www.dmgmori.com
Economical Grinding, Milling and Drilling of Advanced Materials
ULTRASONIC 2nd Generation
ULTRASONIC 10
ULTRASONIC 20 linear
Flexible Technology Integration into DMG MORI machines
ULTRASONIC mobileBLOCK
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3
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The ULTRASONIC technology from DMG MORI enables the economical machining of complex work-piece geometries in demanding high-tech materials like e. g. ceramics, glass, corundum, tungsten carbide or even composites. The kinematic overlapping of the tool rotation with an additional oscilla-tion effects a reduction of the process forces by up to 40 % in comparison to conventional machining. Depending on the workpiece requirements, this allows higher feed and infeed, longer tool life or significantly better surface finishes of up to Ra < 0.1 µm. Based on a consequent development of the ULTRASONIC technology according to the markets requirements, the ULTRASONIC 2nd generation now also is able to cover ultrasonic-assisted milling of hard to machine metal alloys or fibre reinforced materials with defined cutting edge.
ULTRASONIC 2nd Generation
ULTRASONIC grinding, milling and drilling.
Applications and parts
Machine and technology
Application areas
Control technology
Technical data
1 Powerfull ULTRASONIC
with optimised inductive transmission
2 Stronger ULTRASONIC booster
for up to 3 times higher amplitudes
3 Shorter actuator
for higher stiffness
4 Tools
with undefined and defined cutting edge
Functional principleThe tool rotation is superimposed via the HSK-E32 / HSK-E40 / HSK-E50 / HSK-A63 / HSK-A100 interface of the ULTRASONIC actuator tool holder with an additional oscillation in the axial direction (piezoelectric effect).
Highlights + Economical grinding, milling and drilling of hard and
brittle as well as hard to machine Advanced Materials
+ New, stiffer ULTRASONIC HSK actuating tool holder with increased amplitude power for a powerfull ULTRASONIC performance
+ Up to 40 % reduced process forces for highest produc-tivity, surface quality, precision and longer tool life
+ Automatic detection and autotracking of ULTRASONIC frequency and amplitude
> 10 µm
NEW // ULTRASONIC 2nd Generation
03
ULTRASONIC grinding ULTRASONIC milling
Optical industry Aerospace
High performance ceramic components Automotive
Watch industry / fine mechanics Production of composite workpieces
Die & mould MRO* of composite components
* MRO = maintenance, repair, overhaul
04
Applications and parts
Machine and technology
Application areas
Control technology
Technical data
ULTRASONIC milling
Asia Material: CFRP
ULTRASONIC milling
North America Material: titanium
ULTRASONIC grinding
Europe Material: agate
ULTRASONIC 2nd Generation is the result of a consequent, market-oriented development of the well established ULTRASONIC technology for grinding of hard and brittle Advanced Materials. Due to a shorter and FEM optimised geometrical design of the actuating tool holders, these are much stiffer now. Further on, an optimised inductive transmission allows higher amplitudes of up to > 10 µm. This way, it is now possible to use also tools with defined cutting edge – with full availability of the ULTRASONIC benefits. DMG MORI and SAUER go one step ahead and also serve now the application field of hard to machine metal materials like nickel or titanium base alloys and fibre reinforced composites by ultrasonic-assisted milling.
ULTRASONIC 2nd Generation
The world speaks „ULTRASONIC“.
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Conventional machining
ULTRASONIC machining
Machinability LIGHT
Machinability HARD
Machinability DEMANDING
GRINDING
ULT
RASO
NIC
1ST
GeN
eRAT
ION
ULT
RASO
NIC
2N
d G
eNeR
ATIO
N
Green ceramics Quartz glass Zerodur / glass Carbide
White ceramics Optical glass Corundum Tungsten
Oxide ceramics Si3N4
CFRP / GFRP SiC
CMC
MILLING
Aluminum α – Titanium Inconel 718 Rene 41
Copper CoCr Titanium alloy Molybdenum
Brass Hardened steel β – titanium β / γ – titanium
Tool steel Al alloy CFRP / GFRP CMC
Cast Mg alloy Special Al / Mg alloy
Graphite Hardened steel
DRILLING
Light metal Cast CFRP / GFRP Al / Mg alloy
Tool steel Hardened steel Cast (deep drilling) CMC
Hardened steel
Carbide
Possible disadvantages of CONVENTIONAL MACHINING
– High tool wear
– Uncomfortable chip breaking
– Insufficient surface quality
– Insufficient precision
– Built up edges
– Sub surface damaging
Benefits of ULTRASONIC MACHINING
+ Up to 40 % reduced process forces for higher productivity
+ Better surface qualities
+ Lower heat influence onto the material
+ Optimised chip breaking
+ Highest part precision
+ Longer tool life
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Available ULTRASONIC machine types Universal linear monoBLOCK® duoBLOCK® Portal Travelling column mobileBLOCK
ULTRASONIC 10
ULTRASONIC 50
ULTRASONIC 20 linear
ULTRASONIC 30 linear
ULTRASONIC 40 eVo linear
ULTRASONIC 60 eVo linear
ULTRASONIC 80 eVo linear
ULTRASONIC 65
ULTRASONIC 85
ULTRASONIC 60
ULTRASONIC 80
ULTRASONIC 100
ULTRASONIC 125
ULTRASONIC 160
ULTRASONIC 210 P
ULTRASONIC 260
ULTRASONIC 360
ULTRASONIC mobileBLOCK
Series basic machine SAUER DMU SAUER HSC eVo eVo eVo DMU / DMC monoBLOCK®
DMU / DMC monoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU P Portal DMF DMF SAUER
Option MT – – – – – – – – – –
Max. traverse paths (X / Y / Z) mm 120 / 120 / 200 500 / 450 / 400 200 / 200 / 280 300 / 320 / 280 400 / 400 / 375 600 / 500 / 500 800 / 650 / 550 735 / 650 / 560 935 / 850 / 650 600 / 700 / 600 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000 1,600 / 1,250 / 1,000 1,800 / 2,100 / 1,250 2,600 / 700 / 700* 3,600 / 1,100 / 900 500 / 500 / 200
Max. spindle speed milling rpm 40,000 18,000 42,000 / 60,000* 42,000 18,000 18,000 18,000 18,000 / 24,000* 18,000 / 24,000* 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (24,000) 18,000 (24,000) 35,000
Max. spindle speed ULTRASONIC rpm 40,000 18,000 42,000 / 50,000* 40,000 18,000 18,000 18,000 18,000 18,000 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 18,000 – / –
ULTRASONIC HSK actuator system HSK-E32 HSK-A63 HSK-E32 (HSK-E40)*
HSK-E40 HSK-A63 HSK-A63 HSK-A63 HSK-A63 (HSK-E50)*
HSK-A63 (HSK-E50)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-E50)*
HSK-A63 (HSK-E50)*
ER11
Max. workpiece size / clamping surface (5-axis) mm ø 190 ø 630 × 500 ø 200 ø 250 450 × 400 600 × 500 800 × 700 ø 840 × 500 ø 1,040 × 590 ø 630 ø 800 ø 1,100 × 900 ø 1,250 × 1,100 ø 1,500 × 1,250 ø 1,850 × 1,250 2,000 × 650 × 550 3,000 × 1,050 × 750 mobile adaption
Max. table load (5-axis) kg 10 200 15 80 250 400 600 600 1,500 500 / 700 1,200 / 1,500 2,000 / 2,200 2,500 3,000 / 4,000 4,000 / 8,000 500 1,200 mobile adaption
available, – not available, * option
ULTRASONIC 10 ê
ULTRASONIC mobileBLOCK ì
ULTRASONIC 20 linear ê
Since 2001 SAUER represents the Advanced Technologies of DMG MORI and is a synonym for innovation power, technological foresight as well as highest know-how expertise for the economical machining of Advanced Materials. With a consistent ULTRASONIC product line, this innovative technology offers machine solutions for almost every important branche, application field or work-piece size and parallelly serves an unrivalled large material spectrum. Starting with the SAUER own machining centers ULTRASONIC 10 and the new ULTRASONIC 20 linear also the flexible technology integration into almost all high-tech machines of the DMG MORI portfolio is possible.
ULTRASONIC 2nd Generation
ULTRASONIC series for handsized workpieces up to ø 3,000 mm.
