DMG Mori magazine metalworking machines
THE DMG MORI MAGAZINE FOR CUSTOMERS AND INTERESTED PARTIES
02 2019 V MORI TECHNOLOGY
5 digital innovations - Customer story - Three DMG MORI manufacturing systems with a total for connectivity, open integration maximum availability. of eight DMC 60 H ensure maximum machine utilization in 24/7 operation at Zimmer Group.
DMG MORI CONNECTIVITY AUTOMATION - WH FLEX
5 digital innovations consistent and process-wide
my DMG MORI DIGITAL TWIN - DMU 340 GANTRY
The new customer portal for service optimization
Step by step to the DMG MORI Digital Twin
WERKBLIO DMG MORI PALLET AGV
Platform for service and maintenance
DMG MORI ECONOMIC PROGRAM INTERVIEW - LPP 160 AND DMC 210 U
Worry-free investment in turbulent times
VC5 COMPLETE CUSTOMER STORY - ZIMMER GROUP
Up to 30% higher machine accuracy over the lifetime of the machine
WORLD PREMIERE 2019 - CLX 750
CUSTOMER STORY - 2,000 Nm for heavy-duty turning of workpieces weighing up to 600 kg
Partner for the digital factory
CUSTOMER STORY - M5 ULTRASCHALL TECHNOLOGIE
INTERVIEW - SPINDLE EXCELLENCE In-House Production -
Fair price guarantee for the quickest spindle repair
CUSTOMER STORY - CMX V/CMX U/AUTOMATION
SPN SCHWABEN PRÄZISION FRITZ HOPF NEW: inlineMASTER spindle for the CMX V and CMX U
DMG MORI gears KIVINU cut complete machining of gears with 36-month warranty
NHX - HORIZONTAL MACHINING CENTERS TURN MILL COMPLETE MACHINING
The new standard for horizontal machining centers
GRINDING - DMG MORI TECHNOLOGY CYCLES CUSTOMER STORY - GE AV10 AERO
360 Technology Integration
CUSTOMER STORY - GKN AEROSPACE ENGINE SYSTEMS
Ergonomic loading of tools weighing up to 30 kg
Robo2Go VISION
Production assistant with the convenience of VISION
DMGMORI TECHNOLOGY EXCELLENCE
EDITORIAL
Customer story - Using 180 DMG MORI machines - among them cen H5C 55 linear for high-speed cutting and five LASERTEC 45 Shape for surface structuring - OMCO manufactures highly precise glass molds.
WE CONTINUE TO SPEED UP FOR THE BENEFIT OF OUR CUSTOMERS
ALX 1500/2000/2500
ALX-COMPACT turning machines: Automated series production
CUSTOMER STORY - VOLKSWAGEN AG
EMO Hanover 2019 will open in increasingly difficult market conditions. The economic slowdown, geopolitical uncertainties, and a weakening automobile industry are leaving their traces on our industry. We also find ourselves in the middle of deep industrial change: Automation, digitization, ADDITIVE MANUFACTURING, increase in productivity with the DMC 210 U, and increasing demand for integrated technological solutions are confronting companies with great challenges.
We therefore continue to speed up for the benefit of our customers and are investing in future-oriented manufacturing solutions and innovative services:
Smart key components for higher machine availability
DMU 200 GANTRY + Flexible handling of workpieces up to 2,000 x1,350mm
CUSTOMER STORY - OMCO
HSC and laser structuring for glass molds with fine details
DMQP - MIKRON TOOL SA
New DMQP Partner for high-performance micro-machining with internal coating
CUSTOMER STORY - MOLL ENGINEERING GMBH
Production of complex surgical instruments
CUSTOMER STORY - AZUMA KINZOKU SANGYO
High-precision production of complex forms
DMQP POWDER CIRCULATION
Open, continuous, qualified
Convince yourself of our grand display of innovations live at EMO.
WORLD PREMIERE 2019
Additive Manufacturing - LASERTEC 125
DMG MORI ACADEMY
World's biggest CNC academy
CUSTOMER STORY - MWF TECHNIK GMBH CO. KG
Machine and finance from a single source
Dr. Eng. Masahiko Mori Christian Thönes
President Chairman of the Executive Board
DMG MORI COMPANY LIMITED DMG MORI AKTIENGESELLSCHAFT
DMGMORI TECHNOLOGY EXCELLENCE
Mechanical engineering is currently dominated by dynamic alliances. In the interview, Christian Thönes, Chairman of the Executive Board of DMG MORI AKTIENGESELLSCHAFT, explains how the structural change is holistically reflected throughout the portfolio of DMG MORI and which future-oriented innovations customers can expect from the global market leader at EMO.
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M. Thönes, which digital exhibits and solutions can customers expect on the DMG MORI EMO trade fair stand in Hall 2?
We are presenting more than 30 digital innovations at EMO. With DMG MORI Connectivity, we are providing secure networking of not only DMG MORI machines but also selected third-party machines. In addition, our CELOS customers can also carry out a PLC-independent CELOS update to the 2019 version. This applies to every existing CELOS version from the last six years. The new DMG MORI MESSENGER for monitoring now also has an interface for third-party software and can be used on all machines and devices in production that are networked with DMG MORI Connectivity. We will be demonstrating live on machines how DMG MORI NETservice as a direct remote assistant helps to reduce stoppages. We are exhibiting myDMG MORI for the first time, which is our new DMG MORI customer portal for comprehensive service optimization.
Overall, we are presenting ourselves as an end-to-end partner for digitization and automation and showing how the entire DMG MORI manufacturing process can be consistently digitized with the modular Smart Factory products from DMG MORI, from planning and job preparation to production and on to secure monitoring and service.
DMG MORI CONNECTIVITY
What are the special highlights with DMG MORI Connectivity, which you provide orientation?
The focus is clearly on connectivity as far as we are concerned, as it is a basic requirement for digitization and automation. This is why all DMG MORI machines will be equipped with connectivity free of charge in the standard version from EMO onwards. Every one of our 45 high-tech machines at EMO is also networked.
We have established DMG MORI Digital GmbH together with CPRO to provide service and support for all DMG MORI Connectivity solutions. This joint venture specializes in networking machines. It supports our customers directly on-site with advice and qualification and through rapid implementation of digital products from DMG MORI and partners.
How does DMG MORI support its customers with the realization of connectivity and the implementation of digital products?
DMG MORI Connectivity makes it possible to connect to all significant IoT platforms such as ADAMOS, MindSphere, FANUC Field, and others. The customer chooses the direction, and we set up our solutions accordingly. We will be demonstrating this openness and flexibility at EMO in monitoring applications on various platforms.
What exactly is meant by open integration?
With DMG MORI Connectivity, we provide connectivity to DMG MORI and selected third-party machines. In doing so, we are supporting all internationally established protocols such as MQTT, MTConnect, and OPC-UA, plus the new umati language. The customer chooses the direction, and we set up our solutions accordingly.
What is changing, particularly in the CELOS area?
With CELOS, DMG MORI has been the only machine tool manufacturer with an app-based control and operating system since 2013. We started with 11 apps in 2013, which were mainly for simplifying machine operation. This innovation had been future-oriented and correct. It was followed by expansion of app functionalities with approximately 50 new features per year.
Now, in 2019, we have increased the functionality significantly with a total of 25 apps and have made open integration of customized systems possible for the first time.
And we are delivering on our promise to bring all 15,000 installations on the market and all versions from the previous six years to a common level with a PLC-independent update to the new CELOS version.
The data is safely migrated, and all functions supported by the PLC are then fully available.
You have just mentioned the new umati language. What is so special about umati?
The standard is key, and umati is the new standard in the machine tool industry for open and unrestricted communication within the shop floor and with higher-level IT systems.
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DMG MORI TECHNOLOGY EXCELLENCE
DMG MORI CONNECTIVITY
All Machines: DMG MORI and third-party providers
All Relevant Protocols: OPC UA, umati, MTConnect, MQTT
All Relevant Platforms: ADAMOS, MindSphere, FANUC Field, and more
Industrial IT Security: Managed by DMG MORI
DMG MORI Monitoring: MDA with the DMG MORI Messenger
Integration: In the customer’s shop floor environment by DMG MORI Digital
DMG MORI MESSENGER at EMO with the CELOS Update
We are offering the latest CELOS functionality for DMG MORI machines as well as third-party machines on the shop floor networked using DMG MORI Connectivity. Customer feedback has significantly influenced the development of the DMG MORI MESSENGER, which now enables simple machine data acquisition and provides an open database for third-party software. Reports can be generated automatically and displayed clearly on a page. The dashboard of the MESSENGER can be customized, allowing customers to see all relevant information about machine statuses at a glance.
myDMG MORI – Customer Portal
In combination with NETservice, myDMG MORI offers comprehensive transparency across all service processes and procedures. While myDMG MORI is designed for DMG MORI machines, we also offer integration for third-party products via WERKBLiQ, which allows for seamless service management for all machines in the facility.
ADAMOS in the Digital Strategy of DMG MORI
The basic idea behind ADAMOS is to offer mechanical engineering solutions for mechanical engineering, its suppliers, and customers. The partner network of ADAMOS is continuously expanding, with 16 well-known companies now working together. The strong network of certified enabling partners supports the implementation of digital applications. ADAMOS facilitates the exchange of information in the partner network, and we firmly believe that the challenges of digitization can only be tackled together.
Horizontal Integration with ADAMOS
At EMO, ADAMOS will present its range of applications for the digital customer experience via the ADAMOS APP Store for the first time. Machine operators are looking for simple, universal solutions that are independent of manufacturers. ADAMOS offers the necessary tools, technologies, and services for this purpose, including the ADAMOS-OEE app, integration with WERKBLiQ, and many other solutions.
