Highlights
Integrated spindle drives with up to 4,000 Nm for maximum cutting performance
- ISM 102 with 4,000 rpm, 45 kW and 770 Nm in the standard
- Material removal rate ISM 102 to 1.584 cm3 / min (CK45)
- Integrated C-axis (0.001 °)
Complex turning and milling operations with an ultra-compact Turn&Mill spindle with 220 Nm torque
- 420 mm Y-stroke for more flexibility
- Turning and milling spindle compactMASTER with 12,000 rpm, 36 kW and 220 Nm. Available as high-speed version with 20,000 rpm.
- Automatic tool change. 36-fold disc magazine in standard, max. 180 stations in the optional chain magazine.
Optional second tool carrier for highly productive turn & mill machining
- VDI 40 turret rated at 4,000 rpm, 28 Nm and 10 kW or VDI 40 Direct Drive turret rated at 10,000 rpm, 34 Nm and 14.2 kW
- "< 30 sec. tool set-up time and < 6 μm repeatability with
- TRIFIX® precision quick-change interface as standard"
- Easy to use turret steady rests and turret centres with the technology cycle (optional)
Accuracy
Maximum precision and temperature stability
- Direct measuring systems in all axes by Magnescale
- Cooling of the X / Y / Z-axis motors and the turret drives
- Maintenance-free linear drive in the Z-axis * with 5 years warranty
Application Examples
Automation
Standard automation and customised solutions in the VERTICO design
Automation is a key element of digital production. Every DMG MORI machine can be upgraded with standard automation or with a customised automation solution for flexible manufacturing systems:
Flexible workpiece handling up to 115 kg
- One app for uniform control of all Robo2Go variants, setting up a new workpiece < 5 minutes
- Strongest version for 210 kg payload and 115 kg workpiece weight
- Handling of workpieces ø 40 to ø 400 mm as standard
- Fast supply and removal of raw material and finished parts using pallets or workpiece trolleys
- Free access to control and tool magazine
- Integrated in the machine control operation via CELOS APP: No need to change your NC programs!
- Intuitive usability thanks to dialog-guided software
- Creation of the process through predefined program modules via drag & drop: No robot programming knowledge necessary
- Setting up a new workpiece < 5 minutes
- Strongest version for 210 kg payload and 115 kg workpiece weight
- Handling of workpieces ø 40 to ø 400 mm as standard
- Fast infeed and outfeed of part-machined and finished parts by means of pallet or workpiece trolley
GX 35 / 60 T - The gantry loader for the CTX beta (TC) 4A and CTX gamma TC
- Handling of workpieces up to ø 450 × 500 mm and weighing up to 60 kg
- Modular stocker system for chuck parts and shafts, e.g. stacking magazin with up to 40 pallets for chuck parts
- Combinable with various kinds of automatic peripheral equipment (washing, measuring, marking, etc.)
- Easy programming and setup due to integration into the machine control
- Full part management by the machine control
Highlights GX 35 T / GX 60 T
- Handling of workpieces up to a diameter of 450 mm, a length of 500 mm and a weight up to 60 kg
- Easy programming and setup due to integration into the machine control
- Full part management by the machine control
- Modular stocker system for chuck parts and shafts
- Easy maintenance due to optimized cover system
- Integrated functions: Washing, measurement, engraving possible
Flexible modular robot system for ≥ 1 machine
- Modular concept with standardized peripheral devices, e. g. washing, measuring or marking
- 80 % shorter setup time due to modular and standardized peripherals and robot programs
- Flexible adaptation to system changes including after installation
- Simple and easy operation via the MATRIS control system without programming
- Handling of workpieces up to ø 200 × 200 mm, 1 × 20 kg or 2 × 10 kg
- Stacking magazine:
- 14, 20 and 26 pallets: ø 150 × 120 mm, max. 35 kg per pallet
- 10 and 20 pallets: ø 200 × 200 mm, max. 75 kg per pallet
- Loading of oversized tooling in case of vertical machining center
- Available for 13 series, e. g. NLX, NTX, NHX, DMU, NMV, eVo, etc.