Applications and parts
Machine and technology
ê Concept
Application areas
Control technology
Technical data
Available ULTRASONIC machine types Universal linear monoBLOCK® duoBLOCK® Portal Travelling column mobileBLOCK
ULTRASONIC 10
ULTRASONIC 50
ULTRASONIC 20 linear
ULTRASONIC 30 linear
ULTRASONIC 40 eVo linear
ULTRASONIC 60 eVo linear
ULTRASONIC 80 eVo linear
ULTRASONIC 65
ULTRASONIC 85
ULTRASONIC 60
ULTRASONIC 80
ULTRASONIC 100
ULTRASONIC 125
ULTRASONIC 160
ULTRASONIC 210 P
ULTRASONIC 260
ULTRASONIC 360
ULTRASONIC mobileBLOCK
Series basic machine SAUER DMU SAUER HSC eVo eVo eVo DMU / DMC monoBLOCK®
DMU / DMC monoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU P Portal DMF DMF SAUER
Option MT – – – – – – – – – –
Max. traverse paths (X / Y / Z) mm 120 / 120 / 200 500 / 450 / 400 200 / 200 / 280 300 / 320 / 280 400 / 400 / 375 600 / 500 / 500 800 / 650 / 550 735 / 650 / 560 935 / 850 / 650 600 / 700 / 600 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000 1,600 / 1,250 / 1,000 1,800 / 2,100 / 1,250 2,600 / 700 / 700* 3,600 / 1,100 / 900 500 / 500 / 200
Max. spindle speed milling rpm 40,000 18,000 42,000 / 60,000* 42,000 18,000 18,000 18,000 18,000 / 24,000* 18,000 / 24,000* 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (24,000) 18,000 (24,000) 35,000
Max. spindle speed ULTRASONIC rpm 40,000 18,000 42,000 / 50,000* 40,000 18,000 18,000 18,000 18,000 18,000 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 18,000 – / –
ULTRASONIC HSK actuator system HSK-E32 HSK-A63 HSK-E32 (HSK-E40)*
HSK-E40 HSK-A63 HSK-A63 HSK-A63 HSK-A63 (HSK-E50)*
HSK-A63 (HSK-E50)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-E50)*
HSK-A63 (HSK-E50)*
ER11
Max. workpiece size / clamping surface (5-axis) mm ø 190 ø 630 × 500 ø 200 ø 250 450 × 400 600 × 500 800 × 700 ø 840 × 500 ø 1,040 × 590 ø 630 ø 800 ø 1,100 × 900 ø 1,250 × 1,100 ø 1,500 × 1,250 ø 1,850 × 1,250 2,000 × 650 × 550 3,000 × 1,050 × 750 mobile adaption
Max. table load (5-axis) kg 10 200 15 80 250 400 600 600 1,500 500 / 700 1,200 / 1,500 2,000 / 2,200 2,500 3,000 / 4,000 4,000 / 8,000 500 1,200 mobile adaption
available, – not available, * option
é ULTRASONIC 30 linear
é ULTRASONIC 40 eVo linear
é ULTRASONIC 85
ULTRASONIC HSK actuator
system of the 2nd Generation
Flexible Integration into 5-axis milling centers of DMG MORI (HSK-32 / 40 / 50 / 63 / 100): ULTRASONIC milling, grinding and milling of Advanced Materials as well as conventional machining on one machine.
5-axis machine version
All machines available as 5-axis version for ULTRASONIC and (HSC-) milling of complex geometries on one machine.
Powerfull control
Uniform control philosophy with 3D path control SINUMERIK 840D solutionline, user friendly CELOS® operator surface* as well as special ULTRASONIC software features.
* Exception: ULTRASONIC 10 only available with DMG MORI SLIMline® Panel
Available ULTRASONIC machine types Universal linear monoBLOCK® duoBLOCK® Portal Travelling column mobileBLOCK
ULTRASONIC 10
ULTRASONIC 50
ULTRASONIC 20 linear
ULTRASONIC 30 linear
ULTRASONIC 40 eVo linear
ULTRASONIC 60 eVo linear
ULTRASONIC 80 eVo linear
ULTRASONIC 65
ULTRASONIC 85
ULTRASONIC 60
ULTRASONIC 80
ULTRASONIC 100
ULTRASONIC 125
ULTRASONIC 160
ULTRASONIC 210 P
ULTRASONIC 260
ULTRASONIC 360
ULTRASONIC mobileBLOCK
Series basic machine SAUER DMU SAUER HSC eVo eVo eVo DMU / DMC monoBLOCK®
DMU / DMC monoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU / DMC duoBLOCK®
DMU P Portal DMF DMF SAUER
Option MT – – – – – – – – – –
Max. traverse paths (X / Y / Z) mm 120 / 120 / 200 500 / 450 / 400 200 / 200 / 280 300 / 320 / 280 400 / 400 / 375 600 / 500 / 500 800 / 650 / 550 735 / 650 / 560 935 / 850 / 650 600 / 700 / 600 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000 1,600 / 1,250 / 1,000 1,800 / 2,100 / 1,250 2,600 / 700 / 700* 3,600 / 1,100 / 900 500 / 500 / 200
Max. spindle speed milling rpm 40,000 18,000 42,000 / 60,000* 42,000 18,000 18,000 18,000 18,000 / 24,000* 18,000 / 24,000* 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (24,000) 18,000 (24,000) 35,000
Max. spindle speed ULTRASONIC rpm 40,000 18,000 42,000 / 50,000* 40,000 18,000 18,000 18,000 18,000 18,000 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 (12,000) 18,000 18,000 – / –
ULTRASONIC HSK actuator system HSK-E32 HSK-A63 HSK-E32 (HSK-E40)*
HSK-E40 HSK-A63 HSK-A63 HSK-A63 HSK-A63 (HSK-E50)*
HSK-A63 (HSK-E50)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-A100)*
HSK-A63 (HSK-E50)*
HSK-A63 (HSK-E50)*
ER11
Max. workpiece size / clamping surface (5-axis) mm ø 190 ø 630 × 500 ø 200 ø 250 450 × 400 600 × 500 800 × 700 ø 840 × 500 ø 1,040 × 590 ø 630 ø 800 ø 1,100 × 900 ø 1,250 × 1,100 ø 1,500 × 1,250 ø 1,850 × 1,250 2,000 × 650 × 550 3,000 × 1,050 × 750 mobile adaption
Max. table load (5-axis) kg 10 200 15 80 250 400 600 600 1,500 500 / 700 1,200 / 1,500 2,000 / 2,200 2,500 3,000 / 4,000 4,000 / 8,000 500 1,200 mobile adaption
available, – not available, * option
é ULTRASONIC 80
ë ULTRASONIC 260 | 11
Special ULTRASONIC
software features
Special ULTRASONIC cycles for automatic adaption of the feed and CNC-programming as well as ULTRASONIC parameters for auto-matic frequency and amplitude detection and autotracking in the machining process.
Integrated grinding
package
Special grinding package and software cycles for ULTRASONIC machining. ULTRASONIC 20 linear / duoBLOCK® machines optionally available with MT technology for demanding inner and outer cylindrical grinding operations.
Highly efficient coolant
reprocessing
Especially for the ULTRASONIC machining designed, high compact coolant reprocessing plants. Main modules are cooling, heating, dosing, filtration and separation.
The consistent ULTRASONIC product line from DMG MORI / SAUER allows an economical grinding, milling or drilling of an unrivalled large material spectrum – from handsized workpieces up to ø 3,000 mm.
ULTRASONIC series
High-tech on smallest space
The ULTRASONIC 10 is by far the most compact 5-axis milling machine of DMG MORI. It combines 5-axis simulltaneous machining, 40,000 rpm, 16-fold tool changer, laser tool measurement as well as optional available auto-mation solutions on smallest space.
1,90
0 m
m
1,600 mm
The ULTRASONIC 10 with a highly compact footprint of only 2 m² offers unique opportunities for the medical / dental industry – from the small laboratory to a large milling centre – for the production of all implant / prosthetics requirements with all materials. With the 5-axis CNC milling centre, SAUER serves the demand for the best possible utilisation of production areas. In addition comparable applications of the ULTRASONIC 10 can be found in other markets, including the watch industry, precision engineering and tool and mould making.
ULTRASONIC 10
The perfect entrance into the world of 5-axis CNC precision machining.
Applications and parts
Machine and technology
ê ULTRASONIC 10
Application areas
Control technology
Technical data
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Full integrated automation solutions*
+ 4-fold pallet automation PH2 | 4 with extendable drawer (in the working room)
+ Linear magazine PH 2 I 120
* option
Application related options
+ Laser tool measurement
+ ULTRASONIC amplitude measurement by tool laser
+ 60-fold tool changer
Unique technology integration
+ ULTRASONIC grinding
+ 5-axis milling
+ Flexible change based on a standard HSK-32 tool holder
High-tech package in the standard
+ 5-axis simultaneous machining
+ 40,000 rpm
+ 16-fold tool changer
+ Rigid, most compact mineral fiber stand
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Highlights + Integrated 4-fold blank-automation
for integration of blank holders (each of the 2 extendable storages includes 2 blank-holders)
+ Highly dynamic loading / unload-ing at a predefined exchange position by a special gripper located at the spindle (changing time ≤ 30 sec.)
+ Each machine can be individually automated; no additional space requirements
+ Cost efficient automation solution
+ Unattended machining in multi- shift operation
PH 2 | 4
Max. handling weight kg 2
Workpiece change s ≤ 30
Integrable pallet types
Blank holder (ITS 100) yes
Max. pallets 4
1: Working room with integrated 4-fold blank automation 2: Blank holder with CrCo indication
The integrated 4-fold pallet handling system PH 2 | 4 provides a cost efficient entry into automated production. A special gripper mounted at the spindle face enables an unattended machining in multi-shift operation without additional floor space.
ULTRASONIC 10
Automation solution with integrated 4-fold pallet handling PH 2 | 4.
Applications and parts
Machine and technology
ê ULTRASONIC 10
Application areas
Control technology
Technical data
3 4 5
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Highlights + Compact, integrated linear
magazine
+ Main time parallel loading / unloading of raw material and finished parts
+ Unattended production in multi-shift operation
+ Customer specific pallet configuration possible
+ Mixed machining of different workpieces possible
+ Job-management-system enables user-friendly order management
PH 2 | 120
Max. handling weight kg 2
Workpiece change s ≤ 55
Integrable pallet types
ITS 100 yes
Max. number 13
ITS 50 yes
Max. number 50
Finished part reservoir (FPR) yes
Max. number 150
Basic configuration Dental (ITS 100 / ITS 50 / FPR) 10 / – / 150
3: Pickup of a pallet from the rotary magazine of the PH 2 | 120 4: Positioning of a pallet in the working room 5: 5-axis simultaneous machining of a CrCo blank
With the new linear magazine PH 2 | 120 SAUER provides a high-end solution for the automated production in multi-shift operation. Depending on the configuration, various clamping systems can be integrated flexibly (pallets, finished part reservoirs, etc.).
ULTRASONIC 10
Automation solution with linear magazine PH 2 | 120.
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Applications and parts
Machine and technology
ê ULTRASONIC 20 linear
Application areas
Control technology
Technical data
Completely revised, the new ULTRASONIC 20 linear of the 2nd Generation convinces with a new functional design and a reduced footprint of 3.5 m² with in parallel improved rigidity and dynamics. The versatile technical optimisations lead to higher spindle rpm of now up to 60,000 rpm for HSC applications, an optional mill-turn-table with max. 1,500 rpm for economical ULTRASONIC cylindrical grinding operations in Advanced Materials, in up to 50 % increased drive motors (A-axis), an increased table load of 15 kg and in the use of bigger tool diameters of now up to 50 mm. The new ULTRASONIC 20 linear is also equipped now with the powerful and innovative CELOS® from DMG MORI and a new developed ULTRASONIC APPs for an intuitive ULTRASONIC machining.
ULTRASONIC 20 linear
Multitalent in various disciplines – more compact, more power, process reliable.
Stable, most compact, vibration dampening mineral fiber base for optimal long-term-stability, accuracy at the workpiece as well as an optimised chip fall (Y-portal in gantry design).
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“MT-option” for outer- / inner cylindrical grinding
+ Complete machining of rotation symmetrical workpieces: grinding and drilling incl. inner- / peripheral machining in only one clamping
+ Rotary table with max. 1,500 rpm: inner- and outer cylindrical grinding of Advanced Materials for optimal surface qualities
+ Also use of turning tools (with clamped spindle)
Unique technology integration
+ ULTRASONIC grinding of Advanced Materials as well as HSC milling on one machine, with 42,000 rpm in the standard
+ Flexible change based on a standard HSK-E32 / HSK-E40 holder
+ HSC milling with up to 60,000 rpm / HSK-E32*
* option
Integrated NC-swivel- / rotary table
of the latest generation
+ Stronger drive motors in A, C and Z for optimal holding torque
+ Increased 5-axis table load: 15 kg
Latest generation of control
+ CELOS® with SINUMERIK Operate 4.7
+ Integration of ULTRASONIC CELOS® APPs
+ Visualisation of the most important ULTRASONIC process parameters: frequency, amplitude, output power
+ Automatic process control
+ Optimal control of the ULTRASONIC process parameters
1 2
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With the integrated automation solution PH 10 | 100 up to 99 workpieces can be loaded from the top into the working area of the ULTRASONIC 20 linear. Thereby all available clamping systems in the market are flexibly integrable. A pallet change is completed in ≤ 30 seconds. The compact, integrated design guarantees an optimal accessibility to the working area and the PH 10 | 100.
ULTRASONIC 20 linear
Automation solution with linear magazine PH 10 | 100.
Applications and parts
Machine and technology
ê ULTRASONIC 20 linear
Application areas
Control technology
Technical data
1: Integration of almost all available clamping systems 2: Linear handling in 3 axes – positioning of a pallet with electrode
Highlights + Integrated linear magazine
PH 10 | 100 with max. 99 pallet places (max. 10 kg handling weight)
+ Dynamic and stabile pallet change ≤ 30 seconds (workpiece handling from the top)
+ Flexibility: integration of most available clamping systems
+ Six layers in the standard, optional five additional layers
+ Pallet layers are application oriented and can be configured with 3, 5, 7 or 9 pallet places
+ Optimal accessibility to machine and PH 10 | 100
+ Compact and integrated design with only 6 m² footprint
17
The PH 10 | 100 is a full integrated automation system with linear axes in X / Y / Z. The max. number of 99 pallets can be integrated and handled from above. Most of the available pallet types are integrable and the automatic pallet change needs ≤ 30 seconds. A preparation for a later retrofit with PH 10 | 100 is also available.
Linear magazine automation PH 10 | 100
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Highlights + Flexible ULTRASONIC technology integration based on a standard
HSK-40 / -50 / -63 / -100 tool holder
+ Combination of conventional HSK tool holders and ULTRASONIC actuating tool holders in one magazine
+ Flexible change possible (HSC-) Milling and ULTRASONIC machining on one machine
+ ULTRASONIC integration into following DMG MORI series: _ HSC series _ eVo linear series _ monoBLOCK® series _ duoBLOCK® series _ DMF series _ Portal series
In all hightech branches there is a constant demand for new technology solutions and economical machining procedures for hard to machine future materials. Exactly here, SAUER is positioned with its ULTRASONIC technology and underscores with a consistent product line its technological expertise as an innovative pioneer in the ultrasonic-assisted hard machining of Advanced Materials. Based on a standard HSK-32 / -40 / -50 / -63 / -100 tool holder, the patented ULTRASONIC actuator system can be integrated flexible in almost all 5-axis milling machines of DMG MORI.
ULTRASONIC 2nd Generation
Flexible ULTRASONIC integration into 5-axis milling machines of DMG MORI.
Applications and parts
Machine and technology
ê Concept
Application areas
Control technology
Technical data
5
4
2
3
1
19
1: Machining of a diffusor-cage made from Inconel 718 on an ULTRASONIC 125 FD 2: Outer- and inner cylindrical grinding of a pump housing made from mineral cast on an ULTRASONIC 125 FD 3: ULTRASONIC 30 linear with 30-fold tool changer and double gripper (with ULTRASONIC- and conventional tools) 4: Conventional milling machining of an impeller on an ULTRASONIC 65 5: ULTRASONIC complete machining of an mirror support made from Zerodur on an ULTRASONIC 65
20
Repair jobs of damaged fibre composite components are up to now mainly performed as manual operations by hand. In most cases, e. g. the aircraft has to be brought back to the hangar which requires a few days of repair time. In contrast to this time-consuming procedure, the new mobile 5-axis milling unit from DMG MORI enables to handle the actual repair job in only a few minutes, with 100 % constant quality, precision and reproducibility. The 5-axis kinematics with integrated rotary- and swivel-axis allows challenging operations with angles of ±95 °. Due to the lightweight construction and the specially designed vacuum system, the ULTRASONIC mobileBLOCK can be adapted easily and flexible onto the damaged components. Additionally to the repair jobs in the MRO sector, this mobile milling unit can also be effectively integrated in the process chain of challenging production tasks.
* MRO = maintenance, repair, overhaul
ULTRASONIC mobileBLOCK
Mobile 5-axis milling unit for MRO*: small, light, mobile – with best performance in CFRP.