Device Management and Integration
ADAMOS provides the relevant technology for rapid development of applications with its IoT platform. DMG MORI uses Device Management from ADAMOS to connect all machines, systems, and devices to the IoT platform. With this technology, DMG MORI is able to manage more than 60 scheduled maintenance orders per day at FAMOT. More than 50 DMG MORI machines at FAMOT benefit from this connectivity.
Strategy for Developing Digital Products
We start by using our digital products internally, learning from users, gathering feedback, and refining the products before releasing them to the market as proven solutions. For example, customers can experience the digital maturity of our products by visiting our digital factory at FAMOT, where 700 employees work simultaneously across 18 workstations, operating over 50 machines and managing up to 11,000 orders.
The ADAMOS APP Store
The ADAMOS APP Store provides easy access to integrated software applications from machine builders and third-party vendors. It plays a crucial role in offering flexible, manufacturer-independent solutions for the digital factory.
DMG MORI continues to invest in digitization, develop products focused on customer benefits, and collaborate with new startups when appropriate. This approach helps us shape the future of manufacturing technology together with our customers.
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YOUR ONLINE SERVICE MANAGER
The effects of industrial digitization go far beyond technological aspects. Dr. Thomas Froitzheim, Managing Director of DMG MORI Global Service GmbH, understands the strategic importance of the market leader’s latest digitization initiative and the added value it offers. With the new myDMG MORI customer portal, DMG MORI has demonstrated its commitment to efficiency, reliability, and customer-centric service.
Access to More Service and Knowledge Quickly and Easily
Efficiency and reliability of service will be enhanced through myDMG MORI. Customers can now make service requests online directly, eliminating waiting time or misunderstandings over the phone. By simply selecting the relevant machine, adding a brief description of the issue, and attaching photos or videos, the service request will be sent directly to the correct DMG MORI service expert, who will begin processing it immediately. Customers can also track the status of their requests in real-time.
Time Savings with Prepopulated Service Requests
The new service request system streamlines the process:
Machine’s historical data is automatically transferred into the service request.
The machine’s control type, warranty status, and other key details are prepopulated, saving time and reducing errors.
The service status can be checked live at any time.
More Service
No Waiting: Service requests can be submitted online without delay.
Fast Activation: A quick description of the problem is all it takes for DMG MORI to activate the service request.
Prepopulated Service Requests: Machine data, including details, photos, or videos, are automatically included, simplifying the request process.
Immediate Processing: The correct service expert will prioritize the request and begin work immediately.
More Knowledge
Complete Machine History: All events related to the machine are available, including lifecycle documentation for services performed and spare parts ordered.
Digital Documentation: All documents related to the machine, including manuals and service documents, are stored digitally and can be accessed easily.
Future Updates: The portal will be continuously updated with new features, such as the ability to book training courses online and access expert knowledge via an FAQ database.
More Availability
24/7 Access: Access myDMG MORI anytime, from anywhere.
Multi-Device Access: The portal is available on computers, smartphones, and through CELOS.
Customizable Access: Customers can control who sees what information in the portal.
WERKBLiQ – Integrated Solution for the Digital Shop Floor
Managing maintenance processes efficiently in production is more important than ever. WERKBLiQ optimizes the entire service process for all machines and equipment, offering tangible benefits. Even machines without network connections can be integrated and managed via WERKBLiQ using mobile devices. The system simplifies everyday tasks at high speed, helping customers keep service operations under control both internally and externally.
Integrated Service Management: WERKBLiQ offers transparent, efficient management of all maintenance activities and communication channels, regardless of machine manufacturer.
Quick Setup: Implementing WERKBLiQ into existing IT systems can be done quickly and with minimal effort, typically in just 48 hours.
Holistic Machine Management: DMG MORI machines, along with third-party machines and equipment, can be fully integrated and managed within WERKBLiQ.
Platform for Service and Maintenance
Seamless Integration: Once upgraded to WERKBLiQ, all DMG MORI machines are automatically transferred and integrated into the system. Maintenance processes are managed digitally and efficiently across all machines and equipment.
Interactive and Customizable: WERKBLiQ provides customizable interfaces and windows for employees to record and document their activities and processes, all with just a button press.
WERKBLi
BIERKBLIQ - The integrated service and maintenance platform. An end-to-end solution for the shop floor - from the machine to the fire extinguisher.
WERK BLiQ offers Dr. Tίm Busse our employees Managing Director
WERKBLiQ GmbH additional convenience and saves working
The networking of WERKBLiQ and DMG MOR1 Manufacturing companies no longer have hours a day.
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SERVICE Ensures a Particularly High Level of Customer Benefit
All functions available in the myDMG MORI account are also part of WERKBLiQ, ensuring a high level of customer benefit. Customization is key to adapting to flexible needs, as individual challenges require unique solutions. That’s why customer-specific configurations were integrated during the development of WERKBLiQ.
High Degree of Customization Thanks to Digital Modularity
Users can benefit from the modularity of the digital platform, allowing them to develop their own solutions. With WERKBLiQ, tasks that were once managed using paper or Excel can now be solved more efficiently and digitally. For example, employees at Romaco Kilian in Cologne save significant time as they no longer need to go back and forth to the workshop as often.
Generation of Digital Added Value for Customers
Continuous documentation and data recording on the shop floor provide full transparency throughout subsequent processes. The WERKBLiQ evaluation module makes this a reality by enabling maintenance and production managers to assess key performance indicators and implement improvements.
All DMG MORI Machines Are Already Available in WERKBLiQ
Easy Setup: WERKBLiQ can be integrated quickly, within 48 hours, into existing IT structures.
Effortless Integration: WERKBLiQ allows the management of the entire service function both internally and externally, including third-party machines and equipment.
Real-Time Documentation: All maintenance-related activities are documented and available at any time for quick reference.
Identification of Optimization Potential: The platform helps identify areas for improvement, enhancing operational efficiency.
Customizable Interface: WERKBLiQ can be adapted to the customer's corporate language for ease of use.
Customer-Focused Solutions for Greater Efficiency
Markus Kleiner, Managing Director of H.-D. Schunk GmbH, explains that the digital tools provided by WERKBLiQ enable continuous improvements in maintenance operations. These custom solutions streamline tasks and ensure that processes are optimized, all with minimal setup time and maximum efficiency.
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In Turbulent Times, DMG MORI Stands Strong
After a long period of growth, many markets are now facing uncertainty. As a global enterprise with a comprehensive portfolio of machines, DMG MORI continues to be a strong partner in all economic situations. With less risk for our customers and more trust from our side, we strengthen each other, says Markus Piber, Sales and Service Divisional Director, alongside Dr. Maurice Eschweiler, Chief Representative of DMG MORI AG, who jointly initiated the DMG MORI Economic Program.
Our Economic Highlights:
Liquidity with Buyback Option
DMG MORI's buyback program guarantees the immediate payment for used machines. This eliminates the need to consult with dealers or wait for a buyer, providing peace of mind for our customers.
Risk-Free Finance on Utilization
DMG MORI offers flexible finance options, including staggered rates and a focus on liquidity. Our customers can benefit from rate flexibility tied to machine utilization. Additionally, we provide the option to start repayments up to six months after machine commissioning, increasing liquidity during uncertain times.
Attractive Residual Value
The high residual value of our machines at the end of the finance period offers customers confidence and long-term benefits.
Reconditioning Option
For customers who wish to continue using their existing machines instead of purchasing new ones, we offer an attractive reconditioning program. Customers benefit from updates, enhancements, and reconditioning with original spare parts, ensuring optimal performance without the need for a complete system change.
Training Before Commissioning
The DMG MORI Academy guarantees operator training before machine commissioning, regardless of short delivery times. This ensures that customers can start production immediately and avoid delays in accepting orders.
All-Round Carefree Package with Full Service
The 3-Year All-Round Carefree Package provides complete service coverage. It includes a flat rate for spare parts and service calls, Allianz insurance for crashes and breakdowns, and annual maintenance, providing our customers with total planning security and no unexpected costs.
DMG MORI's Financial Flexibility:
The DMG MORI Economic Program offers a variety of financial solutions designed to meet our customers' needs, especially in challenging economic times. Our solutions are carefully constructed to provide comprehensive support, including:
Flexibility in Contracts: Offering start-up finance for recent businesses and flexible contract adjustments for existing customers.
Sale-and-Leaseback Transactions: An option to generate additional cash flow through the sale of equipment and its leaseback.
Accuracy and Performance:
Calibration and Optimization
DMG MORI provides advanced solutions to optimize machine accuracy over its entire life cycle. Our VC5 Complete Calibration ensures precision, with a comparison of accuracy deviation over time. The results show a significant improvement in machine performance with VC5 Calibration, enhancing reliability and efficiency.
Join DMG MORI in Achieving Long-Term Success
Whether it’s financing, training, reconditioning, or maximizing machine performance, DMG MORI is committed to delivering tailored solutions that help customers navigate uncertain times with confidence.
DMC 75 DMC 95 monoBLOCK
Travels X/Y/Z m m
Palet size mm 500 x 500 630 x 630
Maximum load kg 500 800
Maximum load 1c ane loading kg 600 ,
Workpiece dimensions mm
CUSTOMER STORY - KAMPF SCHNLID- UND W1CKllTECHNIK GMBH 00. KG
With DMG MORI PLANNING and WERKBLiQ and more recentfy with CELOS
and my DMG MORI we have taken a great step forward in the direction of the digital factory.
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Customer Story: KAMPF Schneid- und Wickeltechnik GmbH & Co. KG
Partner for the Digital Factory
Since 2015, KAMPF Schneid- und Wickeltechnik GmbH & Co. KG has rapidly accelerated its digital transformation. Initially focusing on its products and services, the company is now equipping its production plants for Industry 4.0. In 2017, KAMPF entered into an innovation partnership with DMG MORI, marking the beginning of an exciting journey into the next era of digital manufacturing.