- Ideal for the flexible production of 50 to 200 workpieces / day
- Space-saving pallet handling for up to 40 pallets
- 400 × 400 mm pallet size
- 150 kg transfer weight (workpiece and pallet)
- Integration of secondary processes such as deburring or marking possible
- Available for the CMX 50 U, CMX 70 U, DMU 50, DMU 65 monoBLOCK, CMX 600 V, CMX 800 V, CMX 1100 V
Holistic automation on the shop floor
- Collaborative automation solution with free layout design
- Omnidirectional movement for minimal space requirements (turning radius 0m)
- Basis for additional tasks, e.g. B. tool handling, chip disposal, etc.
- Material transport from Euro pallets 1,200 x 800 mm
- Maximum transport weight of up to 2,000 kg
- Security based on Sick and Siemens technology
- Autonomous transport of material pallets
- Load capacity up to 2000 kg
- Compact and manoeuvrable
- Integration into existing processes
- Autonomous transport of chip trolleys
- Automatic pick-up order from the DMGMORI master computer
- Integration into existing material processes
- Extension of machine tool autonomy over the night or weekend
- Fleet ready
- Tool identification in the standard
- Quick installation of the automation system
- Reliable technology with proven components
- Integration into existing production possible
- Max. tool dimensions ø 280 / 400 mm
- Max. tool weight 30 kg
- Transport weight 720 kg (24× 30 kg)
- Maximum number of tools: 24 pcs
Control & Software
- For shop-floor programming with easier integration in the NC-program.
- Easy tool definition in for the NC-program due to the integrated tool library
- Possibility to define the adjusting angle (kappa) for each cutting edge and each operation to achieve the best machining results
* Simultaneous movement of Kappa must be programmed with CAM
- Approach to the workpiece with contact detection by means of motor current evaluation of the grinding spindle*.
- Measuring sensitivity adjustable via user interface
- Individual setting of oversize possible after contact detection
*Available as an extension of the grinding package
- Significant reduction of air cuts, so that the grinding process starts directly at the actual dimension of the workpiece
- Extension of the handling capability, especially when the structure-borne noise on the part cannot be determined clearly
- Full integration in the grinding cycle package
- Residual unbalance-based calculation of the permissible tool speed limit in the HMI
- Continuous monitoring and automatic registration of all limit value violations during machining
- Export function of all registered events in tabular form
- High transparency and sensitivity with regard to tool balancing due to simple operation
- Improved dimensional accuracy, surface quality and reduced tool wear due to the consistent use of balanced tools
- Producing high precision oval and und polygon geometries with grinding – tolerance class IT5*
- Easy parametrized definition of the geometries based on DIN 32711
- Perfect complement to technology cycle Polygon- / Oval-Turning
* as extension of the grinding technology cycle
- New machining opportunities for more innovations on the part – e.g. shaft-hub connections.
- Position-oriented polygon and oval geometries due to 6-sided complete machining advantages
- Integrated clamping force calculator according to VDI 3306
- Intuitive calculation of the minimum and clamping forces based on the used machining parameters
- Comprehensive package for internal and external clamping with 3 to 8 jaws for turning, milling and drilling
- Avoidance of component deformation due to unknowingly excessive clamping force
- Increased clamping safety
- Faster set-up and safe clamping in combination with iJAW (DMQP RÖHM)
- Sensitive clamping force with quick-change jaws
- Controlled clamping force during the machining process
- LIVE measurement of the actual clamping forces
- Optimum clamping force monitoring for process-specific applications
- No component deformation due to unknown clamping force
- Indicator for chuck maintenance, in case of clamping force decrease
- Production of hirth serrations by impact milling on turn-mill machines
- Automatic calculation of the tool path movement
- Position-oriented tooth pairings by determining the angular position of the toothing on the component
- For straight external and internal gears with shoulder (interference contours)
- Toothing modules between 0.3 – 1.5 with quality 8 according to DIN 3961
- Up to module 2 on CTX gamma TC*
*Quality and machining time depending on tool and workpiece
- Safe decoupling of mold and component at the push of a button (emergency stop).
