new features for large part machining · panels steel construction compressor housing precision...
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MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING 1
NEW FEATURES FOR LARGE PART MACHINING
AGENDA
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING 2
DMG MORI
Product Portfolio
Target Markets
Applications (Aerospace, Die&Mold, Energy, Engineering)
Preferred spindles
Mill-Turn + Grinding
Automation
Cutting Solutions
WORLDWIDE PRESENCE IN 79 COUNTRIES
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING 3
14 PRODUCTION PLANTS WORLDWIDE
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 4IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
PRODUCTION FACILITY XXL CENTER
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 5IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
PRODUCT OVERVIEW 2019 WITH 168 PRODUCTS*
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 6
*w/o Taiyo Koki
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
TECHNOLOGY EXCELLENCE
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 7IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
TARGET MARKETS
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 8
Gantry Portal
Ae
ros
pa
ce
Die
& M
old
En
erg
yE
ng
ine
eri
ng
Carbon components Bulkheads and structure parts Turbine components Large landing gears
Monocoque Complete processing, mainly finishing Complete processing, mainly roughing
Gears and Pelton turbines CrankcasePump housingCarbon blade Turbine housing
Compressor housingPanels Steel construction Precision components Machinery components
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 9IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
AEROSPACE – APPLICATIONS
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 10
HIGH STRESSED & TITANIUM STRUCTURE COMPONENTS
ROTATION SYMMETRIC ENGINE PARTS
ALUMINIUM STRUCTURAL PARTS & COMPOSITES
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
AEROSPACE – A380 TORQUE LINK: TI10V2FE3AL
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 11
Machining facts Customer BenefitCustomer request
Part name: Airbus A380 Landing
gear torque link
Objective/
requirements:
1) Reduction of
machining time
2) High process stability
regarding tool life and
chattering
3) High position accuracy
Branch: Aerospace
Dimension: h/w/l: 209 / 605 / 1075 mm
Material: Titanium Ti10V2Fe3Al
Set-ups: 3 (Green Button Process)
Number of tools: 21
Machining time: 23 hours
Key facts: DMC 160 U dB, Gearbox
spindle: 6.300 rpm, 1100
Nm / 32 kW (40%dc)
HSK-A100; B-Axis, Active
damping package
43% time reduction (33 23 hours)
5 µm positioning accuracy
Ra 0,4 µm surface quality
Cutting speed of 180 m/min (35 m/min
previously) thanks to innovative CBN
inserts
High process reliability thanks to damping
package (no tool breakage)
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
Finished workpiece Area of applicationClampingTooling
AEROSPACE – COMBUSTOR CASE – INCONEL 718+
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 12
Finished workpiece Area of applicationIn-Process MeasuringSetup
Machining facts Customer BenefitCustomer request
Part name: Combustor case
Objective/
requirements:
1) Reduction of
machining time
2) High raw material
costs require high
process stability
(25.000€)
Branch: Aerospace
Dimension: h/w/l: 686 / 500 / 360 mm
Material: Inconel 718+
Set-ups: 5 set-ups (Green Button
Process)
Number of
tools:
49 tools plus sister tools
1. Ceramic, Carbide partly
2. Carbide, CBN partly
Machining: 60 hours
Key facts: Motor spindle: 12.000 rpm, 430
Nm / 52 kW (40% dc), HSK-
A100; in-process probing,
accuracy package
67% time reduction (180 60 hours)
Reduction of machines (2 1) by one
mill-turn machine = high flexibility
Reliable green button process for high
volume production
High process reliability due to the use of
measuring features
Ceramic roughing (turning, milling)
Fixture concept with rigid clamping,
supports and damping elements
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
AEROSPACE – COMBUSTOR CASE – INCONEL 718+
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 13IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
OP10
Pre-Turning outside +
Milling
OP20
Pre-Turning inside + Milling
OP25
Heat Treatment
OP30
Turning
OP40
Finish-Turning
OP50
Finish-Turning +
Milling
Raw part
pre-machined forging
Finished part
Combustor Outer Case
DMC 125 FD duoBLOCK
5-Axis Mill-Turn Machine
OP 10 OP 20 OP 40 OP 50
Tools: 49 different tools plus sister tools Roughing: Ceramic, Carbide partly Finishing: Carbide, CBN partly
OP 30 (=OP 20)
Total Machining Time: ~ 60 hours
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 14IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
DIE&MOLD – APPLICATIONS
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 15
MOBILITYINDUSTRY &
INFRASTRUCTUREHUMANS & ENVIRONMENT
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
+ Information Technology
+ Mechatronics and Automation
+ Energy Technology, etc.