Digital Integration at KAMPF:
At the KAMPF production site in Dohr, the integration of DMG MORI's PLANNING SOLUTIONS has been a game-changer. For several months now, these solutions have enabled KAMPF to improve efficiency and flexibility. Through CELOS, operators of the new CTV 250 can access WERKBLiQ and the customer portal myDMG MORI directly. This direct connection allows for real-time feedback of order information sent to planning solutions and supports smooth production operations.
Dr. Stephan Witt, Head of Engineering Material Management at KAMPF, emphasizes the significant improvements: "With a 30% reduction in throughput times, we can respond much faster to customer needs," he says. This has empowered the company to improve operational workflows and meet customer demands more quickly.
Advanced Planning and Production Control:
Planning Solutions plays a crucial role in this transformation. The system offers real-time data and feedback from machines and workstations, supporting detailed planning based on accurate production data. The Production Cockpit visually displays real-time information from 19 machines and 10 workstations, helping planners identify potential delivery delays early and take corrective action.
With CELOS, KAMPF has entered a new stage of digital production. The CTV 250 vertical turning center from DMG MORI is fully integrated into this digital ecosystem, enabling real-time capacity management. Marc Jobelius, Plant Manager in Dohr, highlights the flexibility this integration offers: "We can now prioritize and adjust process steps dynamically during production, ensuring our operations stay aligned with actual resource capacity," he explains.
Thanks to Job Import, operators can directly import job orders from PRODUCTION PLANNING into the CELOS system, starting production seamlessly. The integration of new PDA information into the CELOS system further enhances this digital workflow, providing KAMPF with a wide range of options for continuous digital optimization.
Future of Digitalization at KAMPF:
This integration marks just the beginning of KAMPF's journey toward an even more connected and data-driven manufacturing process. By using CELOS, KAMPF plans to continuously improve its planning processes, relying on real-time data from the shop floor to drive better decision-making and predictions.
The system's closed data loop will enable KAMPF to use real-time data to optimize planning, replacing the need for rule-of-thumb estimations. With the addition of machine learning algorithms, KAMPF will soon be able to calculate and predict previously unknown work steps, leading to more precise and efficient operations.
KAMPF Schneid- und Wickeltechnik GmbH & Co. KG – Company Facts:
Founded: 1920 by Erwin Kampf in Wiehl
Employees: 600+
Export Ratio: 90%
Global Presence: Subsidiaries in the USA, China, and India, plus international service and sales offices
Industry Leadership: World market leader for slitting and winding machines for plastic and aluminum foils and composite materials
CTV 250 Key Features:
Maximum Flexibility: Workpieces up to Ø350 x 200 mm, with 180 mm Y-axis
Productivity: 8-second loading and unloading time with twin-track automation
Precision: Equipped with MAGNESCALE linear encoders for all three orthogonal axes
Performance: The most powerful turret in its class with 12 driven tools, up to 85 Nm torque, and 12,000 rpm
Conclusion: KAMPF's collaboration with DMG MORI has significantly advanced its digital transformation, optimizing its operations through enhanced flexibility, real-time data integration, and predictive planning. The company continues to push forward with innovative solutions, ensuring its leadership in the slitting and winding machine market.
DMG MORI
The 11,000 MASTER spindles whićh leave the factory every year are confirmation of customer satisfaction with the DMG MORI spindte service.
FAIR PRlCE GUARANTEE FOR THE QUICKEST SPINDLE REPAIR
HIGHLIGHTS
PROTECTION CONTROL
+ Vibration monitoring in the process
No-one knows the + Switch-off function with teach function heart of the machine + NEW: Torque monitoring as we as its manu- + NEW: Recommended with Protectíon facturer. We under- Package for CTX TC machines take repairs at the + Milling spindle bearing condition diagnosis fairest possibfe price.
Dr. Christian Hoffart
Managing Director
Moгe ínłormatíon about DMG MORI spare Paris GmbH the technotogy cycles at
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Customer Story: SPN Schwaben Präzision Fritz Hopf GmbH
DMG MORI GearSK1V1NG for Complete Machining of Gears
SPN Schwaben Präzision Fritz Hopf GmbH began its journey in 1919 as a mechanical workshop for gear production in Glashütte, Saxony. Today, the company has over 300 employees, providing customized drive solutions for industries such as energy, textiles, mechanical engineering, and increasingly for aerospace. The company's focus is on producing high-precision gears, robot grippers, drive spindles, and planetary gearboxes.
The Digital Transformation at SPN Schwaben Präzision:
In 2015, SPN Schwaben Präzision purchased its first DMG MORI machines, marking the start of its collaboration with the technology leader. One of the key reasons for choosing DMG MORI was the uniform user interface provided by CELOS, which made it easier for employees to operate multiple machines. As Stefan Ohmüller, responsible for production technologies at SPN Schwaben Präzision, explains: "This simplified operation means a machinist from the milling section can easily produce complex parts like robot grippers or ring gears on the CTX beta 1250 TC 4A."
Complete Gear Machining with GearSK1V1NG Technology Cycles:
For Rainer Hertle, Technical Managing Director of SPN Schwaben Präzision, gear cutting is essential for producing reliable drive solutions. The company uses a variety of machines, including special gear cutting machines, but since 2017, the team has also turned to the CTX beta 1250 TC 4A to handle capacity bottlenecks. "With the help of DMG MORI's technology cycles such as GearSK1V1NG and GearMILL, we can quickly cut gears to high accuracy, even on short notice," says Stefan Ohmüller.
The CTX beta 1250 TC 4A is equipped with a 20,000 rpm compactMASTER turn-mill spindle, ensuring the highest performance for milling operations. Additionally, this machine allows for complete gear processing in a single set-up, optimizing both time and resources.
DMG MORI's Exclusive Gear Technology Cycles:
GearSK1V1NG: For turning and milling straight and helical external or internal spur gears and splines, including herringbone gears with tooth offset.
GearMILL: Provides precision milling with enhanced features such as gear tooth crowning using mathematical transformation of the virtual axis on TC machines.
These technologies enable SPN Schwaben Präzision to achieve maximum milling performance while ensuring the highest levels of accuracy, essential for producing mission-critical parts like gears for landing flaps or undercarriage components.
Investing in the Future:
In 2018, SPN Schwaben Präzision expanded its milling capacity with the addition of an NHX 4000 horizontal machining center from DMG MORI. This decision was influenced by CELOS, which offered a user-friendly app-based interface, and the machine's high productivity in both single-part and small-batch production. "We were impressed by the NHX 4000's efficiency and productivity," says Stefan Ohmüller.
The latest addition to their fleet is a CLX 450, intended for training purposes. This machine allows SPN Schwaben Präzision to introduce its trainees to modern machine tool technology early in their careers, ensuring that they are prepared for real-world production challenges. The CLX 450 offers a 426 Nm spindle drive with 4,000 rpm and a Y-axis, making it an ideal choice for versatile and production-oriented training.
SPN Schwaben Präzision Fritz Hopf GmbH – Company Facts:
Founded: 1919 in Glashütte
Employees: 300+ at the headquarters in Nördlingen
Industries Served: Energy, textile, mechanical engineering, and aerospace
Core Competence: Development and production of customized drive solutions, including gears, robot grippers, drive spindles, and planetary gearboxes
Customer Benefits:
Internal Teeth: Capability to produce internal gears without the need for an angle head.
Synchronization and Tool Path: Precision-controlled by cycles for highly accurate results.
Complete Gear Machining: Enabled by advanced turn-mill technology cycles from DMG MORI.
Looking to the Future:
On the anniversary of SPN Schwaben Präzision, Rainer Hertle reflects on the future: "With our SPN goes digital strategy, we are addressing the challenges of digitization. We plan to digitalize and automate our processes from customer acquisition to production and logistics, as far as possible."
The collaboration with DMG MORI continues to support SPN Schwaben Präzision in achieving its goals, ensuring that the company remains at the cutting edge of gear manufacturing technology.
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Faster Payback with the Right Approach
Imagine reducing your machine investment payback time by up to one year. With the right setup from the beginning and optimal tooling, this can be a reality. At Sandvik Coromant, we understand that collaboration is key to successful manufacturing. We work with you from start to part, ensuring that your new machine delivers its full potential. Together, we can help you pay off your machine investment faster.
Grinding Technology Integration by DMG MORI
Grinding on Turning and Milling Machines: DMG MORI offers integrated grinding technology cycles that ensure high precision in grinding operations, whether on turning or milling machines. Key features include:
Acoustic Sensing: Enables dressing and grinding without air cuts.
Conversational Grinding Cycles: Available for internal, external, and surface grinding, as well as face grinding on milling machines.
Surface and Shape Quality: Achieve Ra up to 0.2 μm and roundness up to 1 μm for grinding on turning machines, and Ra up to 0.5 μm and roundness up to 5 μm for grinding on milling machines.
Coolant Systems: Integrated centrifugal filters for particles smaller than 5 μm, ensuring a clean and efficient process.
Grinding Wheels: Partnered with TYROLIT for the best grinding wheels.
In-Process Gauging: Achieve a repeatability of 5 μm during grinding for high-quality results.
Grinding Options for Various Machines:
CTX TC and NTX Machines: Truíng and machining cycles for straight, angled, or cup wheels.
Grinding of Eccentric and Polygon P4H: Advanced grinding capabilities for complex geometries.
Automation with WH FLEX
Modular Automation Solutions for Flexible Manufacturing:
WH FLEX is a scalable, modular system designed for automated handling of workpieces and pallets. With the ability to integrate up to 9 DMG MORI machines, WH FLEX ensures:
Flexible Automation: For various workpiece weights (up to 500 kg) and production series sizes.
User-Friendly Interface: Intuitive job management for efficient planning, control, and monitoring.
Scalable Efficiency: Expand automation with various peripheral options such as passive checking stations, active gripping/turn-over stations, and more.
Key Features:
Automation Integration: Works seamlessly with machines and alternative technologies.
Digital Twin Development: Offers planning security and investment protection.
Cell Controller: For maximum safety and perfect system integration.