- Protection of tool and component against damage, in case of an unexpected event.
- Available as an additional option for the technology cycles gearSKIVING 2.0 and Multi threading 2.0
- Production of high precision eccentric cylinders by means of grinding* – Tolerance class IT5
- Simple parametric definition of diameter and eccentricity
- The perfect addition to the machining cycle Excentric turning and milling*.
*Can be ordered as an extension of the grinding package
- Broaching of internal and external splines with dialogue guided programming
- One-Tooth up to 4-theeth cutting tools with clear tool definition for easy setup.
- Compensation parameters for tool holder deviation in X-direction
- Technology available for the first time on turn-mill machines, as the perfect complement to gear skiving
- Fully integrated operation on the control including automatic probing of the tooth space
- Full technological support from the DMQP partner for tool support for tool design and for start-up
- Smoothing of the profile line and straightening of the flank lines.
- Improvement of the grading due to smoothed feed marking
- Improvement of concentricity
- Improved overall quality*
*By one quality level, depending on the quality of the previous hobbing process.
- Shorter non-productive times thanks to sorting of tools in the tool magazine according to the sequence of the tools in the program
- Time-optimized sorting in the chain magazine due to the use Of the tool shuttle instead of the spindle
* Optimization is not done in parallel to main time
- Minimized tool changing times from lot sizes > 3
- Flexible tooling in the magazine depending on the NC program
Turning
- Turning, milling and grinding in one clamping
- Grinding cycles for internal, external and face grinding as well as dressing cyclesn
- Body-borne sound sensors for start-up and dressing
- Full integration of measurement module for relative and absolute LIVE-Measuring – parallel to main time
Milling
- Better surface quality through integration of the grinding technology
- Grinding cycles for internal, external and face grinding as well as dressing cycles
- Body-borne sound sensors for start-up and dressingn
- 1,300 l Cooling system with integrated centrifugal filter for The filtration of particles > 10 μ
- AKZ nozzle unit optionally available for best possible Flushing of the grinding gap
- Hydraulically operated steady rest to support long and slim components
- Expansion of the possibility of using multi-channel machines
- The cycle allows both approaching to and retraction from the steady rest
- Hydraulically operated steady rest in the tool table
- Position-locking the turret leads to increased process safety
- Fix the steady rest position, to position and shape tolerances to comply with the program after reboot
- Higher stability due to optimal force transmission in thelongitudinal direction of the tool holder
- Generation of tool feed in the Y-direction for parting off components at a push of a button
- Compatible with the standard cycle CYCLE92 (Part off cycle), so that the operator can program as usual (ShopTurn and DIN / ISO)
- Up to three times higher productivity possible (3x feed) with simultaneously improved chip control
- Reduced noise level and higher surface quality through more tool stability
- Less material loss due to reduction of the parting width
- Automatic optimization of servo drives parameters for Main- and Sub-Spindle
- Reduction of Setup time
- Optimization of machining result
- Setup Time reduction
- Automatic determination of parameters independent from machine operator experience
- saving the setting in NC-program for more quality assurancet
- Structured input parameters for the groove geometry, the tool and the machining strategy
- Inner and outer grooves in any position and number freely adjustable
- Easy compensation of tool displacement + Calculation of residual strokes based on selected machining strategy
- Easy handling of non-circular parts
- Intuitive user interface for polygons / oval turning
- Making the required geometries with possibilities of simple fine-tuning
- Possiblity of fine tuning of the geometric parameters (long / short Semi-axis and bearing angle)
- Machining can be combined with main spindle or counter spindle
- Application especially for multi-channel machines for time analysis of the production process and as a basis for the cycle time optimization
- Individual zoom in to view minute details for cycle time optimization
- Histogram up to three channels
- Provides the basis for cycle time optimization by graphical inputs
- Save / Load the recorded data to compare individual optimized steps
- Superposition of the turning movement by additional X- and Y-traverses
- Applicable for turning and milling
- Eccentric geometries easy to manufacture
- Exact axis coupling and synchronization in the background
- NEW: On-Point Threading - Position oriented thread production
- Free definition of contours, pitches and gears possible
- Creation of large transmission threads, which can not be manufactured by simple thread chasing
- Trapezoidal, buttress and knuckle thread easily programmable at the machine
- Screw conveyor with any profile geometry
- Ball screw nut with cross holes simple to realize
Highlights
- Producing profiles with undercut due to the profile splitting option.
