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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

1

2

3

4

02

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 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

1

2

3

4

02

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 grinding, milling and drilling.



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



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.


The world speaks „ULTRASONIC“.

04



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.


The world speaks „ULTRASONIC“.

05

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

06

Available ULTRASONIC machine types Universal linear monoBLOCK® duoBLOCK® Portal Travelling column mobileBLOCK

ULTRASONIC 10

ULTRASONIC 50



ULTRASONIC 40 eVo linear



ULTRASONIC 65

ULTRASONIC 85

ULTRASONIC 60

ULTRASONIC 80

ULTRASONIC 100

ULTRASONIC 125

ULTRASONIC 160

ULTRASONIC 210 P

ULTRASONIC 260

ULTRASONIC 360


Series basic machine SAUER DMU SAUER HSC eVo eVo eVo DMU / DMC monoBLOCK®

DMU / DMC monoBLOCK®

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 series for handsized workpieces up to ø 3,000 mm.



ê Concept

Application areas

Control technology

Technical data

06


ULTRASONIC 10

ULTRASONIC 50






ULTRASONIC 65

ULTRASONIC 85

ULTRASONIC 60

ULTRASONIC 80

ULTRASONIC 100

ULTRASONIC 125

ULTRASONIC 160

ULTRASONIC 210 P

ULTRASONIC 260

ULTRASONIC 360










Option MT – – – – – – – – – –






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




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 series for handsized workpieces up to ø 3,000 mm.



ê Concept

Application areas

Control technology

Technical data


ULTRASONIC 10

ULTRASONIC 50






ULTRASONIC 65

ULTRASONIC 85

ULTRASONIC 60

ULTRASONIC 80

ULTRASONIC 100

ULTRASONIC 125

ULTRASONIC 160

ULTRASONIC 210 P

ULTRASONIC 260

ULTRASONIC 360










Option MT – – – – – – – – – –






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




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


ULTRASONIC 10

ULTRASONIC 50






ULTRASONIC 65

ULTRASONIC 85

ULTRASONIC 60

ULTRASONIC 80

ULTRASONIC 100

ULTRASONIC 125

ULTRASONIC 160

ULTRASONIC 210 P

ULTRASONIC 260

ULTRASONIC 360










Option MT – – – – – – – – – –






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




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.



ê ULTRASONIC 10

Application areas

Control technology

Technical data

11

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

1 2

12

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.



ê ULTRASONIC 10

Application areas

Control technology

Technical data

1 2

12

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




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.



ê ULTRASONIC 10

Application areas

Control technology

Technical data

3 4 5

13

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




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.

14



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.


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).

14




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.


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).

15

“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

16

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.






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

1 2

16

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.






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

18

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.


Flexible ULTRASONIC integration into 5-axis milling machines of DMG MORI.



ê Concept

Application areas

Control technology

Technical data

18

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.


Flexible ULTRASONIC integration into 5-axis milling machines of DMG MORI.



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


Mobile 5-axis milling unit for MRO*: small, light, mobile – with best performance in CFRP.



ê ULTRASONIC mobileBLOCK

Application areas

Control technology

Technical data

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


Mobile 5-axis milling unit for MRO*: small, light, mobile – with best performance in CFRP.



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



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

22



Application areas


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.



Application areas


Control technology

Technical data

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.



Application areas


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 tu 50 %

+ Force reduction in the slots up tu 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 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.



Application areas


Control technology

Technical data

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 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.



Application areas


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



Application areas

ê Optical industry

Control technology

Technical data

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



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



Application areas

ê High performance ceramics

Control technology

Technical data

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



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



Application areas

ê Watch industry / fine mechanics

Control technology

Technical data

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



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


Machining Complete machining of an AI2O2 clock housing from the raw block in 15 machining steps

ULTRASONIC 20 linear Complete machining of a lunette


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


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


Material Blue zirconium oxide


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



Application areas

ê Die & mould

Control technology

Technical data

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



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 min.

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



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

36



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



Application areas

ê Aerospace and automotive

Control technology

Technical data

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



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 x 260 mm deep hole drilling with improvement of the straightness in the channe, 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 min. vs. 32 min.)

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



Application areas

ê ULTRASONIC composites

Control technology

Technical data

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.




Application areas


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 min.

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 min.

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 min.

AerospaceMaterials: CFRP, GFRP, AFRP, stacks, other composites (e. g. CMC = Ceramic Matrix Compounds) Application examples: housings, rotor parts, armatures

Application areas

ULTRASONIC composites.

42



Application areas


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.


Doubled feed rates and reduced process forces for machinig 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

42



Application areas


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.


Doubled feed rates and reduced process forces for machinig 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 machining43

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



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.


– From the idea to the finished product.

ERGOline® Control 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.

44



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.


– From the idea to the finished product.

ERGOline® Control 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.


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.


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



Application areas

Control technology

Technical data

Like on a smartphone, the operator has direct access to all available applications through the APP menu.


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



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


Floor plans



Application areas

Control technology

Technical data

ê Floor plans

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

0

1,375

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


Floor plans



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


Technical data



Application areas

Control technology

Technical data

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


Technical data



Application areas

Control technology

Technical data

DMG MORI recommends

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


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.


Market leader in the machining of Advanced Materials with > 700 installed machines worldwide.



Application areas

Control technology

Technical data

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.


Market leader in the machining of Advanced Materials with > 700 installed machines worldwide.



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.


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

www.dmgmori.comDMG MORI LifeCycle Services

Customer First –Our service promise!

“We have good news for you: Our service and spare parts prices have been completely revised. With our service commitments, we want to meet your high demands with the highest service quality.” Please contact us – your sales and service team is at your disposal!

Available for you around the clock:

service-hotline.dmgmori.com

*All information and price advantages for Customer First are available at: customer-first.dmgmori.com

Best Price Guarantee for Original Spare Parts. Should you get

a spare part offered by us at least 20 % cheaper elsewhere, we will

refund the price difference up to 100 % *.

Up to 50 % lower service costs. New Flat Call-Out Rate –

without travel expenses or any additional costs!

Spindle service at best prices. The highest level of competence

from the manufacturer at new and attractive prices – DMG MORI

spindle service!

Our protective shield for your productivity. Reduced operating

costs, highest machine availability and maximum precision

– DMG MORI ServicePlus!

Top quality at fair prices. It's a promise!

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