Gripper Systems:
Electric and Pneumatic Grippers: For workpieces up to 7 kg.
KUKA and FANUC Robots: Optional robotic solutions for higher weight handling, including grippers for workpieces up to 300 kg.
Expansion Options:
Storage Solutions: Including rotary racks, shelves for forklift use, and storage towers for proprietary pallets.
Additional Functions: Modular expansion options like laser marking, deburring stations, and scanners for component detection.
WH FLEX Concept for Maximum Flexibility
The WH FLEX concept offers unmatched flexibility and scalability for automatic handling of workpieces and pallets. The system's modular design allows it to evolve with your needs, integrating various machines and technologies. Whether you need a rotary setup station for efficient production or a scanner for component detection, WH FLEX adapts to your requirements, ensuring seamless automation.
Markus Rehm, Managing Director of DECKEL MAHO Seebach GmbH and DMG MORI HEITEC GmbH, sums up the flexibility of WH FLEX: "No matter what our customers want to do, we go along with it."
Here's a concise version of your content that captures the key points about automated turning, milling, deburring, and the WH Flex system, with a focus on flexibility, digital twin technology, and system integration:
Automated Turning, Milling, and More: The WH Flex Solution
A Unique Modular Solution: The WH Flex concept provides a unique, flexible approach to automation, integrating up to 9 machines in a system for seamless production. It allows for automated turning, milling, deburring, washing, drying, and quality checking of workpieces and pallets in mixed operations. As Markus Rehm, Managing Director of DECKEL MAHO Seebach GmbH and DMG MORI HEITEC GmbH, highlights, the system adapts to your needs, from raw materials and pallets to finished parts, with minimal manual intervention.
Key Features and Benefits of the WH Flex System
Modular Building Block Concept: Flexible design for easy scalability, capable of handling up to 9 machines. It allows for customized configurations based on your specific needs.
Simultaneous 5-Axis Milling: Capable of executing complex tasks, ensuring efficient and precise complete machining in a single setup.
Digital Twin Technology: Virtualized machine setups through the digital twin reduce engineering costs, enhance system quality, and save up to 80% of commissioning time by simulating all processes in real-time.
Automation and Control: The system includes an intuitive user interface, enabling easy operation without the need for specialized training. It ensures real-time simulation of all processes and seamless integration of machine controls and automation.
Up to 80% Faster Commissioning: Thanks to real-time simulation and virtual optimization, the system is ready for use much faster, improving efficiency from day one.
Flexible Workpiece and Pallet Handling
The WH Flex system integrates various gripper change systems, cleaning stations, laser marking, measuring and testing stations, and more. It adapts to the needs of small and medium-sized enterprises, allowing customers to grow with the system. The modular design and grid programming ensure high productivity, flexibility, and precise handling of different workpieces.
System Integration and Connectivity
The system’s end-to-end connectivity allows for the virtual integration of machines and processes. The CELL CONTROLLER ensures smooth operation with intuitive job management, providing a seamless connection between automation systems and machines.
Example Configurations:
DMP 70 + DMU 40 eVo with rotary racks, SPC drawers, and cleaning stations.
DMU 60 eVo + CMX 800 V with KUKA robot KR 300, rotary setup station, and laser marking units.
The Future of Manufacturing:
The WH Flex is not just about automation; it’s a future-proof solution for flexible, high-precision manufacturing. The Digital Twin and modular building blocks allow companies to enter the world of flexible automation with ease, ensuring long-term reliability and investment security.
Here's a refined summary of the key highlights regarding DMG MORI's Digital Twin technology, its integration with products like the DMU 340 Gantry, and the benefits for manufacturers:
DMG MORI Digital Twin Technology
The Digital Twin Concept: The Digital Twin is an evolving technology that creates a virtual representation of a physical machine, enabling manufacturers to simulate, analyze, and optimize production processes before real-world execution. This virtual counterpart reflects the machine's dynamic behavior, powered by sensors that capture real-time data and are integrated with the PLC and CNC systems.
Key Features of the Digital Twin with DMG MORI Systems:
DMU 340 Gantry:
Outstanding Surface Quality: Achieves surface finishes down to Ra 0.3μm thanks to its double pinion rack and linear drives in the X- and Y-axes.
Dynamic Positioning: C-axis positioning up to 40 rpm, offering high precision for 5-axis simultaneous machining.
Modular Tool Magazine: Accommodates up to 453 tools, with chip-to-chip times under 15 seconds for fast tool changes.
Inherent Rigidity: The machine bed made of GGG 60 cast iron ensures maximum rigidity and effective damping, ideal for high-performance milling.
Digital Twin Benefits:
Iterative Improvement: The Digital Twin technology evolves through iterative simulations, gathering knowledge that improves machine behavior and process efficiency with every cycle.
Predictive Maintenance: With accurate data simulations, future machine performance and maintenance needs can be anticipated, drastically reducing downtime.
Faster Commissioning: Virtual simulations allow for quicker setup and installation, reducing the time spent on commissioning and improving customer satisfaction.
Advantages for SMEs and Manufacturers:
Virtual Testing: SMEs can test new workpiece or pallet setups virtually, while production continues running, optimizing time and resource management.
Reduced Investment Risk: Virtual simulations give manufacturers confidence in their decisions, ensuring investment security and providing a clearer view of potential returns.
Customer-Centric Applications: The Digital Twin allows for virtual assembly, NC program generation, and workholding solution testing, giving customers a comprehensive understanding of their production capabilities before physical implementation.
Future of the Digital Process Twin:
The Digital Process Twin connects the design, development, and customer needs in a continuous loop. By combining data from machine operations with CAD models, it helps manufacturers anticipate future challenges, enhance process efficiency, and ensure products meet quality standards with minimal trial and error.
On-Demand Services: Digital Twins support the On Demand economy, allowing manufacturers to create accurate quotes, simulate processes, and optimize workflow instantly.
From Simulation to Reality:
DMG MORI's goal is to move beyond simple machine simulation to creating a holistic digital factory, where the entire production process can be analyzed, improved, and tested virtually. This leads to faster commissioning times and the ability to provide accurate, on-demand, and customized production services.
Conclusion:
DMG MORI’s Digital Twin and Digital Process Twin technologies revolutionize manufacturing by improving product quality, reducing commissioning time, and providing manufacturers with powerful tools for predictive maintenance and process optimization. With real-time simulations, predictive analytics, and virtual testing, manufacturers can ensure high efficiency, investment security, and fast adaptation to market changes.
To what extent can the customer benefit from the subsequent use of the DMG MORI DIGITAL TWIN?
It wilt soon be possíble to make the processes in the real machine more transparent, easier to interpret and more and more predictable through the continuous acquisition of real data and linking it directly to thé DMG MORI DigitalTwinś .
The added value of the digital twins will increase with the witlingness of customers to enter into a collaborative allíance to share the data as the basis forjoint analyses.
Our goal for the near future is therefore to imptement the DMG MORI
Digital Twin together with our customers over the entire tifecycle.
New knowledge, added value and ultimately growth potential can only be realized by in-depth quality data from our machines and transparent insights into customer processes in combination with modern analytics.
Alfred Geifller
Managing Dïrector
DECKEL MAHO Pfronten GmbH
DMG MORI TECHNoLoGY EXCELLENLE 35
DMG MORI PALLET A6V 60
WITH DRIVERLESS
TECHNOLOGY
Here is a refined summary of DMG MORI's Automation Solutions with a focus on material flow, driverless transport systems, and modular kits like the PH-AGV 50, as well as FAMOT’s XXL automation for large components:
DMG MORI Automation of Material Flow
Material Flow Automation is becoming an increasingly important element of integrated production systems, particularly in digitalized manufacturing. DMG MORI’s modular automation kits are designed to enhance material handling and logistics, improving productivity and flexibility in production processes.
PH-AGV 50 – Automated Guided Vehicle (AGV) System
Flexible Automation: The PH-AGV 50 offers a flexible and configurable solution for automated material flow. It uses driverless transport systems (AGVs) to streamline material handling and reduce dependency on manual labor.
Modular Kit: This product includes a modular kit for individual configuration, allowing manufacturers to tailor the system to their needs.
MCC-LPS Control: The AGV system comes with DMG MORI’s proprietary MCC-LPS control computer for smooth, efficient control of operations.
Pallet Handling: Capable of handling standard machine pallets, zero-point clamping pallets, and material pallets with short pallet change times due to the inclusion of 2-way intermediate storage stations.
No Guide Rails: The AGV system operates without the need for guide rails, allowing machines to remain freely accessible.
Key Benefits:
Free Access to Machines: The AGV system ensures that machines are always accessible for operators, allowing for efficient workflows.
Maximum Safety: The AGV is equipped with laser scanners to ensure safe and precise navigation within the production environment.
Simple Integration: The modular nature of the system allows for easy extension and integration into existing production layouts, ensuring scalability as the needs of the factory evolve.
FAMOT Plant – XXL Automation for Large Components
At DMG MORI’s FAMOT Plant in Pleszew, Poland, a new production facility was designed for the high-precision machining of large components up to 6 tons. The plant is a showcase for digital production, automation excellence, and integrated logistics.
Linear Pallet Pool (LPP) System for XXL Automation:
The core of the FAMOT Plant’s automation is the LPP 160 system, which links three DMC 210 U duoBLOCK machines via a highly flexible pallet system.
Large Workpiece Capacity: The system accommodates workpieces up to ø2,100 mm and 1,400 mm high, making it ideal for large, high-precision components.
Optimized Setup: The integration of two rotary setup stations reduces setup times and increases ergonomic efficiency for operators.
High Transport Capacity: The LPP system supports up to 8 tons of transport capacity, ensuring smooth handling of large workpieces.
Benefits of XXL Automation in Production:
Flexible and Cost-Effective: The LPP system is highly flexible and can be expanded to accommodate additional machines, pallets, and setup stations, enabling cost-effective machining of large components.
