From 22nd to 28th January DMG MORI will be giving a deep insight into its future-orientated product portfolio at the IMTEX 2015 in Bangalore. At the largest exhibition for metal cutting and production solutions in India DMG MORI will be presenting 16 machines from its latest product portfolio and will be focusing on CELOS® – from the idea to the finished product – and the new machine design. All machines shown at IMTEX will be presented in the new DMG MORI design. The ECOLINE series – highest functionality with best price – will be shown with 6 machines at the 600 sqm booth. DMG MORI Systems rounds off the programme with a demonstration of integral manufacturing solutions with a focus on automobile industry. Using the daily shuttle service customers can also visit DMG MORI’s Technical Center close to the exhibition center, where daily seminars are offered.

CELOS® – From the idea to the finished product

All new high-tech machines from DMG MORI will be provided with CELOS®. This new user interface of the control is as easy and intuitive to use as a smartphone. On a unique 21.5” multi touch display CELOS® APPs provide the user with integrated and digitised management, documentation and visualisation of order, process and machine data.

The latest CELOS® version with a total of 16 APPs is available from April 2015 on and includes four new APPs that will be presented for the first time at DECKEL MAHO’s Open House in Pfronten. Also new is the CELOS® PC version. It enables users to plan and control their production and machining processes already during work preparation. CELOS® connects the machine with superordinate corporate structures in a unique way and creates the basis for a consistent paperless manufacturing.

Additionally, it accelerates the way from the idea to the finished product by direct coupling of ERP / PPS and PDM. With CELOS® DMG MORI sets standards and gives the answer to industry 4.0.

UNIFORM
Uniform interface for all new high-tech machines from DMG and MORI

CONSISTENT
Consistent management, documentation and visualisation of order,  process and machine data

COMPATIBLE
Compatible with PPS and ERP systems, networkable with CAD/CAM products,  designed to work with other forward-looking CELOS® APPs

The new DMG MORI design –  multifunctional, user-friendly and value retaining

The design of a product instantly determines the customer’s perception and estimation of value. From this perspective alone, DMG MORI has once again set standards in the field of machine tool manufacturing with the new joint design that illustrates the uniformly high quality standard of the machine tool manufacturer. Additionally, the new design impresses with more functio-nality, extra user-friendliness and high value retention.

Large viewing windows ensure the best possible view of the work area for better monitoring of the production process. Access facilities and the interior working area are designed so that it is easy for operators to reach inside and to ensure optimum chip disposal during the machining process. In addition, the safety glass windows can be removed from the outside, which benefits service friendliness.

Another highlight of the new DMG MORI design is the machine housing which is provided with a special finely textured coating in the premium area. These long life surfaces offer better scratch resistance and better protection against damage in general, which further increases the ability of the high-tech machines to hold their value. Additionally, the new DMG MORI design is optionally available in either “BLACK” or “WHITE” at no extra cost.

Highlights of the DMG  MORI design

User-friendly
• CELOS® from DMG  MORI: ERGOline® Control with 21.5” multi-touch screen and common interface
• Continuously adjustable display and control desk for a comfortable working position
• SMARTkey® for customised authorisation of the operator for
• individual access rights to the control and to the machine

Multifunctional
• Maximum view of the working area for better monitoring of the production process
• Improved functionality, e.g. removal of safety glass windows from the outside

Value retaining
• Premium area with fine texture, for higher scratch resistance and protection against damage

ECOLINE – high-performance CNC technology for price-conscious users

ECOLINE will be present at the IMTEX 2015 with a total of 6 models. The three lathes ecoTurn 310, ecoTurn 450 and ecoTurn 510 and the machining centres ecoMill 50 and ecoMill 635 V stand for efficient and highly accurate metal removal at very low investment costs. The 5-axis MILLTAP 700 will also be on show, a highly productive and versatile compact machining centre whose dynamics set new standards in production.

The ecoTurn models bring together numerous competences: their stable construction guarantees top precision, the extensive equipment promises maximum efficiency, the wide choice of 3D controls ensures flexibility – and the task-optimised expansion options enable an upgrade of the machines right through to Turn & Mill complete machining.