Applications and parts
Machine and technology
ê ULTRASONIC mobileBLOCK
Application areas
Control technology
Technical data
5
6 7
1
2
3
4
21
Highlights + Powerfull, mobile 5-axis milling unit with high
performance spindle (35,000 rpm) and a-axis swivel head (±95 °)
+ Lightweight construction (approx. 130 kg) with CFRP components
+ Universal use: scarfing and edge triming of all composites for production and MRO
+ Easy and powerfull adaption: special developed, exchangeable vacuum feet
+ Precise scarfing with highest reproducibility with parallelly enourmous time benefit
+ Userfriendly due to holistic control guidance from the part drawing, to the definition of the damaged spot and repair job, the laser surface detection, up to the generation of the final NC-files
+ Cross-process technology options: laser-point and -line scanner for surface detection and reverse engineering
+ Documentation of the scarfing parameter and camera monitoring during the machining process*
* option
1: Easy adaption on a fuselage 2: 35,000 rpm high performance spindle with integrated swivel head and rotary axis 3: Special developed vacuum feet for a powerful adaption 4: Reverse engineering of the surface via point- and line-scanner 5: Lightweight construction by use of CFRP components 6: Clean exposure of the individual laminate layers (scarfing) 7: Final reconstruction / lamination of the scarfing
22
Applications and parts
Machine and technology
Application areas
ê ULTRASONIC grinding
Control technology
Technical data
ULTRASONIC represents a future- oriented technology for new markets with significantly increasing demand and rising workpiece requirements. Due to the kinematic overlapping of the tool rotation with an oscillation (in axial direction), conventionally hard to machine high performance materials can be machined economical in highest quality.
ULTRASONIC grinding
ULTRASONIC
23
ULTRASONIC grinding enables an economical machining of complex workpiece geometries in demanding high-tech materials like e. g. ceramics, glass, corundum, carbide or composites. Due to the kinematic overlapping of the tool rotation with an additional oscillation, ULTRASONIC leads to a reduction of the process forces by up to 40 % compared to conventional machining. Depending on the material properties, this allows outstanding surface finishes of Ra < 0.1 μm, the production of thin-walled lightweight structures, longer tool service life and significantly reduced micro-cracks in the material.
Application areas
Economical ULTRASONIC grinding of Advanced Materials with reduced process forces.
Benefits ULTRASONIC grinding
+ Reduced process forces by up to 40 %*
+ Higher stock removal rate*
+ Excellent surface quality of Ra < 0.1 µm*
+ Feasibility of thin walls < 0.5 mm wall thickness*
+ Reduced Sub-Surface-Damaging*
+ Longer tool life, reduction of the tool temperature*
+ Economical, formative machining of sintered, and even hipped technical ceramics (e. g.: Si3N4, SiC, hip-ZrO2)
+ Workpiece precision < 10 µm possible*
+ Optimal particle removal from the working zone
+ Reduced delamination with fibre reinforced composites
* depending on the material and process properties
24
3 ULTRASONIC
face grinding
with tilted cup grinding wheel with cross-side vibration
2 ULTRASONIC
grinding
of a pocket with undercut with cross-side vibration
1 ULTRASONIC
drilling
with longitudinal movement kinematics
ULTRASONIC machining strategies
The demand for best possible surface qualities, longer tool life, increase in productivity and work-piece quality in the machining of future materials is unbroken. Especially the request for more and more complex geometrical shapes needs efficient and economical machining methods. Exactly here is where the patented ULTRASONIC technology of the market leader DMG MORI can convince with versatile unique selling propositions. For each material and every machining task, the perfect machining strategy is beeing developed and made easily operable by the right ULTRASONIC cycle.
ULTRASONIC grinding
ULTRASONIC grinding and drilling with unique selling propositions.
Applications and parts
Machine and technology
Application areas
ê ULTRASONIC grinding
Control technology
Technical data
1 mm
1 mm
1 mm
1 mm
25
Application sampleGrinding of pockets and slots in a Zerodur-glass block with and without ULTRASONIC
with ULTRASONIC
with ULTRASONIC
without ULTRASONIC
without ULTRASONIC
100-fold: bottom face of the slot
ULTRASONIC Conventional Deviation
Ra / μm 0.74 1.28 –42 %
Rz / μm 3.6 7.7 –53 %
Rq / μm 0.92 1.65 –44 %
Rp / μm 1.0 2.4 –58 %
100-fold: side face of the slot
ULTRASONIC Conventional Deviation
Ra / μm 1.15 1.34 –14 %
Rz / μm 6.4 8.0 –20 %
Rq / μm 1.48 1.72 –14 %
Rp / μm 1.8 3.4 –47 %
Result: surfaces (microscope)
Results
+ Force reduction in the pockets up to 50 %
+ Force reduction in the slots up to 50 %
+ Up to 60 % better surface quality
+ Reduced micro cracks up to 40 %
Results: force measurement
Examination of the 3 pockets
Conventional ULTRASONIC
Pocket Nr.
Fx / N Fy / N Fz / N Fx, US / N Fy, US / N Fz, US / N
1 25 23 75 12 11 54
2 25 22 66 13 12 60
3 26 23 70 14 13 61
Examination of the 3 slots
Conventional ULTRASONIC
Slot Nr.
Fx / N Fy / N Fz / N Fx, US / N Fy, US / N Fz, US / N
1 10 50 95 5 25 65
2 10 50 95 5 35 75
3 10 45 95 5 30 65
Operations
Setup
Machine ULTRASONIC 20 linear
Tool
ULTRASONIC actuator HSK-E32-ER11; GVD-mill with MES3-binding D76H, ø 6 mm
Machining 1
3 circular pockets each (ø 11 mm × 10 mm)
Spindle speed N 8,000 rpm
Feed vf 800 mm / min.
Infeed ap 0.25 mm contour helix; ae 5.5 mm 92 %
Tension U 75 Veff ULTRASONIC
Cycle time 85 sec. / pocket
Machining 2
3 slots each (B: 6 mm, T: 10 mm, L: 60 mm)
Spindle speed N 8,000 rpm
Feed vf 800 mm / min.
Infeed ap 0.4 mm; ae 6 mm 100 %
Tension U 75 Veff ULTRASONIC
Cycle time 141 sec. / slot
26
Machining Complete machining of a SiC sealing ring ø 160 × 30 mm
Special Use of ULTRASONIC-MT-grinding cycles for outer- / inner cylindrical grinding with rotating tool
Nr. of tools 6 diamond grinding / drilling tools
Machine ULTRASONIC 65 FD
Clamping 1
Step 1* Roughing of the plane surface and outer contour with ø 100 mm 1A1 grinding discs
Step 2 Drilling of the ø 2 mm thru holes from outside
Step 3* Finishing of the outer and inner contour with radius
Step 4 Grinding of the outer radial slots
Clamping 2
Step 5* Roughing and finishing of the inner contour and plane surface
Step 6 Grinding of the face side slots
* with ULTRASONIC MT grinding cycle for outer- / inner cylindrical grinding
The production of high precise and complex workpieces requires flexible machine solutions. Due to the patented ULTRASONIC technology integration into 5-axis milling centres from DMG MORI, complex workpieces can be machined economically in only a few clampings. For the machining of rotation symmetrical workpieces, several machine series are also available with mill-turn-option. Special ULTRASONIC cycles are available to assist the operator at demanding outer- / inner cylin-drical grinding operations.
ULTRASONIC grinding
Combined ULTRASONIC cylindrical grinding and drilling on one machine.
Applications and parts
Machine and technology
Application areas
ê ULTRASONIC grinding
Control technology
Technical data
65
4
32
1
27
PME – Pumpen- und Modelltechnik GmbH ErfurtKalkreiße 13, 99085 Erfurt
[email protected], www.pme-erfurt.com
PME Pumpen- und Modell-technik GmbH ErfurtWith mill-turn-technology and ULTRASONIC
to the technology leadership
Managing director Mrs. Waltraud Utterodt: “By means of the ULTRASONIC technology we produce precise components made from our high wear resistant PME-mineral-cast. This made PME to strengthen and expand its technology leader-ship in the sector of wear-resistant workpieces. Meanwhile, our mineral cast components are well established in a lot of branches and can not be substituted from the equipment of well-known customers. Through the use of the 5-axis mill-turn technology from DMG MORI we have now nearly unlimited design possibilities.”
4: ULTRASONIC MT machining of a ø 800 mm – paddle wheel made from SiQuartz 5: HSK-100 actuator system – the tool rotation is super-imposed with an additional oscillation 6: Finished paddle wheel
CeramTec GmbHCeramTec-Platz 1 – 9, 73207 Plochingen
[email protected], www.ceramtec.com
CeramTec GmbHTechnical ceramics precisely and economically
machined with ULTRASONIC
The CeramTec group is one of the worlds largest competence providers for technical ceramics. As high-tech problem solver for all kind of questions regarding wear, the company counts on ULTRASONIC technology from DMG MORI since 2010. “Small lot sizes and single parts for samples and prototypes can be machined now even with complex geometries in sintered materials in one clamping”, says Frank Ostertag, production planner at the headquarter in Plochingen, Germany. “Compared to the multi-step processes on standard grinding machines with cost intensive grinding discs, we increase precision, flexibility and economics at the same time, with shorter delivery times”, Ostertag points out.
1: The CeramTec portfolio includes > 10,000 products amongst others from the sectors automotive, electronics, energy, machine tools 2: Nozzle body made from Si3N4 3: Form insert made from zirconium
28
Mirror supports with thin-walled webs and other complex geometries in Zerodur, high precision deep hole drilling in gyroscopes or rod lenses of corundum / optical glass for scanner systems / endoscopy are typical ULTRASONIC applications. In this way the ULTRASONIC series has successfully entered the fields of projection and measurement optics, satellite construction and optical component manufacturing.
Optical industry
Applications and parts
Machine and technology
Application areas
ê Optical industry
Control technology
Technical data
29
Application areas
Optical industry.
ULTRASONIC 50-5 linear Filigree contour with radial drilling in glass
Industry Optics
Material BK-7 (optical glass)
Tools 3 (diamond hollow drill / grinding pins)
Machining Full machining in 17 machining steps in 70 minutes
ULTRASONIC 50 Thin walls with < 0.5 mm in glass
Industry Optics
Material Zerodur (optical glass)
Tools 5 (diamond hollow drill / grinding pins)
Machining Feasibility of threads and thin webs with wall thickness < 0.5 mm
ULTRASONIC 20 linear Deep hole drilling in glass
Industry Optics
Material BK-7 (optical glass)
Tools 1 hollow drill
Machining Through-hole drilling ø 4 × 22 mm in 19 seconds per drill hole
ULTRASONIC 125 P duoBLOCK® Grinding of spheres / aspheres in optical components
Industry Optics
Material Zerodur (glass ceramics)
Tools Diverse diamond coated cup wheels
Machining Feasibility of spheres / aspheres with surface qualities of Ra ≤ 0.2 µm
ULTRASONIC 100 P duoBLOCK® Complete machining of light weight structures for mirror supports of Zerodur
Industry Satellite construction / telescopes
Material Zerodur (glass ceramics)
Tools Diverse diamond drill / grinding tools
Machining Creating pockets with undercut and thin walls (light weight structures)
Materials: optical glass, quartz glass, glass ceramics, corundum Application examples: (rod) lenses, mirror supports, technical parts with thin walls, long holes, slots, pockets, spheres
30
The demand for longer tool service life, increased productivity and component quality makes the use of advanced materials unavoidable. Ceramic high-performance materials, like SiC, silicon nitride (Si3N4) or hipped zirconium oxide (hip-ZrO2) as well as the demand for ever more complex geometrical shapes, require high performance and economical machining procedures. This is exactly where the ULTRASONIC technology offers a competitive advantage.
High performance ceramics
Applications and parts
Machine and technology
Application areas
ê High performance ceramics
Control technology
Technical data
31
Application areas
High performance ceramics.
ULTRASONIC 80 eVo linear Grinding of a housing structure for airspace surveillance camera
Industry Aerospace
Material Silicon nitride
Tools Various diamond drilling, grinding and special tools
Machining Finishing of a sintered semi-finished part with several setups
ULTRASONIC 65 monoBLOCK® Pump housing made from Si-Quartz
Industry Pump industry
Material Si-Quartz
Tools 1 diamondcup wheel
Machining Part machining (face grinding) of the semi-finished part
ULTRASONIC 20 linear Complete machining of an orthopaedic implant
Industry Medical
Material Hipped zirconium oxide
Tools 5 diamond toroidal grinding points
Machining Complete machining in 4.5 hours
ULTRASONIC 20 linear Complete machining of an implant made of zirconium oxide
Industry Dental
Material Zirconium oxide
Tools 7 (diamond ball cutters / grinding points)
Machining In < 30 minutes (cylindrical contour, inner / outer thread, abutment connection)
AerospaceMaterials: silicon nitride / carbide, composites (e. g.: CMC = Ceramic Matrix Compounds) Application examples: casings, wear parts, armatures, blades
Pump- and armature industryMaterials: all wear resistant high-performance ceramics, glass Application examples: spinnerets, pump wheels, sealing / bearing rings, housings
Medical / DentalMaterials: all high-performance ceramics, including hipped ZrO2, glass-ceramics Application examples: dentures, implants, prosthetics, technical medical optics components
32
The use of the innovative ULTRA-SONIC technology for watch components made of zirconium oxide, sapphire or glass ceramics is crucial. Numerous renowned manufacturers of luxury watches manufacture intricate components on ULTRASONIC machines from DMG MORI.
Watch industry / fine mechanics
Applications and parts
Machine and technology
Application areas
ê Watch industry / fine mechanics
Control technology
Technical data
33
Application areas
Watch industry / fine mechanics.
ULTRASONIC 20 linear Watch plate made from sapphire
Industry Watch industry / fine mechanics
Material Sapphire (corundum)
Tools 8 diamond tools
Machining Complete machining in 8 machining steps
ULTRASONIC 20 linear Watch housing made from ceramics
Industry Watch industry
Material Zirconium / aluminum oxide
Tools 9 diamond tools
Machining Complete machining of an AI2O2 clock housing from the raw block in 15 machining steps
ULTRASONIC 20 linear Complete machining of a lunette
Industry Watch industry
Material Zirconium oxide
Tools 6 diamond drilling / grinding points
Machining Complete machining from the raw block
ULTRASONIC 20 linear Complete machining of a clock face
Industry Watch industry
Material Agate
Tools 8 diamond drilling / grinding points
Machining Complete machining from the raw block
ULTRASONIC 20 linear Complete machining of a watch housing made of zirconium oxide
Industry Watch industry
Material Blue zirconium oxide
Tools 9 diamond tools
Machining Complete machining from the material blank with Ra < 0.1 µm
Materials: zirconium oxide, corundum (sapphire), agate, ruby Application examples: watch housing, boards, clock components, bearings
34
Where conventional materials quickly reach their limits, where enormous burdens through chemicals, high temperatures, friction forces or electricity prevail, wear-resistant Advanced Materials are used in. If there are highest demands on mould contour, materials and surface quality, you are spot on with the ULTRASONIC series. Especially in the case that quality should not suffer because of production costs or most complex forms should be manufac-tured through grinding and drilling in the shortest time.
Die & mould
Applications and parts
Machine and technology
Application areas
ê Die & mould
Control technology
Technical data
35
Application areas
Die & mould.
ULTRASONIC 20 linear Drilling of cooling holes into a thread mill
Industry Tool makers
Material Carbide
Tools 1 Diamond high-drill
Machining ø 0.5 mm × 1 mm through hole in 1.5 minutes
ULTRASONIC 220 linear Surface grinding of guiding elements for measuring machines
Industry Machine construction
Material Silicon carbide
Tools Various diamond cup grinding wheels
Machining Face grinding and grinding of recessed grooves with Ra < 0.1 µm
ULTRASONIC 20 linear Grinding of a M6 thread
Industry Tool and mould making
Material Tungsten carbide
Tools 1 diamond thread grinding point
Machining Grinding of a M6 thread in 4.5 minutes
ULTRASONIC 20 linear Complete machining of ceramic gear wheel
Industry Tool and mould making
Material Hipped zirconium oxide
Tools 2 diamond grinding points, 1 ball cutter
Machining Complete machining from the raw block in 24 minutes / tooth
ULTRASONIC 20 linear Complete grinding of a tungsten carbide insert
Industry Mould-making
Material Carbide
Tools Diamond coated 6A9 cup wheel
Machining Grinding of the outer contour (bevels and radii) by hard machining
Materials: carbide, wear-resistant high-performance ceramics Application examples: dies, press tools, moulding dies, matrices, guiding elements, valves
36
Applications and parts
Machine and technology
Application areas
ê ULTRASONIC milling
Control technology
Technical data
Due to a shortened and FEM optimized geometry design of the actuators which ensure a higher stiffness and enable due to the improved inductive transfer the use of amplitudes to > 10 µm, also tools with geometrically defined cutting edges can be used now with complete utilisation of the existing ULTRASONIC benefits.
ULTRASONIC milling
ULTRASONIC
37
The further development of the ULTRASONIC technology in the 2nd generation now as well facilitates its use in classic manufacturing situations. From now on tools with geometrically defined cutting edge can be used securely because of reachable amplitudes of > 10 µm as well as the clearly improved stiffness of the actuators. So process forces during milling e. g. titanium alloys are up to 30 % lower. Feeds can be doubled in inconel and quintupled in other materials as magnesium. Enhanced surfaces, an obviously reduced tool wear and shorter breaking chips are additional advantages of ultrasonic-assisted machining.
Application areas
ULTRASONIC milling and drilling in hard-to-machine materials with geometrically defined cutting edge.
Benefits ULTRASONIC milling
+ Higher stock removal rates during finishing
+ Reduced process forces for optimised roughness values and lower polishing effort
+ Longer tool life
+ Optimised chip-flow reduced temperature on the tool
+ Short-breaking chips
+ Avoidance of the formation of built-up edges during composite machining
+ Potential surface density
+ Avoidance of delamination and fibre tearing at composites
38
Representative ULTRASONIC applications can especially be found in the sector of aerospace and auto-motive. Compared to conventional milling, for example a two times longer tool life can be reached by use of ULTRASONIC e. g. milling a diffuser flange (Inconel) or two times faster cycle time for finishing of a turbine blade (Inconel).