Improved Efficiency: The ability to automate the handling and storage of large components has led to optimized utilization of machines, increasing overall capacity and reducing operator workload, especially during off-hours or weekends.
Reduced Staffing Requirements: With automated material handling, production can run partially unattended, reducing the need for staffing during off-peak hours.
Intuitive Central Control (MCC-LPS 4):
Efficient Pallet Control: The MCC-LPS 4 is the heart of the LPP system, offering an intuitive control system for efficient pallet management.
Tool Management: Integrated tool management displays provide visibility into the tools in use, ensuring seamless integration with production planning.
Material Stock Overview: The system provides a complete overview of raw materials, finished parts, and fixtures, helping managers track production progress and maintain material availability.
Conclusion:
DMG MORI continues to lead in the integration of digital solutions and automation to enhance productivity and flexibility in manufacturing. The PH-AGV 50 and LPP 160 systems showcase the company’s commitment to improving material flow and production efficiency. With these solutions, manufacturers can optimize the handling of components, reduce setup times, increase automation in their factories, and improve flexibility across production lines. Additionally, FAMOT’s XXL automation for large components exemplifies the company's dedication to providing customized, scalable solutions for the most demanding production environments.
DMG MORI TECHNOLOGY EXCELLENCE
JUST IN TIME WITH FLEXIBLE AUTOMATION FROM A BATCH SIZE OF 1
When you enter the modern buíldings and factory workshops of the Zímmer Group ít is
diffícult to imagine that the story of the corporate group began in a converted cow shed
in Rheínau in 1980. At that time the brothers Günther and Martin Zimmer developed theír
first products for automation and handling.
Today the Zímmer Group owns over 980 patents and employs 1,260 people at two productíon plants in Germany and ít has sales centers worldwide. Consístent process optimization has been undertaken ín production, where 85 machine tools from DMG MORI are in operation: eíght DMC 60 H machines with three flexíble production systems for up to 60 pallets have been installed sínce 2016.
AUTONOMOUS PRODUCTION WITH UP TO 60 PALLET POSITI0NS
With ever more new products and countless patents the Zimmer Group is one of the
leading manufacturers in its sector. Günther Zimmer has noticed a change in recent years:
Development cycles are getting shorter and shorter. This has led to an expansion of both
the product portfolio and range of services of the Zimmer Group. Customers see the group ãs a technology parłner that offers complete system solutions as turnkey projects.
Just in Time productíon - 3 production systems with up to 60 pallet posítíons
High competitive pressure and demands on quality call for a leading edge approach in
production. That is why the Zimmer group has worked together with DMG MOR1 since
Programmíng of indívídual orders takes ptace 2016 co install three large production systems oп a PC in the office: production assistants coad the manufacturing cetls via loading stations. in the handling technology division. Fastems,
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CUSTOMER STORY - ZIMMER GROUP
The Zimmer Group, a DMG MORI partner, is grateful to the flexible qualified products supplied by the FMS-ONE 24/7 production system, which includes eight automated machines with two loading stations to provide pallet storage for each system. The machines can operate for seven days in a row with batch sizes ranging from one to several hundred workpieces. In other words, the machines can run unmanned shifts overnight or on weekends. All three systems are based on the DMC 60 H horizontal machining centers with swiveling rotary tables for 5-axis simultaneous machining with ball screw drives. The diversity and precision of these machines make them the ideal choice for automatic production.
Klaus Seifried recalls: "The DMC 60 H machines are capable of machining complex workpieces from aluminum and steel reliably even down to hundredths of a millimeter."
Günther Zimmer is thinking long-term with such investments: "We have to keep the overall picture in mind and ensure that we remain competitive in the future as well." This is also true for their latest acquisition. DMG MORI will acquire another automated production center with 60 pallet positions by the end of the year. This will consist of two DMC 60 H machines and a DMC 60 FD duoBLOCK for even more complex workpieces. The pallet storage system will once again be supplied by DMG MORI partner Fastems.
The three machines in the first system can machine every workpiece flexibly. "This makes us more flexible, more productive, and improves our delivery capability," says Klaus Seifried. Each DMC 60 H has 180 tool pockets, and the pallet store has 40 positions. The pallet rack of the second system is one level higher, with a total of 60 pallet positions. The three DMC 60 H machines have a 5-wheel magazine for 303 tools in an extremely compact footprint. "We have a different approach where this system is concerned: Two machines produce aluminum parts, while the third is responsible for steel machining," explains Klaus Seifried. The wheel magazine also enables setup while machining is in progress.
The system installed in 2018 includes two DMC 60 H machines with the same equipment, which can machine all workpieces.
The largest of the automation systems installed to date includes three DMC 60 H machines, each with a 5-wheel magazine for 303 tools.
ZIMMER GROUP FACTS
Founded in 1980
Two production plants in Germany with 1,260 employees
Over 5,000 different products for the automation and handling technology sectors
WORLD PREMIERE - CLX 750
The CLX 750 is a new, heavy-duty turning machine for workpieces weighing up to 600 kg.
Highlights:
Workpieces with a diameter of up to 700 mm and up to 1,290 mm long
Max. diameter 640 mm in conjunction with the Y-axis
2,000 Nm main spindle with 46 kW
Hollow clamping part diameter 127 mm
12-position VDI 50 turret
Steady rest for workpieces up to a diameter of 430 mm
80 mm Y-axis for off-center machining
Counter spindle with 4,000 rpm and 360 Nm
Wide range of exclusive DMG MORI technology cycles
DMG MORI IoT connector as standard
3D control technology on a 19-inch touch panel, optionally with Siemens or Fanuc
CLX RANGE
Perfect solutions:
GX Loader for fast cycle times or Robo2Go
Standard automation for maximum flexibility
Robot or bar loader for automation of production processes
Bar loader draw tube internal diameter options:
CLX 350: Ø65 mm
CLX 450: Ø80 mm
CLX 550: Ø80 mm (Ø102 mm optional)
CLX 750: Ø127 mm (optional)
Robo2Go for all CLX machines with Siemens or Fanuc:
Workpieces up to Ø170 mm
Load capacity of 10/20/35 kg
Robo2Go VISION
Your universal production assistant with the convenience of vision
Highlights:
Quick loading and removal of raw and finished parts using a lift truck
No restacking required due to the use of standard pallets and trolleys
No specific trays required
Quicker setup thanks to larger workpiece capacity
Handling of chuck components Ø25-175 mm
30-camera detection of workpieces
MODULARITY - THE POWERFUL CLX MODEL SERIES FROM DMG MORI
Turning diameter range (mm):
CLX 350: Ø168
CLX 450: Ø320
CLX 550: Ø426
CLX 750: Ø700
Turning length (mm):
CLX 350: 530
CLX 450: 800
CLX 550: 1,225
CLX 750: 1,290
IN-HOUSE PRODUCTION
The CLX and CMX machines are attractively priced, allowing MS Ultraschall Technologie GmbH to manufacture more than 90% of its products in-house. Founded in 1965, MS Ultraschall specializes in ultrasonic technology for welding plastics and textiles in industries such as automotive, textile, and medical technology.
MS Ultraschall Technologie has been using various DMG MORI machines, including CMX 50 U, CMX 70 U, and CLX 450 machines, since 2018. These machines are particularly well-suited for the company's need to produce high-quality surfaces and handle complex workpieces. The CLX 450, for example, is ideal for turning-milling operations.
Sascha Medenica, Production Manager at MS Ultraschall Technologie, explains, "Manufacturing our products ourselves gives us better control over quality and allows us to work more flexibly to meet deadlines." The company also produces complex workpieces with the help of CMX U machines, which offer high dynamic spindle drive, up to 426 Nm torque, and a maximum speed of up to 4,000 rpm.
MS ULTRASCHALL TECHNOLOGIE FACTS
Founded in Spaichingen in 1965
400 employees
Develops and manufactures machines for ultrasonic welding
Customers from the automotive, textile, and medical technology industries
CUSTOMER STORY - MS ULTRASCHALL TECHNOLOGIE GMBH
Complex workpieces are an integral part of MS Ultraschall Technologie's product range. The company uses CMX 50 U and CMX 70 U machines to handle these pieces. The CMX U machines are versatile all-rounders, with a swivel range of -10 to 95 degrees and a table that can handle heavy components weighing up to 350 kg.
The rigid design and roller guideways ensure maximum rigidity and stable machining, while the linear scales guarantee high precision. The 5-axis CMX U machines are designed for 6-sided complete machining, which is critical to MS Ultraschall's operations.
The accessibility of the CMX U machines, particularly the tool magazine, makes setup during machining possible. The 19-inch multi-touch screen enables intuitive and user-friendly operation. Additionally, all CMX U machines come equipped with the DMG MORI IoT connector as standard, ensuring greater connectivity and productivity.