Highlights of the ecoTurn 450

• VDI 40 servo turret with up to 12 driven tool stations (Option)
• 3D control technology:
_ 15” SLIMline® with Operate 4.5 on SIEMENS 840D solutionline,
_ 15” SLIMline® with HEIDENHAIN CNC PILOT 640 or
_ 10.4”-TFT with MAPPS IV with MITSUBISHI
• Large bar capacity up to ø 65 mm (Option: ø 75 mm)
• Rapid traverses of 30 m/min in all axes
• Small footprint of only 4.9 m²
• Automatically moveable tail stock
• Rear chip conveyor (Option)

With the ecoMill series DMG MORI offers milling machines that can machine complex work pieces accurately and efficiently. The ecoMill 50, in particular, is a universal genius in the entry-level segment. With powerful spindles and the proven concept of 5-sided machining it attracts quality-oriented users with a moderate budget.

Highlights of the ecoMill 50

• Highest efficiency: 5-sided machining of easy to highly complex work pieces
• Highest precision: NC swivel rotary table with digital drives
• Milling spindle 12,000 rpm / 83 Nm (40% DC) / 13 kW (40% DC)
• Tool changer (optional) with 16 pockets and a pick-up magazine (30 pockets)
• Direct measuring system (optional) and centrally lubricated roller bearing guides for continuous high accuracy
• SLIMline® with Operate 4.5 on SIEMENS 840D solutionline or
• SLIMline® with HEIDENHAIN TNC 620 with clear text dialogue
• DMG SMARTkey®
• DMG Netservice

Highlights of the ecoMill 635 V

• Powerful spindle: 12,000 rpm / 83 Nm (40% DC) / 13 kW (40% DC)
• Tool magazine with 20 tool pockets – (30 pockets optional) with fast double gripper
• Reduced downtimes: 30 m/min rapid traverse, 1.6 sec. tool change time
• Highest rigidity and precision as well as a small footprint with the C-frame design
• Largest control variety
_ SLIMline® with Operate 4.5 on SIEMENS 840D solutionline,
_ SLIMline® with HEIDENHAIN TNC 620 with clear text dialogue and
_ MAPPS IV from Mitsubishi
• DMG SMARTkey®
• DMG Netservice

NHX 4000 2nd Generation and NHX 5000 2nd Generation: Horizontal machining centres with outstanding rigidity, precision and speed

With the new NHX 5000 2nd Generation DMG MORI offers a horizontal machining centre that is as compact as it is dynamic; a machine ideally suited for the manufacture of complex and demanding components and on through to highly efficient serial production, e.g. in the automotive industry or machine and plant engineering. Together with its new smaller sister machine – the NHX 4000 2nd Generation – the new NHX series now boasts a Direct Drive Table (DDM® technology) with speeds of up to 100 rpm and direct scale feedback systems from MAGNESCALE on all axes as standard to provide high-precision positioning using absolute magnetic linear scales.

The magnetic linear scale has better vibration- and impact-resistance characteristics than those of an optical scale and is far less affected by condensation or oil which is inseparable from machining operations. It offers high-accuracy measurement with a resolution of 0.01 μm even in a severe environment. What’s more, the magnetic linear scale has the same linear expansion coefficient as cast iron used for machine tool components, so it exhibits the same behavior as the machine body on which it is mounted, thereby providing highly stable machining accuracy even in a temperature-fluctuating environment. Equipped with the high-precision scales and structural components built with carefully-selected castings and sophisticated assembly techniques, the new NHX machines surpass all others in their classes in positioning accuracy and roundness.

The construction of the machines has also been optimised with regard to the use of shorter tools. The distance from the spindle nose to the centre of the pallet has been minimised to 70 mm thus ensuring longer tool service life and higher process stability. The new NHX 2nd Generation machines also offer all the advantages of the new joint DMG MORI design and CELOS®.