Aerospace and automotive
Applications and parts
Machine and technology
Application areas
ê Aerospace and automotive
Control technology
Technical data
39
ULTRASONIC 85 Deep hole drilling in gear shaft
Industry Automotive (gear manufacturing)
Material MnCr
Tools 1 carbide twist drill
Machining Machining of a ø 2 mm × 260 mm deep hole drilling with improvement of the straightness in the channel, short-breaking chips and increased feed in 60 sec.
ULTRASONIC 85 Deep hole drilling in a cylinder head
Industry Automotive (motor production)
Material Cast
Tools 2 carbide tools (ø 10 mm pilot drill, ø 10 mm step drill)
Machining Machining of fuel drillings with improvement of the straightness in the channel and optimised surface finish
AutomotiveMaterials: cast, MnCr, Al- / Mg-alloys, hardened steel Application examples: engine- / cylinder blocks, gear components, rims
ULTRASONIC 65 Complete machining of a turbine blade made from the raw block
Industry Aerospace (turbines)
Material Inconel 718
Tools 1 carbide mill, 1 ceramic mill
Machining Complete machining with reduced machining time (23 minutes vs. 32 minutes)
ULTRASONIC 80 Complete machining of flange (diffusor cage)
Industry Aerospace (turbines)
Material Inconel 718
Tools Ceramic tools
Machining Complete machining of the inner and outer contour with significantly increased tool life and optimal surface quality
AerospaceMaterials: Inconel 718 Application examples: turbine components (casings, blades, ... )
Application areas
Aerospace and automotive.
40
The directed overlapping with ULTRASONIC in cutting direction enables a higher cutting speed to get a clean fibre cut and therewith meets the high requirements concerning productivity and work-piece quality. The reduction of the process forces by up tu 40 % allows clean edges and prevents from fibre tearing as well as delamination on the part.
ULTRASONIC composites
Applications and parts
Machine and technology
Application areas
ê ULTRASONIC composites
Control technology
Technical data
41
ULTRASONIC 65 Edge trimming, machining of holes in a longboard
Industry Lifestyle (sports)
Material CFRP
Tools 1 carbide mill / 1 carbide drill
Machining Complete machining of the pre-laminated part with double feedrates and without fibre tearing in < 5 minutes
ULTRASONIC 85 Edge trimming, machining of holes and pockets in a center console
Industry Automotive (interiors)
Material CFRP
Tools 1 carbide mill / 1 carbide drill
Machining Complete machining with double feedrates and without fibre tearing in < 4 minutes
Automotive / lifestyleMaterials: FRP, GFRP, AFRP, stacks, other composites (e. g. CMC = Ceramic Matrix Compounds) Application examples: interiors, rims, watch-components, sports-components
ULTRASONIC mobileBLOCK Four stepped scarfing in a rotor segment
Industry Aerospace (MRO)
Material CFRP
Tools 1 carbide mill
Machining Machining of rectangular, elliptical, square, circular as well as free-form scarfings with variable number of steps directly on the damaged area
ULTRASONIC 85 Four stepped scarfing in a rotor segment
Industry Aerospace
Material CFRP
Tools 1 carbide mill
Machining Clean exposure of the single laminate layers without fibre tearing or delamination in < 1 minute
AerospaceMaterials: CFRP, GFRP, AFRP, stacks, other composites (e. g. CMC = Ceramic Matrix Compounds) Application examples: housings, rotor parts, armatures
Application areas
ULTRASONIC composites.
42
Applications and parts
Machine and technology
Application areas
ê ULTRASONIC composites
Control technology
Technical data
The use of CFRP and GFRP in civil aviation continues to grow and all premium manufacturers in the automotive industry produce important structural components out of fibre reinforced plastics. In addition to the actual production applications, there is also an ever-growing demand for auto-mated, economical machining options for maintenance and repair (repair & rework) of damaged fibre composite components. In both cases the use of ULTRASONIC technology enables an efficient machining of these high-performance materials with optimal component quality.
ULTRASONIC composites
Doubled feed rates and reduced process forces for machining of CFRP by ULTRASONIC.
Serial production
Trimming and drilling of CFRP / GFRP / AFRP components in serial production
+ Trimming with optimal surface quality without chipping or chatter marks for the subsequent joining process
+ Creation of drill- or rivet holes with the best possible roughness values in the channel, diameter toler-ances in the μm range as well as reduced chipping on the drill entry and exit side
+ Feasibility of through-hole and blind hole drilling, threads, grooves, pockets and other geometric free forms
+ Full cut machining without fibre tearing or de-lamination
Maintenance, Repair & Overhaul (MRO)
Scarfing by means of accurate exposure of individual laminate layers
+ Full cut scarfing without fibre tearing or de-lamination
+ Integrated laser scanner for surface recognition, reverse engineering and measuring
+ Integrated atmospheric pressure plasma: surface activation / cleaning for optimal preparation for subsequent reconstruction processes
+ Possible stationary as well as mobile
Mobile and stationary ULTRASONIC machining
43
The most important target markets
Scarfing in fuselage
Adaption on car roof
Repair of a damaged rotor blade
Milling of the bull-eye
Watch housing / CFRP
Rotor blade segment / CFRP
Center console / CFRP
Rotor cover / CFRP
Dashboard / CFRP
Frame Swing Arm / CFRP
Aerospace
Automotive
Regenerative energies
Ship building
Lifestyle
44
Applications and parts
Machine and technology
Application areas
Control technology
Technical data
CELOS® by DMG MORI enables consistent administration, documentation and visualisation of order, process and machine data. CELOS® can be extended with APPs and is also compatible with your company’s existing infrastructures and programmes.
ULTRASONIC 2nd Generation
– From the idea to the finished product.
ERGOline® Control panel with 21.5" multi- touchscreen and SIEMENS.
Uniform
Uniform user interface for all high-tech machines from DMG MORI.
Consistent
Consistent administration, docu-mentation and visualisation of order, process and machine data.
Compatible
Compatible with PPS and ERP systems. Can be networked with CAD / CAM products. Can be extended with future-oriented CELOS® APPs.
Simplified machine operation. Seamless integration of machine and company.
1
45
SMARTkey® – Customised user authorisation. Individually adapted access privileges to the control system and the machine.
Standard CELOS® APPs + Job Manager: systematic planning, administration and preparation of orders
+ Job Scheduler: systematic creation and administration of all order data
+ Job Assistant: assists set-up and processing of jobs from the job queue
+ Tool Handling: tool change list for anticipated, optimised retooling
+ Control: machine control system with touch operation and additional DMG MORI functions
+ Pallet Changer: easy handling of two or three pallets
+ CAD / CAM View: remote operation from any PC workstation
+ Tech Calculator: calculate technology data, measurements and values
+ Documents: digital library with full text search
+ Organizer: calendar, note and alarm functions
+ Netservice: direct DMG MORI support through qualified online diagnostics
+ Service Agent: assistant to help plan and carry out maintenance
+ Energy Saving: manages the energy consumption of the machine
+ Settings: individual configuration of CELOS® applications
+ Status Monitor: detailed machine and order status display in real time
+ Messenger: live status and evaluation of all machines
+ ULTRASONIC „side APPs“
1: APP menu: central access to available applications
Like on a smartphone, the operator has direct access to all available applications through the APP menu.
Simplified machine operation. Seamless integration of machine and company.
46
ULTRASONIC CELOS® APPs
+ Visualisation of the most important ULTRASONIC process parameters: frequency, amplitude, output-power
+ Automatic process control: monitoring of the existing process parameters
+ Management of the ULTRASONIC specific tool parameters (easy handling also from demanding actuator-tool-combinations)
SIEMENS 840D solutionline
+ SINUMERIK Operate ≥ 4.5
+ The simplest interactive programming
+ Quick editing of large programs
+ Comprehensive 5-axis functionality
+ Quick view simulation of complex part programs
+ Direct spline processing of CAD data
+ Sophisticated tool handling
Applications and parts
Machine and technology
Application areas
Control technology
Technical data
47
ULTRASONIC Parameter Detection (UPD)
+ Automatic detection of the resonance frequency for all ULTRASONIC HSK-actuators for evaluation of the optimal working frequency / oscillation amplitude
+ No manual action of the operator neccessary
+ Simplified operator mask shows all functions and detects the parameters
ULTRASONIC parameterisation
ULTRASONIC Auto Tuning (UAT)
+ Autotracking of the ULTRASONIC frequency and amplitude within the machining process for compensation of the damping of the tool edge
+ Achievement of a stable, reliable ULTRASONIC process
ULTRASONIC Programming Cycle (UPC)
+ Integration of ULTRASONIC specific cycles (e. g. use of different amplitudes within an operation task, other power restrictions) directly in the NC-programme
+ Optional available for all ULTRASONIC machines
Special programming cycles
ULTRASONIC Feedrate Cycle (UFC)
+ Automatic adaption of the feed rate in the machining process (analog to ACC = Adaptive Control Constraint)
+ Depending on the application, additional ULTRASONIC specific influencing factors (e. g. output power in W) can be used beside the standard values (e. g. torque in Nm)
+ Definition of a minimum and a maximum value
V
A
Frequency / kHz
Amplitude
1
0.5
0
15 20 25 30
Machining progress
Example: thru holeAmplitude
Drilling operation
Entry Exit
Start cycle
Programmed feed
Active tool / work piece protection
Control range
min
.
max
.