MS ULTRASCHALL TECHNOLOGIE GMBH FACTS
Founded in Spaichingen, Germany
Employees: 400
Works in ultrasonic welding for industries like automotive, medical, and textile technologies
Here's the corrected version with the mistakes fixed, without dashes, numbers, points, and in English:
DMG MORI TECHNOLOGY EXCELLENCE 45
CMX V1 CMX U AUTOMATION
NEW: InlineMASTER SPINDLE FOR THE CMX V AND CMX U WITH 36-MONTH WARRANTY
HIGHLIGHTS
Proven DMG MORI quality with MASTER spindles
12,000 rpm inlineMASTER spindle with 83Nm and 13kW (optional)
15,000 rpm inlineMASTER spindle with 121 Nm and 20kW (optional)
36-month warranty on all MASTER spindles with unlimited spindle hours
Direct delivery from EMO 2019 onwards
PH 150 PALLET HANDLING PH 150
OPERATION DIRECTLY FROM THE MACHINE CONTROL
HIGHLIGHTS
Available for all CMX V and CMX U machines
Operation directly via the machine control, no additional external control for automation
Max. load capacity 150 kg
One handling unit for all pallet sizes:
10 pallets 320 x 320 mm
6 pallets 400 x 400 mm
4 pallets 500 x 500 mm
EROWA workholding system as standard, optionally SCHUNK
Maximum clamping force of up to 112 kN with turbo function and SCHUNK VERO-S chuck
Reduced downtime
Highly repeatable clamping accuracy of the pallets with EROWA UPC-P chuck
INLINE MASTER SPINDLE
Better cutting performance due to 53% higher spindle power and 45% higher torque with the 15,000 rpm inlineMASTER 20 kW, 121 Nm at 40 DC
25% faster spindle speed for improved surface quality
BIG PLUS interface for longer tool service life: Elimination of Z-axis movement at high rotational speeds due to face contact
Oil/air lubrication of the spindle bearing and improved ribbed structure for long service life
Liquid cooling for optimum thermal stability
WH CELL MODULAR WORKPIECE AUTOMATION FOR THE CMX V AND CMX U
HIGHLIGHTS
Modular automation system for workpieces up to 15 kg
Recirculating or drawer workpiece storage: max. workpiece size of up to 300 x 300 x 220 mm, max. load capacity of 250 kg
KUKA industrial robot with different gripper variants from SCHUNK: Single or double gripper including customer-specific gripper jaws
Expansion options: SPC drawer, NOK chute, blow-off station, turnover unit, and much more
Availability:
CMX 600 V, CMX 800 V, CMX 770 V, CMX 50 U, CMX 70 U
EXCLUSIVE TECHNOLOGY CYCLE
TURNING AND TURN MILL
30 quickSET TURNING
Measurement and correction of the position of turning and pivot axes C4/C3/B1
Sag compensation possible
Can be used in combination with standard probes from customers, recommended Renishaw, Blum
CUSTOMER BENEFIT
Reliable re-calibration of the machine before highly precise processing
Continuous documentation of machine accuracy
No rejected parts due to unknown geometric deviations
Find out more about the Technology Cycles at: techcycles.dmgmori.com
TURN MILL PORTFOLIO
CUSTOMER STORY - GE AVIO AERO
MANUFACTURING CAPACITY DOUBLED
GE Avio Aero, a subsidiary of GE Aviation, manufactures turbines for civil and military aircraft engines. These special nickel alloys are highly heat-resistant and corrosion-resistant. Mauro Canola, manufacturing engineer at the Piemont site, explains: "As they are extremely tough, they are difficult to machine, and a high level of technological expertise is required to meet the high-quality standards."
The company focuses on the production of turbine disks for CFM International's LEAP engine, a joint venture of SAFRAN Aircraft Engines and General Electric. The outer diameters of these disks range from 400 to 1,000 mm, with materials such as Inconel 718 and René 88.
To meet the demand for increased production, GE Avio Aero expanded its turbine disk production capacity. Originally producing 1,500 disks per year for SAFRAN Aircraft Engines, the company needed to increase its manufacturing capacity to 3,200 turbine disks per year.
The solution was to automate the production process using four DMU 80 FD duoBLOCKs linked to a pallet storage system, doubling the production capacity. The pallets are transferred directly from the storage system to the working area, ensuring efficient and flexible operation.
GE Avio Aero's investment in automated production is a customized solution that ensures higher production rates and improved quality control. The DMG MORI Aerospace Excellence Center played a key role in providing the right manufacturing solutions.
CUSTOMER-SPECIFIC AUTOMATION
Four automated DMU 80 FD duoBLOCKs linked to a pallet storage system.
QUALITY CONTROL
Visual inspection of a turbine disk made from Inconel 718. Setup station for the production line with the four DMU 80 FD duoBLOCKs.
GE AVIO AERO FACTS
Subsidiary of GE Aviation
Manufacturer of turbines for civil and military aircraft engines
Specializes in high-performance materials like Inconel 718 and René 88
DMG MORI TECHNOLOGY EXCELLENCE 53 ALX 1600 / 2000 / 2600
BMT turret wíth max. 12,000 гpm and max. 15,9 Nm for machiníng wíth driven tools.
ALX 2500 wíth a GX 15 gantry loader for workpíeces up to o 200 н 150 mm
ALX-COM PACT TURNING MACHINES:
AUTOMATED SERIES PRODUCTION
ALX-SERIES HIGHLIGHTS
+ 36 expansion optíons to meet all production requirements
+ 4 turníng lengths: 300, 500, 1,000 und 2,000 mm HYDRAULIC AUTOMOTIVE
distance between centres
FITTING CASING
+ turnMASTER 5píndles Direct Drive with
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DMG MORI TECHNOLOGY EXCELLENCE 51
DMC 125 FD duoBLOCK COMPLETE PRODUCTION IN A SINGLE SETUP
HIGHLIGHTS
Milling and turning in a single setup with Direct Drive table and speeds up to 500 rpm
High surface quality thanks to integrated grinding technology
Maximum component accuracy due to water-cooled axis drives
SGS: Spindle Growth Sensor for compensation of spindle growth
Fast, extremely compact rotary pallet changer in the standard version for setup during machining
PowerMASTER 1000 motor spindle with 1,000 rpm and 77 kW
5X torqueMASTER with 1,800 rpm and 52 kW
CUSTOMER STORY - GKN AEROSPACE ENGINE SYSTEMS
t. to r.: Kenneth Lööf, Technological Coordinator, Purchasing, GKN Aerospace Engine Systems; Sandra Broberg, Project Leader; and Björn Nilsson, Machine Operator.
Accounting for 39 percent of group turnover, GKN Aerospace Engine Systems is a supporting pillar of the organization, which boasts 51 production sites in 14 countries. The boom in the aerospace sector plus the fact that all leading engine manufacturers order products from GKN has put the company on a sound economic footing. Consistent investment in both the training of employees and in production technology means we can keep pace with the demanding order situation, explains Joakim Wilson, Manager Machine Maintenance Procurement at GKN Aerospace Engine Systems.
The experience they had made to date meant that Sandra Broberg, project manager at GKN Aerospace Engine Systems, and her colleagues knew exactly what was required of an alternative solution: "We needed an ergonomic solution that would be easy for all our male and female employees to use." DMG MORI worked together with GKN Aerospace Engine Systems and developed a loading station that enabled more ergonomic and easier loading and unloading.
The station has eight horizontally arranged tool pockets, and its height can be adjusted to that of the respective operator, explains Kenneth Lööf. This has created the shortest possible distance from the tool trolley to the magazine. Once all eight tools are in place, the machine automatically exchanges the tools into the rotary magazine.
SOLUTION ORIENTED DEVELOPMENT FOR A HIGH LEVEL OF USER FRIENDLINESS
Perfect ergonomics: Height-adjustable tool loading station for setting up sets of 8 tools, each weighing 30 kg, including tool identification
Automatic exchange of the tools from the loading station to the wheel magazine, especially during peak times
Joakim Wilson, well satisfied with the solution-oriented development for this special requirement, says: "We are pleased with all the effort GKN and DMG MORI put in to finding this solution. DMG MORI understood the daily work of our operators and helped us to arrange it in a more ergonomic way." This led to the development of a more ergonomic and efficient solution.
Björn Nilsson points out another positive side effect: "Loading times have been reduced by up to 75 percent."
From special solution to new option
DMG MORI recognized the added value of the loading station it had developed for GKN Aerospace Engine Systems and has now included it as an additional option, so other customers can also benefit from this solution.
GKN AEROSPACE FACTS
2,300 employees at the headquarters of GKN Aerospace Engine Systems in Trollhättan
Development and manufacture of turbines
Supplier to all leading engine manufacturers
GKN Aerospace Engine Systems
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DMG MORI TECHNOLOGY EXCELLENCE
ALX 1600 / 2000 / 2600
Storage for up to 20 pallets with a loading arm and integrated double gripper for workpieces.
Inspection station for in-process measurement during production.
Maximum weight of 75 kg per pallet, with up to Ø200 mm, 150 mm in length, and 15 kg per hand measurement.
ALX - SUCCESSOR OF THE CL SERIES, OF WHICH 10,000 HAVE BEEN INSTALLED
Temperature Concept
Integrated coolant circulation in the machine bed for enhanced thermal stability (300, 500, and 1000 versions)
Integrated oil cooling of the turning spindle and BMT turret
Accessibility and Maintenance
Ideal for automation, with direct access from the front for daily maintenance
Tank for oil lubricant and waste oil container
Chip conveyor with discharge to the right or left (optional)
EXPANSION OPTIONS WITH 4 TURNING LENGTHS
BMT-turret MC, Y, SY turnMASTER spindles with 12,000 rpm, 15 kW / 179 Nm, direct drive with 38-month warranty (unlimited hours)
| Chuck Size | Turning Length | Rotation Speed | Power/Torque |
|---|---|---|---|
| ALX 1500 | 6 | 6,000 rpm | 15 kW / 179 Nm |
| ALX 2000 | 8 | 4,500 rpm | 22 kW / 253 Nm |
| ALX 2500 | 10 | 3,500 rpm | 30 kW / 796 Nm |
| - | Counter Spindle | 7,000 rpm | 11 kW / 78 Nm |
CUSTOMER STORY - VOLKSWAGEN AG
FLEXIBILITY IN HIGH-VOLUME PRODUCTION AT VW IN WOLFSBURG
Volkswagen (VW) has closely cooperated with DMG MORI within the FAST partnership to optimize its manufacturing solutions. The FAST program aims to enhance interactions between the Volkswagen group and its suppliers.
The resulting CTV 250 DF 3rd Generation is tailored to the requirements of component production in Wolfsburg. Key development goals included further enhancement of dynamics and thermal rigidity for even higher productivity, as explained by Dr. Peter Blümel and Torsten Giessler from the Planning Department of Components Chassis Wolfsburg.
Matthias Schrader, Head of Planning Components Chassis, adds that another goal was greater flexibility of the CTV 250 DF 3rd Generation. DMG MORI was able to realize these requirements decisively.