Highlights of the NHX 4000 2nd Generation and NHX 5000 2nd Generation

• High machine dynamics for shortest possible chip-to-chip times of up to 2.2 sec.:
1 / 1 / 1 g (NHX 4000) or 1 / 1 / 0.8 g (NHX 5000); up to 96 m/min rapid traverse,
60 m/min in the standard versions; 35% higher dynamic stability
• Maximum machining performance thanks to the new speedMASTER spindle:
15,000 rpm with 111 Nm in the standard version; 15,000 rpm as a high-torque
version with up to 200 Nm and a 20,000 rpm high-speed version available as options
• Direct Drive Table (DDM®) with up to 100 rpm for the shortest possible positioning times of 0.8 sec. for the NHX 4000, or 1.38 sec. for the NHX 5000
• Optimum chip flow thanks to steep covers in the work area and a sturdy Y-axis cover in “pantograph” design
• CELOS® with MAPPS V for maximum user-friendliness and an increase in manufacturing profitability

i 50 – The key to more productivity: for large-scale production of motor components

With the i 50, DMG MORI presents an ultra-compact horizontal machining centre for the highly productive large-scale production of motor components such as cylinder blocks and heads in the automotive sector. Featuring a patented (registered) Z-axis kinematics of the spindle, the
i 50 guarantees greatest stability with two angled guides positioned outside the chip disposal area. Vibrations during machining are minimized for high-precision machining and long tool lives.

The linear axes are positioned in the spindle area, which means minimal moving masses through X / Y / Z travel for the spindle. Together with lightweight moving parts, these design features allow for high-speed machining and high machine dynamics for short chip-to-chip times. Moreover, DMG MORI has positioned all feed drives outside the work area, meaning no temperature impact and unparalleled precision.

Optionally, customers can choose from a range of automation options, such as workpiece transfer systems including roller conveyors and gantry loaders. The gantry loader’s short vertical stroke reduces cycle times and combined with the machine’s compact footprint, the i 50 compact machining centres can be combined for highly-productive machining lines.

Highlights of the i 50

• Patented (registered) Z-axis kinematics of the spindle:
greatest stability with two angled guides
• Positioned outside of the chip disposal area
• Minimal moving masses through X / Y / Z travel for the spindle:
high machine dynamics for short chip-to-chip times; optimal chip
disposal through the machine bed with steep work area covers
• All feed drives are positioned outside of the work area: no temperature
impact for unparalleled precision
• Low machine height for fast workpiece loading
• Table versions with A- and B-kinematics

DMG MORI Systems – a full-service provider for integral system solutions

The scope of performance of DMG MORI Systems ranges from standard automation right through to fully integrated 360° solutions. The continuing trend towards ever shorter development phases and higher cycle frequencies with a simultaneous increase in quality demands is also setting new standards in production. While the level of automation is growing, the increasing diversity of models demands a high degree of flexibility in manufacturing processes. With its many years of experience in the field of technology planning and automation DMG MORI Systems offers a wide range of solutions starting with standard automations and including the development of holistically coordinated manufacturing systems that encompass technology, machines, automation and customised peripherals.

With this one-stop-sourcing DMG MORI Systems saves customers’ time and money normally spent on coordination and reconciliation already during the project development phase. At the same time the automation experts ensure the necessary reliability. Another advantage is the communication between both parties. The customer has just one contact person from DMG MORI Systems, who is responsible for all questions that arise in the course of a project.

DMG MORI SEIKI CO LTD has recently announced that it will be constructing a new plant dedicated to turnkey solutions at its Nara Campus in Yamato-Koriyama City, Nara. In preparation for the construction of this new plant, the company have purchased land from Nara Hino Motors, Ltd, with the aim of commencing construction of the plant in May 2015, and completing its construction in November 2015.

The Nara Campus currently consists of the No. 1 and No. 2 Plants, and this new plant will be utilized as the third plant for the Campus.

These days, there is a rising demand for so called ‘turnkey’ solutions where multiple machines are integrated into a complete system that enables immediate start of mass production after delivery, in line with the trend towards globalization of the company’s automotive customers, and the expansion of the automobile industry, centered on emerging countries.

The new plant will be a dedicated turnkey one that can accommodate four 80-m long production system lines, where machine tools intended for the production lines of completed vehicles or automobile parts will be assembled. The assembly and production of the i50 high-speed horizontal machining centers, MAX 3000 high-productivity vertical machining centers, multi-axis turning centers, and other products for mass production parts machining that are currently taking place in the assembly plant at the Nara Campus will be relocated to the new plant.

In addition, DMG is taking over the lathe division from Amada Machine Tools Co Ltd in April 2015. The new turnkey plant will make it possible to secure a production site for them in the Nara Campus No. 1 Construction of this new plant will allow the company to respond even more rapidly to the demand for turnkey solutions from customers around the world, and to offer optimum solutions from the vicinity of the customer.

Visitors to the EuroMold Show can see machining demonstrations on a DMG Mori Seiki, programmed with the WorkNC CAM system, creating a Porsche 919 model.

Fast, precise and reliable manufacturing!

The HSC series of DMG MORI clearly focuses on tool and mold making and the manufacturing of mold inserts or dies, with surface quality being the highest priority. Constant process conditions are extremely important because of the long run duration. These parts are manufactured precisely and in the shortest time with HSC30 linear and  HSC 70 linear milling centers.

The Porsche 919 was programmed by DMG application engineers with the support of the WorkNC CAM System in a scale of 1:10 and machined on a HSC 70 linear milling center.

• Material: AlMg4, 5Mn
• Dimensions: 465 x 200 x 125 mm
• Machining time: 60h

The live machining demonstration can be seen on the DMG MORI booth at the EuroMold trade show in Frankfurt Hall 8, booth F10. WorkNC can be seen in Hall 8, booth F22.

WorkNC CAM software is the premier automatic CNC software for surface or solid models in mold, die and tooling businesses for 2 to 5-axis CNC programming. WorkNC is best of breed, complementary CAM software that enhances all design and manufacturing systems by providing the most reliable, efficient, easy-to-program cutter paths, resulting in unmatched productivity and safety.

Vero Software, the specialists in CAD/CAM software development, work hand in hand with experienced tool and die makers – both in development as in customer service. This is the only way to be at the cutting edge of your industry. Therefore, we have specialized in your industry and we are precisely aware of your requirements and turn them into feasible solutions.

CNC Software, developer of Mastercam CAD/CAM software, announces their collaboration with DMG MORI USA to produce a seamless interface to the Mori-APT workflow. DMG MORI has certified Mastercam to program the DMG MORI mill, lathes, and mill-turn machines that are supported within their Manufacturing Suite Post Processor.

DMG MORI has provided a standard tool path format, called Mori-APT, which acts as the generic input into their Manufacturing Suite post processor to power a growing number of their machines. The intent of this format is that CAM packages, such as Mastercam, will only have to output tool path to this format, and the DMG MORI interface will then tailor the NC code output for the target machine. With the DMG MORI Manufacturing Suite, customers will use a post processor developed and provided by DMG MORI for any of the DMG MORI machines supported by the Manufacturing Suite.

Mastercam users will continue to program their parts in the same manner they do today, but will be able to select the Mori APT-CL for the output format, which then can be post processed to generate NC code through the Manufacturing Suite from DMG MORI. Mastercam’s Mori-APT output interface will be available from CNC Software and the Manufacturing Suite Post Processor will be available from DMG MORI.

As DMG MORI adds post processing of newer machine series to the Manufacturing Suite, Mastercam will support them naturally. In the future, all DMG MORI machines will be able to handle this output format. For the time being, Mastercam will continue to support all DMG MORI machines that are not yet supported in the Manufacturing Suite with a post processor available through the worldwide Mastercam Reseller Channel.

At the upcoming IMTS 2014 show, DMG MORI will be giving demonstrations in their booth, of this interface between Mastercam and their machines in the Manufacturing Suite. Stop by booths E-5010 or S-8900 to see it in action.

The first quarter was according to plan for the DMG MORI SEIKI AKTIENGESELLSCHAFT. Order intake amounted to € 601.2 million (+16%), compared with € 518.7 million in the previous year‘s period. Sales revenues rose to € 505.1 million (previous year: € 466.1 million). The earnings situation continued to develop positively: EBITDA amounted to € 39.5 million (previous year: € 28.1 million), EBIT reached € 28.4 million (previous year: € 17.0 million) and EBT was € 26.1 million (previous year: € 15.1 million). As at 31 March 2014, the group reported earnings after taxes of € 18.0 million (previous year: € 10.4 million).

Sales revenues in the first quarter were € 505.1 million and thus exceeded the previous year’s figure by € 39.0 million (€ 466.1 million). Domestic group sales revenues increased by 12% to € 168.8 million and international sales revenues rose by 7% to € 336.3 million. The export ratio was 67% (previous year: 68%).

Highlights:

• Order intake increased by 16% to € 601.2 million (previous year: € 518.7 million).
• Sales revenues were € 505.1 million (+8%; previous year: € 466.1 million).
• EBT increased to € 26.1 million (+73%; previous year: € 10.4 million).
• Earnings after taxes climbed to € 18.0 million (previous year: € 10.4 million).
• Cooperation strengthens market presence and product development.

In the first quarter, order intake was € 601.2 million and thus 16% above the previous year (€ 518.7 million). Domestic orders amounted to € 222.7 million (previous year: 163.7 million); international orders amounted to € 378.5 million (previous year: € 355.0 million). Thus the proportion of foreign business amounted to 63% (previous year: 68%) in the first quarter of the financial year.

On 31 March 2014, order backlog within the group was € 1,128.0 million.

The DMG MORI SEIKI group was able to improve its key earning figures as of 31 March 2014 against the previous year: EBITDA amounted to € 39.5 million (previous year: € 28.1 million), EBIT amounted to € 28.4 million (+67 %; previous year: € 17.0 million) and EBT reached € 26.1 million (previous year: € 15.1 million). As of 31 March 2014, the group reports earnings after taxes of € 18.0 million (previous year: € 10.4 million).

Investments in intangible assets and plant, property and equipment were € 20.4 million during the first three months (previous year’s figure: € 10.6 million).

On 31 March 2014, the group had 6,937 employees of whom 205 were trainees (31 Dec. 2013: 6,722). The number of employees has thus risen by 215. At the end of the first quarter, there were 3,831 domestic employees (55%) and 3,106 employees (45%) working for the international companies. Personnel costs amounted to € 121.6 million (previous year’s period: € 114.3 million). The personnel expenses ratio was 23.0 % (previous year’s period: 23.0%).

The share price of DMG MORI SEIKI AKTIENGESELLSCHAFT was quoted at the start of the year at € 23.02 (2 Jan. 2014) and closed at the end of the first quarter at € 22.24 (31 March 2014). The current share price is € 22.63 (30 April 2014).

With an order intake of € 47.0 million and 206 machines sold, DMG MORI takes positive stock of the METAV in Dusseldorf. The trade fair, which ended on Saturday, attracted around 31,000 trade visitors. DMG MORI reaffirmed its good start to the year 2014. As the largest exhibitor at the trade fair for manufacturing technology and automation, DMG MORI presented a total of 24 exhibits – including nine machines in the new design.

The main visitor interest fell on CELOS: This unique software development simplifies the process from the idea to the finished product and creates the basis for paperless production. In total, the 3,538 registered trade visitors initiated 1,081 new requirements at our trade fair stand.

DMG MORI additionally took part in the METAV special shows “Rapid Tech“, “Metal meets Medical“, “BLUE COMPETENCE“ and “Young People“. Under the slogan “Your opportunity in mechanical engineering“, together with the VDW-Nachwuchsstiftung (youth foundation) we introduced more than 3,000 pupils and students to the speed of innovation and a variety of occupations and training possibilities.

The orders placed at the METAV 2014 confirm the good start to the current financial year.