DMG MORI will impress visitors at the Industrie Paris 2016 with advanced machine tools and a focus on future sectors

From 4 to 8 April 2016 DMG MORI will presenting its range of products and services during Industrie Paris, the biggest French trade fair in the field of manufacturing, with a total of 14 highly modern exhibits. The innovation leader in machine tool manufacturing will be focussing there on industry 4.0, aerospace and automotive. The ULTRASONIC 20 linear 2nd Generation that was presented at the beginning of this year will be one of the highlights on side of machine tools.

CELOS® & DMG MORI Technology cycles for Industry 4.0

With CELOS®, DMG MORI is offering a cutting-edge user interface that can be expanded with new APPs and updates and which provides an immediate solution to Industry 4.0. CELOS® is as easy to use as your smartphone,

networks all machines within a manufacturing organisation and therefore simplifies the process from the idea to the finished product. 16 APPs help the operator prepare, optimise and process production jobs without any errors and enables the consistent administration, documentation and visualisation of order, process and machine data, consequently holistically improves the profitability of production.

With 31 DMG MORI technology cycles as another highlight, DMG MORI is presenting software solutions on the cutting-edge 5-axis and turn-mill machining centres to make complex machining processes an effortless reality. Thanks to parameterised context menus, complex processes can be directly programmed on the machine up to 60 percent faster. For the easy to learn and ready-made windows to enter data, programming is hardly needed and complicated DIN programming are avoided. Therefore, DMG MORI technology cycles are ideal for application-specific shop floor programming.

DMG MORI Aerospace Excellence Center – revolutionising the market with innovative turnkey solutions
For several years now the aerospace industry has been undergoing radical change: A shortage of resources and the demand for an improved CO2 balance are forcing manufacturers to invest in more economical and

environmentally friendly aircraft. This in turn gives rise to completely new challenges where the manufacture of sophisticated aerospace components is concerned.

As a leader of innovation in the field of machine tool construction DMG MORI supports the development of the aerospace industry in its Aerospace Excellence Center at DECKEL MAHO Pfronten with future-orientated manufacturing solutions developed in close cooperation with users from the branches. These include options such as the heavy-duty machining package, which includes among other things a powerful gear spindle with a torque of up to 1.300 Nm enabling maximum metal removal volumes and at the same time top precision. With its ULTRASONIC technology, DMG MORI also addresses the question of the efficient machining of fibre-composite materials. Added to this is the integration of laser deposit welding in the LASERTEC 65 3D and the LASERTEC 4300 3D in the field of additive production.

Automotive – individual solutions for large series production
A growth area at DMG MORI for years, the automobile branch is now experiencing a major structural change. There are a growing diversity of models and versions and at the same time shorter product life cycles, extensive

modularisation and building block strategies, high dynamics in the use of new technologies in the car plus enormous cost pressure and the increasing growth in production in emerging countries. This all adds up to demand strong, innovative and flexible suppliers who can hold their ground under these conditions. As a manufacturer of machine tools and complete production systems operating on a global level DMG MORI meets these demands with its close-meshed sales and service network and a highly flexible group of supply plants in all key sales markets and so remains an indispensable partner for the automobile and supplier industry worldwide.

The machines in the product portfolio for the automotive sector range from the cost and space-saving i-series for mass production to the machines in the NHX series with a 4-axis table and pallet changer and the highly productive centers of the DMC H linear series with their innovative linear drives. For the mass production of rotatory components, DMG MORI offers among other things vertical lathes in the CTV series and horizontal lathes of the CTX, NLX and NZX product series. With DMG MORI Systems, the machine tool manufacturer also has an experienced service provider on board that concentrates on the target-oriented implementation of the demands of automated solutions.

ULTRASONIC 20 linear 2nd Generation
Even externally, the completely revised ULTRASONIC 20 linear 2nd Generation with its new, functional design and

a reduced footprint of just 3.5 m² is impressive compared to its predecessor. The diverse technological optimisations include the now optional 60,000-rpm speed of the spindle, the up to 47 percent (A-axis) more powerful drive motors, a 15-kg higher load weight and the use of larger tool diameters of up to 50 mm. Another highlight is the high-speed C-axis (1,500 rpm) for high-precision and productive internal and external cylindrical grinding of rotational-symmetric workpieces made of advance materials.