DMG MORI Technology Cycles
For grinding and gearSK1V1NG, the product demands the highest precision and productivity in mass production. Manufacturers continuously optimize their processes to produce sophisticated workpieces efficiently. The installation of the first vertical turning machine at the VW plant, the CTV 160, in 2009 was a turning point. Short cycle times, optimum chip flow, and high precision convinced VW to add more models over the years, including the CTV 250 and CTV 250 DF. The latest purchases, six CTV 250 DF 3rd Generation machines, are now the 100th vertical turning machine in the CTV series delivered by DMG MORI to VW.
COOPERATION BETWEEN VW AND DMG MORI
The CTV 250 DF 3rd Generation is designed for machining materials in both their soft and hardened states. An optional mini turret with eight additional tool stations ensures enhanced machining possibilities.
One notable development was the energy-efficient design of the machine, which achieved up to 30% energy savings in terms of electricity and air consumption. This energy-saving feature is essential in large-volume production where machines run around the clock.
CELOS for End-to-End Integration in the Production Process
The CTV 250 DF 3rd Generation, like all high-tech machines from DMG MORI, is equipped with CELOS, enabling integration into the entire production process.
CTV 250 DF 3rd Generation HIGHLIGHTS
Turn-mill swiveling tool carrier with Direct Drive and a swivel range of ±300
Up to two milling spindles with H5K-C63-F80, 6,000 rpm, 46 Nm, 40 DC
Capto C5 holder for multiple tools with up to 4 cutting edges
Additional turret with 8 tool stations (optional)
DMG MORI Technology Cycle for gearSK1V1NG (for straight and helical gears)
Volkswagen AG FACTS
Founded in 1937
Over 650,000 employees worldwide
Headquarters in Wolfsburg with over 55,000 employees
Production in Wolfsburg includes chassis and plastics technology
Thanks to the integration of technology cycles such as gearSK1V1NG, DMG MORI achieves maximum machining capability on the CTV 250 DF.
The excerpt you've provided showcases the success stories of companies utilizing DMG MORI technology in their manufacturing processes. Below are key points from these customer stories:
RU1GU Technology Co. Ltd. (Dalian, China)
Industry: Bearing cages and steering components.
Machine Tools: RU1GU Technology uses DMG MORI's high-precision 5-axis machines, such as the DMU 50 and DMC 210 U, to produce bearing cages in various sizes.
Productivity Gains: They have increased their production capacity by 30%, with productivity further boosted by the introduction of the DMC 210 U machine.
Key Benefits: The company has realized higher precision, efficiency, and stability through DMG MORI's machinery. The collaboration with DMG MORI has helped them enhance the quality of their products and meet demanding customer needs.
Hack Formenbau GmbH (Germany)
Industry: Mould manufacturing, including multi-component and multi-cavity moulds.
Machine Tools: Hack Formenbau uses DMC 80 U duoBLOCK machines for high-precision, reliable 5-axis milling and machining of complex moulds.
Innovation Focus: The company is known for its ability to deliver large-scale multi-cavity moulds, with some producing over a million parts per year.
Customer Orientation: Hack Formenbau focuses on fast delivery with high-quality manufacturing, and their investment in DMG MORI equipment supports their commitment to meeting customer needs.
Technology Cycle: Their use of exclusive DMG MORI technology cycles, such as TURN MILL/MILLING/MILL TURN, optimizes machining processes, ensuring excellent component quality and reducing machine downtime.
Key Highlights Across Both Stories
Precision and Efficiency: Both companies emphasize the importance of high precision and operational efficiency, which is made possible by DMG MORI machines.
Automation and Flexibility: Automation features like rotary storage units for multiple pallets enhance productivity, and flexibility in production allows for meeting varied customer demands.
Long-Term Partnership: Both companies express strong satisfaction with the performance, reliability, and support from DMG MORI, positioning their machines as critical to achieving growth and meeting future production goals.
These customer stories highlight how DMG MORI's advanced technology and solutions in machine tools contribute to increased productivity, quality, and the ability to handle complex manufacturing tasks across industries like automotive, bearing production, and mould making.
The additional details you’ve shared further highlight the innovative approaches and successes of companies using DMG MORI technology in their operations, particularly in industries like mold manufacturing and machine tool production. Below are the highlights from these customer stories:
Hack Formenbau GmbH (Germany)
Industry: High-precision mold manufacturing for plastic injection molding.
Upgrades: Hack Formenbau replaced older DMC 80 U duoBLOCK machines with the latest versions to benefit from enhanced dynamics and higher performance values.
Automation: The new machines feature RS 12 rotary storage units, allowing for parallel setup and unmanned production in two shifts, increasing productivity and reducing downtime.
Key Features:
CAM Programming: Programmed directly next to the machines in a quiet room, enabling close collaboration between programmers and operators.
Reliability: DMG MORI's speedy response service ensures minimal downtime in case of issues, ensuring continuity in production.
Machine Features: DMC 90 U duoBLOCK machines are equipped with speedMASTER spindles offering high speeds (20,000 rpm) and integrated digitization, ensuring top-quality performance.
Special Capabilities: Their technical center allows customers to test molds on-site before dispatch, ensuring higher tool reliability and faster product maturity.
Schaeffler Technologies AG Co. KG (Germany)
Industry: Supplier of linear axes, rolling bearings, and guidance systems.
Innovation Focus: Schaeffler is incorporating smart technologies to enhance machine tool performance:
Schaeffler SpindleSense: Monitors spindle loads and predicts wear on the main axes, which helps protect spindles from overload and improves machine tool productivity.
Schaeffler DuraSense: Detects wear conditions in linear guidance systems, enabling automated lubrication and real-time monitoring of defects such as leaks, ensuring higher machine availability and precision.
Collaborative Projects: Schaeffler is working with DMG MORI to integrate sensor rings and digital monitoring for better spindle and linear axis management. This integration improves machine life cycle management, ensuring that equipment runs smoothly with minimal downtime.
Key Benefits:
Increased Productivity: Sensors on spindle bearings allow for optimized machine usage, increasing productivity by predicting failures and mitigating risks.
Longer Service Life: Schaeffler's advanced bearing technology, such as the VACRODUR material used in X-life spindle bearings, extends service life and ensures high performance under demanding conditions.
Key Takeaways:
Enhanced Productivity and Performance: Both Hack Formenbau and Schaeffler are leveraging DMG MORI's advanced machinery, incorporating automation, and using innovative monitoring systems to achieve higher levels of productivity, precision, and reliability.
Smart Solutions: Schaeffler's use of smart sensor technology to monitor and predict wear in spindles and guidance systems is an example of how digital solutions are transforming traditional machine tool processes to improve operational efficiency.
Collaboration and Customization: The partnership between Schaeffler and DMG MORI represents a strong collaboration, with customized machine solutions that help to maximize both machine performance and longevity.
These customer stories emphasize how DMG MORI’s machine tools are integral to industries seeking high performance, precision, and innovation. Their success in automating complex processes and ensuring high machine availability is a testament to the advanced engineering capabilities of DMG MORI equipment.
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SCHAEFFLER
AEROSPACE MECHANICAL ENGINEERING AUTOMOTIVE E-MOBILITY AUTOMOTIVE
INTEGRAL PART COOLING PLATE BATTERY BOX STRUCTURAL COMPONENT
Dimensions: 1750 x 200 x 300 mm Dimensions: 1300 x 700 x 40 mm Dimensions: 1650 x 900 x 110 mm Dimensions: 1400 x 600 x 90 mm
Material: Aluminum Material: Aluminum Material: Aluminum Material: CRP
Cycle time: 18 minutes Cycle time: 31 minutes Cycle time: 15 minutes Cycle time: 4 minutes
CUSTOMER STORY - FRITZMEIER TECHNOLOGIE
DMU 200 GANTRY - SUCCESS FROM THE WORD GO
Since its successful world premiere at EMO 2017, DMG MORI has installed 21 of the DMU 200 Gantry machines in the market. The company Fritzmeier Technologie GmbH was the first customer to have a DMU 200 Gantry commissioned. Fritzmeier Technologie GmbH develops, designs, and manufactures high-accuracy components for the automobile industry.
As Fritzmeier had already been involved in the development of the DMU 200 Gantry, the machine could be adapted directly to its production requirements. Furthermore, the excellent collaboration with Fritzmeier and the company’s experience have enabled new, useful options and additional improvements to be developed.
Highly dynamic low-gantry machine with Since the successful commissioning of the DMU 200 Gantry in June 2018, we have mainly been producing aluminum prismatic parts for the automobile industry. We have easily been able to meet all requirements for accuracy and surface quality. Due to the high machine availability of over 93%, the purchase of the DMU 200 Gantry was a very good decision. Furthermore, we are so pleased with DMG MORI’s gantry concept that we have ordered the larger DMU 340 Gantry, which will be installed by the end of 2019.
Robert Huber
Managing Director
FRITZMEIER
Fritzmeier Technologie GmbH
Die Mold: 5-axis simultaneous machining of an aluminum mold insert.
DMGMORI TECHNOLOGY EXCELLENCE 67
CUSTOMER STORY - OMCO
Using 180 DMG MORI machines - among them ten HSC 55 linear for high-speed cutting and five LASERTEC 45 Shape for surface structuring - OMCO manufactures highly precise glass molds.
HSC AND LASER STRUCTURING FOR GLASS MOLDS WITH FINE DETAILS
Since its founding in 1964, just as the industrial production of glass containers started to gain momentum, OMCO has become the leading supplier of molds for the manufacture of glass bottles. The company is a subsidiary of the Belgian BMT Group. After years of rapid growth, it now has 1,800 employees at sites in Belgium, Croatia, Romania, England, Turkey, and Slovenia. OMCO meets the high demands on machining both for turning as well as milling with around 180 DMG MORI machine tools, amongst others.
