Highly dynamic, long-term stable 5-axis machine concept – compact on just 3.5 m² footprint
With the ULTRASONIC 20 linear, DMG MORI relies on a long-term stable gantry machine design, to be able to safely meet all demands of ultrasonic machining. Despite this, the machine tool manufacturer was able to reduce the footprint of the machine to only 3.5 m². A double drive for the Y-axis and the concept of integrated cooling, which uses the temperature monitoring of drives, spindles and the control as well as all media guarantee highest precision and workpiece quality. The linear measuring systems from MAGNASCALE are a good example for the high-tech components which DMG MORI has used here.
DMG MORI has also significantly increased the capacity of the drives for the new development: by 47 percent for the A-axis, 27 percent for the C-axis and 34 percent for the Z-axis. The linear drives achieve maximum acceleration of more than 2 g and provide rapid traverse speeds of up to 40 metres per minute. Due to the large swivel range of the A-axis of the work table, ranging from -15° to 130°, and the fully integrated 360° endless rotation axis - both with torque technology, the ULTRASONIC 20 linear is optimally suited to 5-axis simultaneous machining. The rotational speed of 1500 rpm that can optionally be achieved for the C-axis also enables circular milling/circular grinding as well as turning/milling operations.
After the revamp, the ULTRASONIC 20 linear can now also be used with larger tool diameters of up to 50 mm. It was also possible to increase the maximum workpiece weight from 10 kg to 15 kg. The basic version of the machine is equipped with a powerful 15 kW motor spindle and a HSK-32 tool holder, the maximum rotational speed is at 42,000 rpm. Higher demands on the rotational speed can be achieved with an optional spindle, which reaches an impressive 60,000 rpm. The range in this segment is rounded off by an HSK-40 spindle with permanent lubrication.
The modular concept of DMG MORI enables a wide-ranging application-specific configuration of the machines - of course this also applies to the ULTRASONIC 20 linear. For example, the machine can also be supplied with a 1,500 rpm turning/milling table, which extends complete machining of rotation-symmetric workpieces in a single setup to the operations of milling, turning and grinding. In addition to the tool magazine with 24 pockets and minute wheel, a 60-pocket chain magazine is optionally also available.
Unique integration of technologies
The ULTRASONIC 20 linear with its special features enables the use of ultrasonic support for specific materials, namely the milling and drilling of nickel or titanium “super alloys” or of materials like magnesium, tungsten as well as composite materials. Process forces have been reduced for milling applications in titanium by up to 30 percent. For steel, double feed speeds are possible, for other materials, like magnesium, the feed speeds can be increased by up to five-fold. In addition, an improved surface quality can be achieved. The ULTRASONIC process has a significant impact on the chip breaking behaviour and the chip removal from the tool. Further to the shorter chips, this also results in drastically reduced tool wear. This makes the technology interesting for almost all future-oriented target markets with high-tech products. The specific benefits associated with the option of using the ULTRASONIC technology have also taken the flexibility to a new level. It is now possible to machine workpieces from very different materials, from soft to hard-brittle, in five axes for mould making, medical technology, the automotive and aerospace industry.
ULTRASONIC 20 linear with new design and CELOS
High-quality, long-lasting covers as an external distinguishing feature with functional added value thanks to optimum accessibility are the most important properties of the new standardised DMG MORI design. The ULTRASONIC 20 linear also has this new look, whose impact on value retention must not be underestimated. Furthermore, the machines also offer CELOS. This user interface with its unique multi-touchscreen can be used as easily as a smartphone. This user friendliness is further increased by CELOS apps which were specifically developed for ultrasonic machining. They visualise the ULTRASONIC technology cycles and the most important process parameters like frequency, amplitude and output power. At the same time, the apps monitor the process forces of the actuators and also support configuration of the tools.