100
0Spindle torque (Nm)
Feed (F) %
t
48
800 1,200
480
Chiller: 3.3 kW 50 / 60 Hz
400
1,647
1,304
450215
2,371
1,66
5
3,48
0
580
845
Oil mistseparator
60 × toolchanger
Coolanttreatment
system KM10
2,25
2.5
1,65
7
1,85
0
2,62
8
Oil mist separator
1,57
3
3,61
01,375
845
510
1,647
2,344
1,304
580
210450215
480
687
411.
5
Spindle cooling Oil mist
separator
60 × toolchanger
Coolant treatment system KM10
2,25
2.5
1,65
7
2,62
8
1,85
0
Oil mist separator
Floor plans of the HSC linear / eVo linear / DMF / monoBLOCK® / duoBLOCK® / Portal machine versions in the relevant product brochures
Presentation of floor plans with optional swivel rotary table, 60 × tool changer and oil mist separator
Floor plan ULTRASONIC 10 with automation PH 2 | 120
Front view Top view
Floor plan ULTRASONIC 10
Front view Top view
ULTRASONIC 2nd Generation
Floor plans
Applications and parts
Machine and technology
Application areas
Control technology
Technical data
ê Floor plans
49
80
1,92
0
3,100 708
705
145
54077
6
790 max. travel of the cabin door
2,72
9
721 39
8
1,1891,260
1,50
1
4,23
0
701
2,03
53,
318
2,43
02,
810
80
1,884
1,92
0
540
2,72
9
790 max. travel of the cabin door
708
705
145
461
1,50
1
701
1,191
4,23
0
Floor plan ULTRASONIC 20 linear with automation PH 10 | 100
Front view Top view
Floor plan ULTRASONIC 20 linear
Front view Top view
50
ULTRASONIC 10 ULTRASONIC 20 linear
Traverses
X- / Y- / Z-axis mm 120 / 120 / 200 200 / 200 / 280
A-axis degree –10 ° to 120 ° –15 ° to 130 °
C-axis degree 360 ° 360 °
Main drive
Max. speed range ULTRASONIC rpm 40,000 50,000
Max. speed range milling rpm 40,000 60,000
Positioning accuracy in X / Y / Z µm P10 P5
Repeatability accuracy in X / Y / Z µm P8 P3
Feed
Feed range up to mm/min 10,000 20,000
Rapid traverse X / Y / Z m/min 10 40
Working table
Clamping surface rigid table mm – 370 × 320
Max. table load kg – 100
Clamping surface NC swivel rotary table mm ø 190 ø 200
Max. table load kg 10 15
Max. speed of rotational axes (A / C) rpm 100 / 150 50 / 150
Positioning accuracy (A- / B- / C-axis) " ±5 ±5
Tool
Tool holder spindle type HSK-32 / HSK-40 HSK-32 / HSK-40
Tool magazine (standard / option) places 16 (60 chain magazine) 24* (60 chain magazine)**
Type – tool magazine (standard) type changer wheel (horizontal) changer wheel (horizontal)
Max. tool length at full capacity and max. speed mm 130 200
Max. tool diameter at full capacity and max. speed mm 6*** 50
Chip-to-chip time s 15 10
Options
Work piece measurement type DMG PP-400 DMG PP-400
Tool measurement type RS NC-4 Blum NT, RS NC-4
Coolant treatment system type Toolsmart Toolsmart
Floor plan and connection data / basic machine
Floor space m² < 2.5 3.5
Dimensions L / W / H (incl. signal lamp) mm 1,775 / 1,530 / 2,253 1,884 / 1,920 / 2,427
Footprint L / W / H (incl. access to all service doors) mm 4,100 / 3,700 / 2,300 3,500 / 3,100 / 2,500
Weight kg 2,500 3,750
Power rating kVA 25 40
Operating voltage / max. fuse rating V 400 (N/PE) / 50 A 400 (N/PE) / 80 A
Required compressed air connection bar 6 6
Average air consumption m3/h 20 15
Controls
DMG MORI SLIMline® Panel with 15" screen SIEMENS 840D solutionline –
DMG MORI ERGOline® Control with 21.5" screen – SIEMENS 840D solutionline
Floor plans of the HSC linear / eVo linear / DMF / monoBLOCK® / duoBLOCK® / Portal machine versions in the relevant product brochures; * in combination with HSK-40: only 22 magazine places, ** only every second magazine position can be used with an HSK-40 actuator, *** tool shaft diameter
ULTRASONIC 2nd Generation
Technical data
Applications and parts
Machine and technology
Application areas
Control technology
Technical data
51
ULTRASONIC-HSK actuator systems HSK-E32 HSK-E40 HSK-E50 / HSK-A63 HSK-A100
Machine types
ULTRASONIC 10 / 20 linear
ULTRASONIC 20 / 30 linear
ULTRASONIC linear / monoBLOCK®
duoBLOCK®
ULTRASONIC P / FD
duoBLOCK®
Max. speed rpm 50,000 40,000 30,000* / 24,000 12,000
Tool interface ER, 14 H 6, shrink
ER, 14 H 6, shrink
ER, 20 H 7, shrink
ER, 20 H 7, shrink
* HSK-E50
Automation PH 2 | 4 PH 2 | 120 PH 10 | 100
Available for ULTRASONIC 10 ULTRASONIC 10 ULTRASONIC 20 linear
Automation type integrated blank automation 4-fold
linear magazine linear magazine
Max. handling weight kg 2 2 10
Workpiece change s ≤ 30 ≤ 55 ≤ 30
Integrable pallet types
Erowa ITS 100 yes yes yes
Max. number 4 13 27
Erowa ITS 50 no yes yes
Max. number – 50 / 250* 99
Finished parts storage (FPS) no yes no
Max. number – 150 –
Basic configuration Dental (ITS 100 / ITS 50 / FTS)* 4 / – / – 10 / – / 150 27 / – / –
Mixed mode no yes yes
Floor plan data / basic machine and automation
Floor space m² < 2.5 < 4 < 6
Dimensions L / W / H (incl. signal lamp) mm 1,775 / 1,530 / 2,253 1,775 / 2,000 / 2,253 2,020 / 3,250 / 3,400
Footprint L / W / H mm 4,100 / 3,700 / 2,300 4,100 / 4,000 / 2,300 4,400 / 5,200 / 3,700
Weight kg 1,900 2,700 4,900
Handling of unpalleted material no yes no
Job Management-System no yes no
* additional variants available
1 4
2 3
52
Breakdown by branches
Dental / medical 25 % Watch industry / fine mechanics 10 %
Ceramic components 20 % Optical industry 10 %
Die & mould 15 % Automotive 3 %
Institutes / universities 15 % Aerospace 2 %
Breakdown by machines
ULTRASONIC 10 12 % Flexible ULTRASONIC technology integration into DMG MORI machines
35 %
HSC / ULTRASONIC 20 linear 53 %
America
> 50 machines
Europe
> 300 machines
Germany
> 200 machines
Asia
> 150 machines
1
2
3
4
In all hightech branches there is a constant demand for new technology solutions and economical machining procedures for hard to machine future materials. Exactly here, SAUER is positioned with its ULTRASONIC technology and underscores with a consistent product line its technological expertise as an innovative pioneer in the ultrasonic-assisted hard machining of Advanced Materials.
ULTRASONIC 2nd Generation
Market leader in the machining of Advanced Materials with > 700 installed machines worldwide.
Applications and parts
Machine and technology
Application areas
Control technology
Technical data
5
4
3
1 2
53
Take advantage of the technical expertise of our competent team of application engineers and the numerous unique selling points of the ULTRASONIC series – visit SAUER ULTRASONIC in Stipshausen. Besides the actual production of machines, SAUER support their customers with feasibility studies, process optimisation and turn-key technology solutions by SAUER´s development and application department. In addition SAUER GmbH regularly organises ULTRASONIC technology seminars for customers and interested parties on the demonstration machines in a modern ULTRASONIC showroom.
ULTRASONIC 2nd Generation
Expert advantage in ULTRASONIC machining of advanced materials.
