oncoming CIMES. The highlight of this model as well as the whole ecoMill V series is the completely revised ECOLINE design. DMG MORI has improved working ergonomics as well as the visibility into the working area and achieved a high degree of value retention. The new 19" DMG MORI SLIMline multi-touch control with Operate on SIEMENS as well as 15" DMG MORI SLIMline with MAPPS IV on FANUC applies for the innovative and modern user interface so that the customer has a wide variety of 3D controls.
The ecoMill V series is based on a C-frame cast iron bed for the best stiffness and vibration characteristics ensuring highest precision. Ball screws of the highest quality and a powerful 12,000 rpm spindle were combined to meet the highest standards in production. A comprehensive options kit, e.g. with linear scales for direct distance measurement or a production package with a 12-bar internal coolant supply among many other options is at the customer’s disposal. The low connected load, efficient power consumption and energy recovery ensure a good energy utilisation.
The performance of the ecoMill V series is outstanding, even in the standard version. The highest precision (without direct scales) can be realized, due to direct coupling in X / Y, no belt drive for no backlash. In total, the cutting speed has been increased by up to 25 %. An optimized machine structure also increases stability during machining, and a high degree of manufacturing flexibility is provided in the standard version by having 30 tool pockets in the tool magazine.
Local production – DMG MORI extends strategy of global production
A total number of 21 production plants worldwide and a production capacity of over 20,000 machines a year make DMG MORI a global player with a strong local connection. Manufacturing locally ensures an integrally high standard of quality – in both production and service.
In China, DMG MORI began producing machine tools in Shanghai in 2003 continuously improving production and process standards in this plant. In 2007, it passed ISO 9001 ensuring global standards. Today DMG MORI Shanghai focuses on the automotive industry, electronics, and mechanical parts as well as educational customers. The machine tool manufacturer has been extending production capacities in China at the ultra-modern plant in Tianjin since 2013.
With the local production, DMG MORI is following the global quality criteria and latest engineering standards. Additionally, the machine tool manufacturer achieves shorter lead times as well as significant cost savings on shipping, customs and exchange fees due to the production within the country.
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