+ Automotive
+ Railway
+ Logistics, etc.
+ Nutrition (e.g. Packaging)
+ Consumer Electronics
+ Medical, etc.
DIE&MOLD – FORM PLATE
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 16
Finished workpiece Final productMachiningSetup
Machining facts Customer BenefitCustomer request
Part name: Vehicle Components
Objective/
requirements:
1) Surface quality below
Ra 0.4
Branch: Die&Mold
Dimension: h/w/l: 310 / 240 / 170 mm
Material: 1.2312 40CrMnNiMo8-6-4
Set-ups: 1
Number of tools: 8
Machining time: 51:44:23
Key facts: Technology cycle 3D
quickSET
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
Surface quality Ra 0.3 achieved
Precision better than 0.01 mm achieved
DIE&MOLD – RADIATOR GRILL MOLD
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 17
Workpiece Machining
Machining facts Customer BenefitCustomer request
Part name: Radiator Grill Mold
Objective/
requirements:
1) Machining time
reduction
2) Elimination of EDM
processes
3) Reduction of polishing
time
Branch: Die&Mold
Dimension: h/w/l: 578 / 970 / 1.570
mm
Material: S55C (JIS)
Set-ups: 1 set-up
Number of tools: 11 tools
Machining time: 8 hours
Key facts: 5-axis simultaneous
milling, Aqueous coolant
25% total machining time reduction
Complete elimination of EDM
processing time of 136 hours
Reduction of polishing time of 14 hours
Reduction the number of tools due to 5-
axis machining
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
DIE&MOLD – NEW BENCHMARK AT VW GROUP
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 18
Requirements:
+ Programmed machining feed rate: 10,000mm/min and 15,000mm/min
+ Contour accuracy: max. permissible deviation from given contour at TCP = 0.01mm
+ Surface quality: visual and tactile inspection
Results to the DMU 600 Gantry linear
+ Elapsed time 25% faster compared to all other machines at Audi Tool Shop
+ Contour accuracy deviation < 10µm at TCP
+ Linear drive technology: minimum vibration compared to ballscrew and/or rack & pinion
+ Best surface quality, no irritations and perfect transitions
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
HIGHER PERFORMANCE WITH LINEAR DRIVE
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 19
Tim
e [s]
0.0
0
5
10
40
0.0
5
0.1
0
0.1
5
Distance [mm]
0.2
0
0.2
5
0.3
0
Tim
e [s]
0.0
0
3.0
linear
conventional drive
0.0
5
0.1
0
0.1
5
Acceleration [m/s²]
0.2
0
0.2
5
0.3
0
0.3
5
0.4
0
0.4
5
0.5
0
Time to max.
acceleration9× shorter
5,000 mm/min 6,500 mm/min 7,500 mm/min 10,000 mm/min
Rack & Pinion / Ballscrew
Advantages
+ Highest surface quality
+ Significant reduction of the machining time
+ Long-term precision and maintenance-free
+ Highest contour accuracy
35
30
15
20
25
0.5
1.0
1.5
2.0
2.5
Acceleration time
around 3× shorter
linear
conventional drive
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
ENERGY – APPLICATIONS
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 20
GEARS & PELTON TURBINES CRANKCASES INDUSTRIAL GAS TURBINE
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
ENERGY – DRILLING HEAD
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 21
Finished workpiece Final productMachining
Machining facts Customer BenefitCustomer request
Part name: Drilling head
Objective/
requirements:
1. Reduction of
processing time by
75 %
2. Machining of
negative angles with
angular head
3. Complete machining
in one setup
Branch: Energy
Dimension: h/w/l: 330x400x400 mm
Material: 1.6523 (21CrNiMo2)
Set-ups: 1
No. of tools: 20
Machining time: 18 h
Key facts: Motor spindle:
12.000 min-¹, 288 Nm / 44
kW (40% ED)
75% machining time reduction
from 70 18 hours
Achieved surface quality of Ra 1 μm
Complete machining in one setup
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
ENERGY – LEDSKENESEGMENT A STEG3 SGT-800
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 22
Finished workpiece Final productPicture 2 “Machining”Picture 1 “Machining”
Machining facts Customer BenefitCustomer request
Part name: Gas Turbine
Components
Objective/
requirements:
1) Machining the gas
turbine component
without manual
intervention
2) Reduction of
processing time
3) In-process measuring
4) Programming with
NX
Branch: Energy
Dimension: h/w/l: 1.060 / 690 / 160
mm
Material: 1.4305 X8CrNiS18-9
Set-ups: 6
Machining time: 4 h
Key facts: Alternate spindle speed,
Probing
33% machining time reduction
from 360 240 min
Processing without manual intervention
In-process measuring with automatic tool-
correction
Program was created with NX
In-process measuring was programmed
via CAD/CAM-system – NC-CAM / Janus
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
ENGINEERING – APPLICATIONS
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 23
STEEL CONSTRUCTION MACHINERY COMPONENTS COMPRESSOR HOUSING
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
ENGINEERING – GEAR WHEEL
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 24
Finished Part Final ProductPicture 2 “Machining”Picture 1 “Machining”
Machining facts Customer BenefitCustomer request
Part name: Drive Technology
Objective/
requirements:
1) Technology integration
of milling, turning and
grinding in one machine
2) Reduction of setups
3) Grinding an internal
cone of length 444 mm
Branch: Engineering
Dimension: h/w/l: 1.510 / 459 / 472
mm
Material: 18CrNiMo7-6 EN10084
No. of set-ups: 2
Number of tools: 24
Machining time: 8 hours 10 minutes
Key facts: Hard turning, Grinding
and pallet station
Reduction from 3 1 machine
Reduction from 5 2 set-ups
Grinding a cone inside with a length of
444 mm (grinding tool length = 560 mm)
Milling slots inside 90 mm with angle head
and three different tools
Automatic measuring and correction of
tools and positions with 3D-touch probe
and L-touch probe
Mill-turn the hardened outside diameter
over the gearing for more process stability
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
PRODUCTIVITY & EFFICIENCY
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 25
Zero clamping systems
Increase of Productivity (Increase the utilization of machine tool)
Complete
5-axis-machining
High availability Tool magazine Best ergonomics
Increase of Efficiency (Increase the output of machine tool at high utilization)
Powerful gearbox
spindles
High speed
motor spindles
Linear drives Endless C-axis
rotationTechnology Cycles
∞IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
OVERVIEW SPINDLES
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 26
12.000
288 Nm | 430 Nm
44 kW | 52 kW
SK50 | HSK-A100
› Universal
› Engineering
› FD - applications
15.000
404 Nm
52 kW
HSK-A100
› Mold
› Heavy cutting &
finishing
20.000 / 30.000
130 Nm | 67 Nm
35 kW | 32 kW SK40 | HSK-A63
› Mold
Finishing
24.000 / 30.000 Pick-up
33 Nm | 9,6 Nm
20 kW | 18 kW
HSK-A63 | SK50 | HSK-E50
› Mold
› Finishing
8.000 gear spindle / 9.000
1.800 Nm | 700 Nm
52 kW | 54 kW
SK50 | HSK-A100
› Heavy machining
› Titanium processing
15.000 / 30.000
192 Nm | 51 Nm
100 kW | 79 kW
HSK-A100 | HSK-A63 | HSK-A63/80
› Aerospace
› Aluminium
› Structural parts
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
MILL-TURNING (FD) TECHNOLOGY
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 27
Mill-Turn (FD) package
› Automatic balancing cycle
Display of size and position of the counterweight
› Covering for the work space as safety cabin
with safety glass screen
› Speeds up to 250 rpm (210) / 200 rpm (270) / 120rpm (340)
› Moment of inertia
up to 2.900kgm² (210) / 9.000kgm² (270) / 8.000kgm² (340)
› Unique technology integration
› Tool taper HSK-A100
Direct
measuring
system
Rotary encoder
in table center
Hydraulic table
clamp
Direct drive
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
TECHNOLOGY INTEGRATION: GRINDING
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 2828IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
TECHNOLOGY INTEGRATION: GRINDING
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 2929IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 30
› 4 x DMC340U
› 18 pallet locations
› 2 loading stations
› Long set up times due to
complex components
› Vacuum clamping
AUTOMATION – CUSTOMER PROJECT
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
DMG MORI LARGE PART MACHINING
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 31
Project Scope:
• 3x DMC 210 U (incl. 2x µPrecision)
• LPP – 22 No. of pallets
• 3x DMC 340 U
• 2x DMU 600 P
IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
CUTTING SOLUTIONS
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 32IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING
THANK YOU FOR YOUR ATTENTION
MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING