ULTRASONIC 200 Gantry
5-axis ULTRASONIC machining in XXL
Max. X-axis stroke
157 in.
4,000 mm
Max. Y-axis stroke
79 in.
2,000 mm
Max. Z-axis stroke
47 in.
1,200 mm
Max. workpiece length
169 in.
4,300 mm
Max. workpiece width
79 in.
2,000 mm
Max. workpiece height
49 in.
1,250 mm
Max. workpiece weight
44,092 lbs.
20,000 kg
Control & software alternatives
SIEMENS
Highlights
ULTRASONIC by DMG MORI
ULTRASONIC technology integration - reduced process forces for higher productivity
- Technology integration via HSK-A63 / HSK-A100 interface for ultrasonic superimposition of the tool rotation with amplitudes up to 15 µm
- Process forces reduced by up to 50% through ULTRASONIC enable, depending on requirements: higher feed rates, improved surface quality up to Ra <0.1 µm, longer tool life
- Specific coolant treatment systems with centrifuges, optimized for the ULTRASONIC processing of Advanced Materials
ULTRASONIC 3rd Generation - Optimal process control through intelligent controls
- Constant amplitude in the process to ensure reproducibility
- Automatic detection of the working frequency, significantly improved hardware for signal acquisition
- Frequency tracking and simultaneous power control in real time for optimal process stability
- Ensuring the ULTRASONIC advantages even with non-optimal tools
- Fully compatible with 2nd generation ULTRASONIC actuator
Flexibility through spindle versions
- Vertical spindle with 20,000 rpm
- 45° head and 90° head for 5-axes machining up to 30,000 rpm
- Ready for new technologies like Ultrasonic, Laser or machining of carbon material
Working area concept
- Fixed table 2,250 x 2,000 mm with 10,000 kg loading capacity
- T-slots across the table for easy chip removal
- Chip conveyors on both sides of the table
Low Gantry Design
- 50 m/min rapid traverse
- Best visibility into the working area through missing side walls
- Maximum utilisation of the working area
5-axes machining
- 45° head with 90° swivel range and +/- 300° rotating range
- compactMASTER spindle with 20,000 rpm
- 90° head with +/- 120° swivel range and +/- 300° rotating range
- compactMASTER spindel with 20,000 rpm up to 30,000 rpm
Application Examples
Control & Software
intoolSENSOR
- Automatic detection of contact with the workpiece
- Tool breakage detection without additional measuring device
- Self-learning algorithm for precise contact detection
Highlights
Customer benefits
- Precise drilling depth independent of tool wear
- Time saving due to automatic recognition of the workpiece contact
- Increased process reliability due to closed control loop
Left: The ULTRASONIC system reacts to external load; Right: Tool contact detected
ULTRASONIC feedCONTROL
- Automatic reaction of process changes (materials, tool abrasion) by adapting the feed rate in the process
- Directly evaluates the signals (frequency and power) of the ULTRASONIC system
- Optionally also takes the spindle utilization into account
Highlights
Customer Benefits
- Always optimal process performance
- Process control through predefined parameter windows
- Safety for fragile workpieces made of brittle-hard materials
Left : ULTRASONIC feedCONTROL sets limit values “Upper / Lower Limit” for the machining process and monitored in real time. This determines the optimum “Operating Range” of the process. / Right : Via an intuitive user interface, ULTRASONIC feedCONTROL can be set up quickly. Parameters and required reactions are defined in this way.
ULTRASONIC axialGRINDING
- Grinding of rotationally symmetrical structures and in particular 3D contours in hard-brittle materials with maximum performance
- Production of bearing rings, wafer chucks, microwave windows for many areas of the semiconductor industry, optics and technical ceramics
- Grinding of spheres possible
Highlights
Customer Benefits
- Simple programming of complex 3D contours* and rotationally symmetrical geometries using intuitive operator screens
- Selection of different cutting edges and setting angles of the grinding tool
- Automatic adjustment of the tool contact point depending on the contour
*Only the ULTRASONIC axialGRINDING cycle can grind 3D contours. The standard grinding cycle from DMG MORI for FDS machines cannot grind 3D contours.
Left : Different tool settings for changing the engagement point of the of the ULTRASONIC grinding tools. / Right : Simple setup of the grinding tools including edge radii.
Sealing ring, SiC
Ring, quarts glass
Resonator, quartz glass
3D quickSET
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
Highlights
Turning Customer Benefits
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
Dialogue-guided measurement of the B- and C-axis.
Milling Customer Benefits
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
Define kinematics head
Application Tuning Cycle
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight
Highlights
Customer Benefits
- User friendly setting of the machine dynamics with included DMG MORI knowhow
- Time saving in roughing
- High surface finish during finishing
Left : ATC 2.0 – Milling: Consideration of table loading. / Right : ATC – Turning: for CTX TC for easy adjustment of the machine dynamics.
MPC 2.0 – Machine Protection Control
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
Highlights
Customer Benefits
MPC Graph: current and learned process values. / MPC Diagnostics: stock condition, number of impact and crash.
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
ULTRASONIC microDRILL
- With ULTRASONIC 2nd Generation and 32.000 rpm for micro drilling with highest process safety
- Fully integrated regulation of the drilling force in the preset- spindle down to smaller 1 N – independent from the z-axis of the machine
- ICS with seperate fine filtration and flow rate control starting from 1 l/min
- Automatic ejector mechanism for drill cores from the diamond hollow drills
Highlights
Customer Benefits
- Drilling diameter from 0.1 mm – 2.0 mm
- Several thousand holes per part possible without manual interaction
- Applicable for diamond hollow drills and spiral drills
Left : Fully integrated into the display in the CELOS SideScreen / Right : Precise regulation of the drilling force incl.
Service & Training
Downloads & Technical Data
Workpiece
Max. workpiece length
169 in.
4,300 mm
Max. workpiece width
79 in.
2,000 mm
Max. workpiece height
49 in.
1,250 mm
Max. workpiece weight
44,092 lbs.
20,000 kg
Work Area
Max. X-axis stroke
157 in.
4,000 mm
Max. Y-axis stroke
79 in.
2,000 mm
Max. Z-axis stroke
47 in.
1,200 mm