Complete machining with enhanced ULTRASONIC

With the ULTRASONIC technology developed in collaboration with SAUER, DMG MORI has for many years now been offering high-performance machine tools for the high-precision 5-axis machining of complex workpieces made of advanced materials. The series has now entered a new league with the new 2nd generation ULTRASONIC 20 linear. Extensive optimizations across the board, from the expanded ULTRASONIC technology and the machine construction, the performance and on to include the options available, further enhance the technical edge of the machining center. Spindle speeds of optionally up to 60,000 rpm, more powerful drive motors, an even smaller footprint plus CELOS® with apps developed specifically for ULTRASONIC are among the innovations that users from the optical, clock and watch, medical and high-precision mold construction sectors will benefit in future.

 

Reduced process forces for filigree structures, surface qualities up to Ra < 0.1 µ and longer tool service life

The decisive technological innovations of the 2nd generation ULTRASONIC 20 linear include a new, completely digitally controlled ultrasonic generator plus ULTRASONIC actuators with enhanced performance. The tool holders with adapted actuator technology are changed into the milling spindle simply and automatically. Each of these holders contains so-called piezo elements, which are activated by a program-controlled inductive system with a high frequency of between 20 and 50 kHz. The actual tool rotation is thus superimposed with an additional tool movement in the longitudinal direction so that a defined amplitude, which can be programed in the NC-program, in the range of up to more than 10 µm is generated on the cutting edge of the tool or on the grinding layer. During grinding, drilling and milling this ULTRASONIC superimposition of vibrations has a direct, positive impact on process forces, metal removal performance and tool service life and thus on the machining result in the form of cost efficiency and accuracy.

 

More exactly ULTRASONIC results in a higher removal rate, accurate edge machining and up to 40 percent reduced process forces in the machining of advanced materials such as glass, ceramics, corundum, composite materials and hard metal. Deflections are minimised while workpiece accuracy and process reliability are increased. In addition, this oscillating contact interruption results in better lubrication and cooling of the cutting edge as well as optimum removal of particles from the active zone. This enables longer tool service life as well as excellent surface qualities of up to Ra < 0.1 µ for hard-brittle high-performance materials.The 2nd generation ULTRASONIC 20 linear thus uniquely combines high speed cutting and highly efficient ULTRASONIC grinding of advanced materials on one machine. It allows the machining of an unrivalled broad range of materials.

 

Intelligent ULTRASONIC technology for process-compliant amplitudes

The smartSONIC is used in the 2nd generation ULTRASONIC 20 linear as a new ULTRASONIC generator. This automatically recognizes the ULTRASONIC frequency that is best suited for actuator and tool. As another world first it also tracks the frequency and amplitude power during the machining process. To achieve this the smartSONIC automatically tracks the frequency response and compensates all external impacts, such as damping of the ULTRASONIC vibrations caused by the prevailing process forces. This results in consistent control of the set amplitude or that defined in the NC-program. So the user can maximize his process to the utmost and thus increase tool utilization, minimize cycle times and most especially achieve even more filigree, accurate and high-quality manufacturing results thanks to the reduction of process forces.

 

Highly dynamic, long-term stable 5-axis machine concept – compact on 37.7 ft²

DMG MORI relies on the long-term stable gantry design for the 2nd generation ULTRASONIC 20 linear in order to meet the demands on precision for ultrasonic machining. Whereby the machine tool manufacturer was able to reduce the footprint to a compact 37.7 ft². A duel drive in the Y-axis and the integral cooling concept that includes temperature monitoring of drives and spindles as well as the control cabinet and all media guarantee top precision and component accuracy. The linear scales from Magnescale are another example of the high-tech components used by DMG MORI here.

 

DMG MORI has increased the performance of the drives significantly in its latest development: by 47 percent in the A-axis, 27 percent in the C-axis and 34 percent in the Z-direction. The linear drives achieve maximum accelerations of > 1.2 g and a 2,000 ipm rapid traverse. With the very large swivel range in the A-axis of the work table of -15° to 130 ° and the fully integrated infinitely rotating 360 ° rotary axis - both with torque technology - the 2nd generation ULTRASONIC 20 linear is optimally equipped for highly flexible 5-axis simultaneous machining. The up to 1,500 rpm available as an option for the C-axis enables cylindrical mill-grind and mill-turn operations.

 

After its revision the 2nd generation ULTRASONIC20 linear is now also capable of handling larger tool diameters of up to ø 2.0 in. It has also been possible to increase the workpiece weight from 22 lbs to 33 lbs. The basic machine is equipped in the standard version with a powerful 19 kW motor spindle, HSK-32 tool holder and 42,000 rpm. Higher speed requirements are met with an optional spindle that offers an impressive 60,000 rpm. An HSK-40 spindle, optionally with permanent grease lubrication, rounds off the offer in this segment.

 

DMG MORI’s modular concept allows very application-specific equipping of its machines, also in the case of the 2nd generation ULTRASONIC 20 linear. The machine is also available with a 1,500 rpm mill-turn table, for example, which expands complete machining to include milling, turning and grinding of rotational-symmetrical components in a single setup. In addition to the standard 24-fold tool changer with pick-up, the chain magazine is optionally available for 60 tools.

 

Unique integration of technology

In particular, the 2nd generation ULTRASONIC expands the use of ultrasonic assistance to applications with a defined cutting edge – in particular the milling and drilling of nickel or titanium-based superalloys or materials such as magnesium, tungsten as well as composites. Process forces have been reduced for milling applications in titanium alloys by up to 30 percent. Feed rates for steel can be doubled, for other materials, such as magnesium, these rates can be increased in part by anything up to five-fold. And in addition surfaces are also better. ULTRASONIC has a special effect on chip breaking and the removal of chips on the tool. The chips break shorter and tool wear is reduced significantly. This makes the technology interesting for almost all future-oriented target markets with high-tech products. The opportunity of using ULTRASONIC technology also with a defined cutting edge has raised flexibility to a new level. Now it is possible to machine parts made of the most different materials from soft to hard-brittle in five axes for die & mold, medical technology, automotive, and aerospace.

 

2nd generation ULTRASONIC 20 linear in the new design and with CELOS®

High-quality, long-lasting covers as an external feature and functional added value thanks to optimum accessibility are the key properties of the new DMG MORI joint design. The 2nd generation ULTRASONIC 20 linear also appears in this new look, thus lending the machine a high level of value retention. It is also equipped with CELOS®. This uniform user interface with its unique multi-touch screen is as simple to operate as a smartphone. This user-friendliness is further boosted by CELOS® APPs developed specifically for ultrasonic machining, which visualise ULTRASONIC technology cycles and key process parameters such as frequency, amplitude and output. These apps also monitor the process forces of the actuator and aid setting up of the tools.