- Applying standard tools and tool holder for left and right sided machining of the flanks
- Surface quality of Ra 0,3 an CrNi-Alloys possible
- Centring tip mounted on the turret
- Centring tip data is saved directly in the tool memory
- For fixed and spring-loaded centring tips
- Easy operation for positioning the centring tip
- Position-locking the turret leads to increased process safety
- Pressing force of the tip is variable, programmable and monitorable
- In combination with the Gildemeister structure programming, A safe and fast reboot of the machining program after an interruption
- Easy program operation especially with multiple spindles or tool magazine
- Displays the process status of the workpiece
- Display of the detailed status on the controller
- Enter remarks automatically by the GILDEMEISTER structure programming.
- Safe re-entry into the program by the press of a button instead of searching for a specific block.
- Structured approach with more than 20 standard programs and more than 200 processing variants incl. automation (bar processing, robot / portal loading, ...)
- Display of the program status with additional markers (EPS) for the sub-programs.
- With interpolation turning, the tool cutter follows a circular movement, where the cutter is always oriented towards the center Of the circle.
- Possible for external and internal machining
- Synchronization and tool path controlled by the cycle
- NEW: in version 2.0 complex turning contours are possible (currently only available on the DMU 50, other machine types will follow)
- Easy manufacturing of sealing surfaces where milling operation might not be possible.
- Complete component processing in one clamping possible
- Reduced investment costs for tools
- Straight and helical external or internal spur gears and splines
- Arrow teeth with tooth offset Turn-mill machines
- Ball-shaped toothing by mathematical transformation of the 6th virtual axis
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
- Programming of the gearing parameters via dialog input
- For spur gear, helical gear and worm gear
- Gear cutters and disk cutters can be used
- Maximized tool life by shifting of the cutter
- Achievable quality ≤ DIN 7
- Easy to operate through three parameters and without additional sensors
- Avoiding vibrations by means adaptation of the speed
- Application for the main spindle and counter spindle, or for milling machines with FD tables with Direct Drive
- No manual intervention by the operator
- Identical repeatability for all components
- Increased process safety for special applications by avoiding vibrations. example, When using long thin drills or for milling parts with critical clamping
- Productive complete processing
- Cost-effective gear cutting on standard machine with standard tools
- Flexible for different gear geometries
- Quality inspection in the process
- Program creation based on blank drawings and gear data
- Optimization of workpiece orientation e.g. after heat treatment
- Interface for coordinate measuring device (Klingenberg, Leitz, Zeiss)
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
- Efficient use of multi-tip turning tools with more than one cutting edge on turn & mill
- Several "sister tools" on one main tool holder
- Reduction of tool change times
- Saves tool magazine space
- Prevention of damage due to tool breakage or tool overload
- Sensorless with automated learning of load limits
- For turning, milling and drilling (up to 3 mm diameter)
- NEW: User interface on CELOS SideScreen
- NEW: Powerful algorithm for efficient monitoring after the first workpiece
- Protection Package: Perfect supplement to MPC Lathes. Price advantage (approx. 40%)
- Save the monitoring limits for each tool and every cutting edge in the program
- By pushing the associated key the X- axis and the Y-axis travel to the positive end-positions for external machining
- Ideally suited to prepare the work space for set-up and alternatively also as an emergency rescue function.
- Easy operation when setting up multi - channel machinery
- Possibilty of a fast response during external machining as a rescue function
- Free form surfaces by 5-axis interpolation on the main and counter spindle
- Turning and milling with interpolated B-axis
- Programming the 5-axis movements via customer CAD / CAM systems
- An intellegent Look-ahead function for a continuous process
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight