DMG MORI’s integrated manufacturing solutions
Photos courtesy of DMG MORI

DMG MORI’s integrated manufacturing solutions

The Deckel Maho Pfronten open house will be dominated by integrated manufacturing solutions for integral processes.

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At the start of the EMO exhibition year, DMG MORI will be presenting 70 high-tech machines, 20 of them with automation and the world premieres of the

DMP 70 and Lasertec 125 Shape, at its open house event at Deckel Maho in Pfronten, Germany, January 22-26, 2019. The future-orientated focus topics include digitalization for production and service, integrated automation solutions for competitive manufacturing, and additive manufacturing. 

© DMG MORI | https://en.dmgmori.com/
DMP 70

DMP 70 dynamic production machine
DMG MORI’s DMP 70 is a compact production machine with a footprint of 4.2m², and is ideal for medical technology applications, job shop, aerospace, and more. Traveling paths of 700mm x 420mm x 380mm offer space for a range of components, offers traverse speeds of up to 60m/min, acceleration to 2g, and tool change chip-to-chip time of 1.5 seconds. The tool magazine has space for up to 25 tools. A one-piece machine bed made of cast iron, direct absolute travel measuring systems, and optimal cooling system ensure precision. Automation solutions such as the workpiece handling WH 3 cell, which the DMP 70 is presented with at the open house, can be connected from the right, left, or the front. 

Lasertec 125 Shape
The Lasertec 125 Shape has been designed for surface structuring of large molds up to 1,250mm x 700mm and workpiece weights of up to a maximum of 2,600kg. The optional high-speed Z-shifter increases travel speed in the Z-direction from 1.5m/s to4m/s, while the laser achieves a pulse rate of up to 1,000kHz. Texture quality has been optimized while maintaining the high process speeds, resulting in up to 69% shorter process times and significantly lower costs per component. 

© DMG MORI| https://en.dmgmori.com/
Integrated Digitization

Integrated digitization
DMG MORI will present pathways towards networked production – integrated digitization – offering visitors a 45-minute Digital Pfronten Tour where digital products and solutions for integrated digitalization will be presented. DMG MORI will be presenting Production Planning at five stations for workforce planning at Deckel Maho Pfronten and a fully integrated production planning and control system and the Preparation & Production area for the digital process of manufacturing a mold insert – from job scheduling using a CAD/CAM system (Siemens NX) and CELOS PC version through to production on the DMC 1850 V with CELOS Version 5. After a Digitization Show of the entire value-added chain, the tour will end with Monitoring with the DMG MORI Messenger, Condition Analyzer, Performance Monitor and Production Cockpit and, in the area of service & maintenance, with WERKBLiQ. The web-based and multi-vendor platform makes it possible to manage the maintenance of a total of eight 5-axis milling machining centers and three universal surface grinding machines in mechanical manufacturing and the 17 milling machining centers in the technology center at Deckel Maho Pfronten. Benefits of the direct service support with the NETservice, including the SERVICEcamera, will be demonstrated. 

Automation
Automated machines are crucial components of a digital factory and an integral part of Industry 4.0. The DMG MORI HEITEC joint venture supports DMG MORI in the development and realization of flexible automation solutions, such as workpiece handling, and the expertise is integrated into the production plants of DMG MORI. The interplay between engineering from the DMG MORI production plants and automation expertise on the part of DMG MORI HEITEC provides users with a customized, integrated, reliable solution.

Current examples of DMG MORI’s automation offerings are the Robo2Go 2nd Generation for flexible workpiece handling on lathes and the wide range of pallet handling systems. A PH 150 with up to 12 pallets and a maximum load capacity of 250kg will be shown on a DMU 65 monoBLOCK. A DMU 85 monoBLOCK is presented by DMG MORI with the new PH 400 is a pallet automation system for loading large workpieces up to 800kg for DMU machines and is also available for the DMU 80 P duoBLOCK and DMU 90 P duoBLOCK for palettes up to a weight of 800kg.

 
Additive manufacturing
DMG MORI combines its additive machines from the Lasertec 3D and Lasertec SLM series with machining centers from its machine portfolio. The continuous further development of additive manufacturing (AM) is demonstrated by the Lasertec 12 SLM and Optomet software, while the DMG MORI Academy complements the service range with a consultancy approach that is specially tailored for the AM sector.

With a focus diameter of just 35µm, the Lasertec 12 SLM is four times more precise than the current industry standard. This allows a significantly finer structure resolution, which in turn makes thinner wall thicknesses possible. At the same time, the powder bed machine offers a construction volume of 125mm x 125mm x 200mm, which is unique for this precision class. The Stealth Design and rePLUG powder module – familiar from the Lasertec 30 SLM 2nd generation for material changes in less than two hours – deliver process automation and work safety.

With a 30% share in the Indian software developer, Intech, DMG MORI has opened up access to important software and technology know-how for generative production. As a pioneer in the area of 3D printing in India, the company has specialized in AM and the associated software solutions – including artificial intelligence (AI). One of the initial results of this cooperation is the new Optomet software, which Intech offers for the DMG MORI Lasertec SLM series. It automatically calculates the optimal process parameters. This simplifies programming and leads to significantly improved surface qualities and reproducible material properties. 

Technology excellence
The DMG MORI Aerospace Excellence Center at Deckel Maho Pfronten develops optimal and integral manufacturing solutions in the aerospace sector. DMG MORI has more than 20 years of technology experience ranging from complex 5-axis simultaneous milling through complete machining using milling-turning technology including the integration of grinding and Ultrasonic milling. Highlights of the DMG MORI Aerospace Excellence Center are the industry-typical applications such as e.g. an angular head resolution for housing production on a DMU 125 FD duoBLOCK. Here the front tools can be automatically changed. The sensor-controlled Tool Control Center (TCC) on a DMC 65 monoBLOCK ensures greater process reliability, allowing you to react swiftly to unplanned tool wear so that the workpiece and machines can be protected from damage.

Projects in the DMG MORI Die & Mold Excellence Center focus on a range of workpieces – from 10mm punches up to 6,000mm workpiece molds, which all find sufficient space in the XXL machining center. The presentation in this area is the DMU 600 P with double table. The DMG MORI Technology Cycle VCS Complete on the DMC 85 monoBLOCK supports good accuracy. Moreover, DMG MORI can guarantee surfaces of up to 0.15µm with reliably accurate linear drives, measuring systems by Magnescale and speedMASTER spindles with up to 30,000rpm and HSC spindles with 60,000rpm. 

DMQP
The highest machine performance and the best-possible component quality can only be achieved with coordinated and certified technology and peripheral components. DMG MORI thus defines its high demand on quality within the scope of the DMG MORI Qualified Products (DMQP) program. The supporting pillars of this DMG MORI quality guarantee are the many years of innovation partnerships for peripherals and accessories. DMQP partners have to satisfy the most stringent requirements relating to innovative capacity, technological expertise and quality. Coordinated interfaces, securing connectivity, price maintenance and defined warranty conditions ensure optimal productivity of their manufacturing solutions for DMG MORI customers.

At the same time, DMG MORI has recently begun to offer its customers DMQP certificates. The DMQP certificate offers DMG MORI customers unique benefits – a diverse selection of high-performance tool systems, individually compiled by the DMQP partner experts at exclusive conditions.