Since 2012, a total of ten HSC 55 linear and five LASERTEC 45 Shape have been used in factories in Croatia, Romania, and Turkey. OMCO achieves excellent surface quality with high-speed cutting, which significantly reduces the amount of manual post-processing required.
From design of the mold up to the finished product, OMCO realizes efficient manufacturing processes with an extremely diverse range of machines. Amongst others, DMG MORI has supplied turning machines from the NRX series, milling-turning centers, and LASERTEC Shape machines for laser engraving. The array of machines also includes the HSC 55 linear for high-speed cutting. The HSC 55 linear is intended to further optimize our processes when it comes to machining speed and precision, explains Darko Ranogajec. Linear drives enable dynamic acceleration of up to 2G and rapid traverses of maximum 90 m/min. The 40,000 rpm HSC spindle ensures the best-possible surface quality.
Darko Ranogajec
CEO of OMCO Group
OMCO FACTS
Minimum polishing effort thanks to HSC 55 linear
HSC machining has allowed us to achieve our goal of surface quality so good that the requirement for subsequent polishing is kept as low as possible, is how Darko Ranogajec explains the HSC technology. The ratio of machining time for the HSC 55 linear to the time needed for polishing is optimal. The 5-axis HSC 55 linear also demonstrates its strengths for OMCO when it comes to complexity. Bottle designs are becoming increasingly more sophisticated, says Darko Ranogajec. This requires a versatile machine that can precisely profile even the finest details in the molds.
OMCO INTERNATIONAL
Veneco Laan 10
9880 Aalter, Belgium
DMG MORI TECHNOLOGY EXCELLENCE 69
CUSTOMER STORY - MIKRON TOOL SA
NEW DMQP PARTNER FOR HIGH-PERFORMANCE MICRO-MACHINING WITH INTERNAL COOLING
Titanium bone plate
DMG MORI has found a new partner for its DMG MORI Qualified Products Program in the Swiss toolmaker Mikron Tool. The products of Mikron Tool now carry the DMG MORI seal of quality for premium accessory components. The DMQP portfolio has been expanded to include high-precision tools for the micro-machining of hard-to-machine materials such as stainless and heat-resistant alloys, titanium alloys, or cobalt chrome.
Core target industries for Mikron tools with a diameter of 0 to 8 mm include medical technology and watchmaking as well as the automotive and aerospace sectors. Mikron Tool has already been working closely with the DMG MORI Medical Excellence Center in Seebach for about three years. Substantial increases in productivity have been achieved in customer projects thanks to the intensive exchange of technology and experience. The machining of a titanium bone plate on a DMP 70, for example, impressed visitors attending the Medical Days at DMG MORI in Seebach on 14 and 15 May 2019. The Crazy tools from Mikron Tool surpassed all benchmark specifications for process reliability, machining time, and service life.
The special feature of the Crazy tools is that they are always cooled internally through the shaft, in some cases even through to the tip of the tool. In contrast to an external cool jet, we achieve consistent cooling of the cutting edge with no temperature shock, which in turn leads to longer service life, explains Dr. Alberto Gotti, Head of Research and Development at Mikron Tool. In addition, the flushing of chips from the workpiece is considerably more efficient and reduces the risk of fire, in particular when machining titanium.
MIKRON TOOL SA FACTS
Founded in 1998 as a spin-off from the in-house Cutting Tools department of Mikron SA Agno
CrazyDrill, launched in 1999 as the fastest small drill bit in the world, is available as CrazyDrill Cool with internal cooling
In 2013 Mikron Tool sets a milestone in milling technology with the launch of the CrazyMill Cool: hard-to-machine material like titanium or CoCr can be machined up to 20 times faster
Early involvement of customers in the Mikron Tool Technology Center with DMG MORI expertise
Mikron Tool Agno
Here is the corrected text with the requested modifications:
MGmOri Medical Excellence
Early Involvement of Customers in the DMG MORI Medical Excellence Center
Development and consultation for and with our customers: greenfield consultation, process development, consultation for regulatory issues, etc.
Full-service provider - machine, automation, and technology from a single source:
Turning, milling, and advanced technologies such as ultrasonic or additive manufacturing
Automation incl. Digital Twin for the Green Button Process
Integral Process Chain - from production planning with 1ST0S, to CAD/CAM programming with NC CAM, and on through to production
Horat Lindner
Head of the Medical Excellence Center
horst.in.com
DMG MORI Technology Excellence
Customer Story - Moll Engineering GmbH
Production of Complex Surgical Instruments to Within Microns on 14 DMU eVo Machines
Orthopedic instruments made of carbon and stainless steel have been the core business of Moll Engineering GmbH from Lübeck for over 20 years. Since 1998, production of orders from industry giants such as Stryker has taken place in Wenglon GmbH, Dobra near Stettin in Poland, a company founded solely for such production. At the beginning of 2019, Ensinger GmbH from Nufringen, which had supplied Moll with CFRP materials for many years, took over both companies, including all 80 employees, thus enabling new investment and further growth.
Two DMU 60 eVo machines from DMG MORI, for example, were recently installed at Wenglon, bringing the number of models in operation from the machine tool manufacturer to 16, including 14 high-tech machines from the DMU eVo series. X-ray transparent instruments made of carbon, which were introduced as bestsellers in the medical technology industry, have been produced with the help of these machines, says Stefan Moll.
The tolerances of the parts are often within microns, while the exotic materials place maximum demands on machines and tools. Added to this is the complexity of the components. Trained specialists are needed for the efficient and quality-oriented handling of production processes on the modern machine tools, Stefan Moll tells us.
Due to their carbon content, orthopedic instruments are x-ray transparent.
DMG MORI Technology Excellence
Customer Story - Moll Engineering GmbH
The DMU 60 eVo linear installed in 2019 is just one of 14 machines from the successful DMU eVo series at Wenglon.
Wenglon machines demanding materials such as carbon and stainless steel on the 5-axis DMU eVo machines.
The tolerances of the medical technology products are often to within microns.
Moll Engineering has worked closely with the DMG MORI Medical Excellence Center in Seebach on the process optimization of demanding and high-precision components.
Primarily machines from the 5-axis DMU eVo series have been employed since 2000. The swivelling rotary table with a-5 to B-axis enables efficient 5-axis simultaneous machining. DMU eVo machines are also stable and guarantee top precision.
Competitive thanks to Maximum Availability and Good Service
The latest models on our shop floor are all DMU eVo linear machines, says Stefan Moll, citing the enhanced accuracy attainable using linear drives. The required milling performance is provided by the 20,000 rpm speedMASTER spindle included in the standard version. Moll Engineering and Wenglon have optimized their service to such an extent that they receive help immediately whenever needed.
Moll Engineering Facts
Over 20 years of experience in the production of orthopedic instruments made of carbon and stainless steel.
Wenglon was founded as an independent company in Poland in 1998.
80 employees in Lübeck and Dobra.
Supply of industry giants such as Stryker.
Growth through investment.
Customer Story - Azuma Kinzoku Sangyo Co. Ltd.
LASERTEC 30 SLM 2nd Generation High-Precision Production of Complex Forms with <6 Surface Quality
DMG MORI has emerged as the best partner for additive manufacturing. Kentaro Tanaka scrutinized the different manufacturers extensively before procuring his first additive manufacturing machines. He was supported by the General Manager of the AM Division, Shinya Okuma, who joined the company as an AM specialist. Until 2017, it was very difficult to convince customers of the quality of additively manufactured products and to gain orders in this area. However, more and more machine producers then started to take an interest in this type of manufacture, and the situation changed radically.
Azuma Kinzoku Sangyo Co. Ltd. was established as a foundry in 1942 in Omori, Ota-ku, Tokyo. It moved to Numazu in 1951, where customized sheet metal forming was added as a second business area, in addition to the foundry. Its expertise includes production processes in which deformation can be taken into account or prevented early on during processing. It is one of the few companies in Japan that processes MMC materials (Metal Matrix Composite) and does so in compliance with all applicable quality standards. Azuma's latest business field is additive manufacturing.
Highlights
Highly complex components with function integration
Internal conformal cooling channels
Weight reduction due to topology optimization, lattice, and honeycomb structures
High-precision build of 3D components with dynamic adaptation of the focus diameter between 70 μm and 200 μm, plus layer thicknesses in the 20-100 μm range
rePLUG - The powder module for fast material change in <2h
In 2018, Azuma Kinzoku Sangyo installed the first LASERTEC 30 SLM 2nd Generation machine in its production facility, which was also the first such machine in Japan. Powder bed technology for additive manufacturing of metal parts enables a reduction in the weight of workpieces through topology optimization, the manufacture of complex forms, and the production of internal channel structures. These capabilities cannot be realized with metal removal processes.
Customer Story - Azuma Kinzoku Sangyo Co. Ltd.
Complex, lightweight geometries can be produced with the LASERTEC 30 SLM 2nd Generation, achieving surface qualities of Ra <6 μm during additive manufacturing.
Surface qualities of <6 μm during additive manufacturing can only be achieved on DMG MORI machines.
Azuma Kinzoku Sangyo Co. Ltd. Facts
Founded in 1942.
Diverse production technologies: casting, machining, sheet forming. NEW: Entry into additive manufacturing.
Familiar with every type of material, provides suggestions for product improvement for numerous customers in many different industries.
Hybrid Manufacturing Solutions: This includes the combination of laser deposition welding and milling, enabling efficient, high-quality production. The ability to automatically switch between additive and milling operations in a single setup adds flexibility.
AM Assistant: A tool that ensures adaptive process control and optimal process security for additive manufacturing (AM).
Global Training at DMG MORI Academy: The company invests in education through an extensive training program with over 85 machines and more than 20,000 participants annually.
Partnership with WorldSkills: DMG MORI sponsors competitions and supports the development of young talent at global competitions like WorldSkills.
Customer Stories: MWF Technik GmbH's use of DMG MORI’s high-precision machines and the accompanying flexible financing options provided by DMG MORI Finance.
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