Where control is concerned, the ULTRASONIC 20 linear 2nd Generation supports users with a multitude of new functions. The ULTRASONIC parameters are automatically determined and tracked during processing. In the clearly arranged CELOS® control a CELOS® APP expressly developed for the purpose shows the ULTRASONIC technology cycles and key process parameters such as frequency, amplitude and output, thus enabling maximum utilisation of the ULTRASONIC and machine performance.

DMG MORI CO., LTD. (hereinafter called DMG MORI) has installed two DMC 340 FD large 5-axis machines in its Iga Campus.

The Iga Campus is the manufacturing facility equipped with the state-of-the-art machines and equipment which help achieve a production environment that keeps pace with Industry 4.0. At the facility, manufacturing information including tooling information and machining schedule is centrally managed by connecting large machines like the DMC 340 FD with peripherals for automation such as a tool presetter and a pallet pool system over the network, and controlling them with our original embedded software.

The DMC 340 FD is a large 5-axis machine equipped with a pallet changer. The machine is currently manufactured at the Pfronten factory in Germany, one of the manufacturing bases of our group company DMG MORI AKTIENGESELLSCHAFT. Featuring the direct drive turning table with a maximum rotational speed of 120 min-1 , the machine combines milling with turning on one machine. This allows, for example, a workpiece requiring both 5-axis machine and vertical lathe to be completed with the DMC 340 FD alone.

The spindle with a speed of up to 12,000 min-1 *, output of 52 kW*and torque of up to 430 Nm* achieves high-efficiency machining of large workpieces such as machine tool beds and aircraft & ship components. The 5X-torqueMASTER, a gearbox spindle unit with a spindle speed of up to 6,300 min-1, output of 44 kW and torque of up to 1,550 Nm, is also available as an option.

As for the machine construction, the DMC 340 FD employs a high-rigidity, single-piece bed with 3-point support. The robust, 3-point support structure minimizes gradual deterioration in static accuracy. As a result, the frequency of time-consuming leveling with jack bolts is reduced and the operators’ workload is alleviated.

Up until now, a 5-face machine has been used at the Iga campus. The 5-face machine has no cover, so cutting chips or fragments of a broken tool could scatter during machining, possibly causing injury to the operators. Moreover, the use of long, small-diameter tools and an angled attachment for the spindle imposes restrictions on spindle speed.

The DMC 340 FD, meanwhile, comes with a full cover to ensure safety. The high-speed spindle enables the machine to achieve high-speed machining of castings by means of a ceramic tool, which has been considered difficult on the conventional 5-face machine, resulting in shorter machining time. Additionally, thanks to the swivel milling head, the spindle requires no attachment change. This, coupled with high-speed tool change achieved with rapid traverse rates of 60/30/40 m/min (X/Y/Z), contributes to significant reduction in non-cutting time. The DMC 340 FD with improved performance and shorter non-cutting time has allowed us to reduce total machining time by approximately 49%* compared to the conventional 5-face machine. And the machine’s superior capability to achieve process integration through simultaneous 5-axis machining brings much greater productivity to us.

Currently, the Iga Campus is the only facility in Japan where the DMC 340 FD is running. This means the machine in the Iga Campus can serve not only as a production equipment but also as a display model to showcase its high-precision, high-efficiency machining. A documentary video showing how the DMC 340 FD was transported from Germany to Japan and installed in the Iga Campus is available on DMG MORI Video Clips.

With order intake of € 177.1 million and 688 products sold – including major orders from the USA (€ +11.7 million), from China (€ +10.4 million) and Japan (€ +4.9 million) – DMG MORI takes positive stock of the in-house exhibition in Pfronten this year (previous year: € 167.6 million). This industry-highlight was held for the 20th time at DECKEL MAHO and is the traditional kick-off for the new financial year. Nevertheless the financial year 2015 remains volatile.

From 3-7 February, DMG MORI registered a record number of 8,797 international trade visitors in Pfronten. In particular international customers and potential customers (percentage: 59%) contributed to this. Their main interest fell on innovations, trend-setting products and particularly on CELOS. With its apps, CELOS control technology simplifies the process from the idea to the finished product. Four new CELOS apps and a CELOS PC version were presented for the first time. In total, 76 high-tech exhibits were presented over the 5,800m² floor area,
including four world premieres. Other focus points included system solutions for the automotive and aerospace industry, as well as for line production. With its additive manufacturing machine LASERTEC 65 3D, DMG MORI presented an innovative combination of additive and cutting machining.

At the press conference on the balance sheet on 12 March 2015, the Group will publish the figures for financial year 2014 and will present an outlook for the current financial year.