5: The SAUER LASERTEC location in Pfronten repre-sents itself with 5-axis laser precision machines in the five technology fields: Shape (3D machining, texturing), PrecisionTool (PCD / CVD-D / CBN precision tools), FineCutting (3D fine cutting parts), PowerDrill (turbine components) and Additive Manufacturing (3D laser deposition welding and milling on one machine)
ULTRASONIC excellence
+ More than 30 years experience in machining hard-brittle and difficult to machine materials
+ More than 700 installed ULTRASONIC machines (worldwide)
+ Strong, competent team of application engineers
+ Feasibility studies, process development / optimisation, complete turn-key solutions
1: View of the ULTRASONIC showroom 2: SAUER ULTRASONIC in Stipshausen 3 + 4: ULTRASONIC
technology seminars in the showroom
DMG MORI Europe AGSulzer-Allee 70, CH-8404 WinterthurTel.: +41 (0) 58 / 611 5000, Fax: +41 (0) 58 / 611 [email protected], www.dmgmori.com
Germany: DMG MORI Deutschland Riedwiesenstraße 19 D-71229 Leonberg Tel.: +49 (0) 71 52 / 90 90 - 0 Fax: +49 (0) 71 52 / 90 90 - 20 00 Service Hotline: +49 (0) 180 5 49 00 22
Europe: DMG MORI Europe Sulzer-Allee 70 CH-8404 Winterthur Tel.: +41 (0) 58 / 611 5000 Fax: +41 (0) 58 / 611 5001 Service Hotline: +41 (0) 446 545 670
Asia: DMG MORI Japan 2-3-23 Shiomi Koto-ku, Tokyo JP-135-0052, Japan Tel.: +81 3 - 6758 - 5900 Fax: +81 3 - 6758 - 5919
America: DMG MORI USA 2400 Huntington Blvd. Hoffman Estates, IL 60192 Tel.: +1 (847) 593 - 5400 Fax: +1 (847) 593 - 5433
DMG MORI Austria Oberes Ried 11 A-6833 Klaus Tel.: +43 (0) 55 23 / 69 141 - 0 Fax: +43 (0) 55 23 / 69 141 - 100 Service Hotline: +43 (0) 17 95 / 76 109
_ Stockerau Josef-Jessernigg-Straße 16 A-2000 Stockerau Tel.: +43 (0) 55 23 / 69 141 - 0 Fax: +43 (0) 55 23 / 69 141 - 100
DMG MORI Benelux _ Netherlands Wageningselaan 48 NL-3903 LA Veenendaal Tel.: +31 (0) 318 - 55 76 - 11 Fax: +31 (0) 318 - 52 44 - 29 Service Hotline: +31 (0) 202 00 81 83
_ Belgium Hermesstraat 4B B-1930 Zaventem Tel.: +32 (0) 2 / 7 12 10 - 90 Fax: +32 (0) 2 / 7 12 10 - 99 Service Hotline: +32 (0) 2 / 2 200 62 - 52
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_ Planá Chýnovská 535 CZ-39111 Planá nad Lužnicí Tel.: +420 381 406 914 Fax: +420 381 406 915
_ Slovakia Brnianska 2 SK-91105 Trenčín Tel.: +421 326 494 824
DMG MORI France Parc du Moulin · 1 Rue du Noyer B.P. 19326 Roissy-en-France F-95705 Roissy CDG Cedex Tel.: +33 (0) 1 / 39 94 68 00 Fax: +33 (0) 1 / 39 94 68 58 Service Hotline: +33 (0) 8 10 90 20 20
_ Lyon Parc des Lumières 1205 Rue Nicéphore Niepce F-69800 Saint-Priest Tel.: +33 (0) 4 / 78 90 95 95 Fax: +33 (0) 4 / 78 90 60 00
_ Toulouse Futuropolis Bat. 2 · 2 Rue Maryse Hilsz F-31500 Toulouse Tel.: +33 (0) 5 / 34 25 29 95 Fax: +33 (0) 5 / 61 20 89 19
_ Haute-Savoie Espace Scionzier · 520 avenue des Lacs F-74950 Scionzier Tel.: +33 (0) 4 / 50 96 41 62 Fax: +33 (0) 4 / 50 96 41 30
DMG MORI Hungary Vegyész u. 17 – 25 · B. Building H-1116 Budapest Tel.: +36 1 430 16 14 Fax: +36 1 430 16 15 Service Hotline: +36 1 777 90 57
DMG MORI Ibérica Pol. Ind. Els Pinetons Avda. Torre Mateu 2 – 8 · Nave 1 E-08291 Ripollet · Barcelona Tel.: +34 93 586 30 86 Fax: +34 93 586 30 91 Service Hotline: +34 91 - 2 75 43 22
_ Madrid C / Alcañiz 23 · E-28042 Madrid Tel.: +34 91 66 99 865 Fax: +34 91 66 93 834
_ San Sebastián Edificio Igaraburu Pokopandegi 11, Oficina 014 E-20018 San Sebastián Tel.: +34 943 100 233 Fax: +34 943 226 929 Service Hotline: +34 91 - 2 75 43 22
DMG MORI Italia Via G. Donizetti 138 I-24030 Brembate di Sopra (BG) Tel.: +39 035 62 28 201 Fax: +39 035 62 28 210 Service Hotline: 199 177 811
_ Milano Via Riccardo Lombardi 10 I-20153 Milano (MI) Tel.: +39 02 48 94 921 Fax: +39 02 48 91 44 48
_ Padova Via E. Fermi 7 · I-35030 Veggiano (PD) Tel.: +39 049 900 66 11 Fax: +39 049 900 66 99
DMG MORI Middle East Jebel Ali Free Zone · JAFZA Towers Lob 18, Office 2403, P.O. Box 262 607 Dubai, U.A.E.Tel.: +971 - 4 - 88 65 740 Fax: +971 - 4 - 88 65 741
DMG MORI Polska ul. Fabryczna 7 · PL-63-300 Pleszew Tel.: +48 (0) 62 / 7428 000 Fax: +48 (0) 62 / 7428 114 Service Hotline: +48 (0) 62 / 7428 285
DMG MORI Romania DN 65B, KM. 4 + 471 RO-110180 Pitesti Tel.: +40 248 610 408 Fax: +40 248 610 409
DMG MORI Russia ul. Novohohlovskaya 23 / 1 RU-109 052 Moscow Tel.: +7 495 225 49 60 Fax: +7 495 225 49 61 Service Hotline: +7 495 912 50 09
_ Jekaterinburg ul. Sofi Kowalewskoj 4, litera Z RUS-620049 Jekaterinburg Tel.: +7 343 379 04 73 Fax: +7 343 379 04 74
_ St. Petersburg pr. Obuhovskoy Oborony 271, litera A RUS-192012 St. Petersburg Tel.: +7 812 313 80 71 Fax: +7 812 313 80 71
DMG MORI Scandinavia _ DMG MORI Finland & Baltics Jasperintie 310 FI-33960 Pirkkala Tel.: +358 10 271 4450 Service Hotline: +358 10 271 4460
_ DMG MORI Sweden E A Rosengrens gata 5 SE-421 31 Västra Frölunda Tel.: +46 (0) 771 364 6674 Fax: +46 (0) 31 476 351 Service Hotline: +46 (0) 771 365 724
_ DMG MORI Denmark Robert Jacobsens Vej 60, 2.tv DK-2300 København S Tel.: +45 70 21 11 11 Fax: +45 49 17 77 00 Service Hotline: +45 70 21 11 12
_ Norway Bergsli Metallmaskiner AS Bedriftsveien 64 NO-3735 Skien Tel.: +47 35 50 35 00 Fax: +47 35 50 35 70
DMG MORI Schweiz Sulzer-Allee 70 CH-8404 Winterthur Tel.: +41 (0) 58 / 611 5000 Fax: +41 (0) 58 / 611 5001 Service Direct Line: +41 (0) 58 / 611 5555 Service Hotline: +41 (0) 446 545 670
DMG MORI South East Europe Ag. Georgiou 5 – Patriarchiko Pylaias, Cosmos Offices, PO 60233 GR-57001 Thessaloniki Tel.: +30 2310 474486 Fax: +30 2310 474487
DMG MORI Turkey Ferhatpaşa Mah. Gazipaşa Cad. No: 11 TR-34885 Ataşehir · İstanbul Tel.: +90 216 471 66 36 Fax: +90 216 471 80 30 Service Hotline: +90 216 47 16 636
DMG MORI UK 4030 Siskin Parkway East Middlemarch Business Park Coventry CV3 4PE · GB Tel.: +44 (0) 2476 516 120 Fax: +44 (0) 2476 516 136 Service Direct Line: +44 (0) 2476 516 130 Service Hotline: +44 (0) 20 30241514
DMG MORI Africa Representative WIN-TECH Machinery & Tooling 90 El Thawra Street El Golf Area Heliopolise 11341 Cairo, Egypt Tel.: +202 2 690 36 08 Fax: +202 2 690 36 09
Headquarters Europe
Always close by! www.dmgmori.com
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