Gildemeister AG chairman Dr Rüdiger Kapitza was joined, for the second year running, by Mori Seiki president Dr Masahiko Mori at the February event. Still not well understood in the UK, perhaps, these two machine tool firms are co-operating in sales and service, component manufacturing, procurement and product development; the pair having a cross-shareholding of 5%. The UK is not one of the sales co-operation markets as yet, so the pair's relationship is less clearly visible here.
Image: The DMG Open House event draws 1,000s of visitors
Image: Inside the show rooms – people galore
What UK customers will see during this year, however, is an extension of the financing initiative that the two companies have set up elsewhere (see article here). Called MG Finance, this will support purchasers of DMG and Mori Seiki machines in the UK - it is also being rolled out in Italy and France. To support this move, the original €100 million fund has been extended by a further €80 million, it was said.
Already the two cross-sell each other's machines, dressing them up in different clothing, so to speak. So, at the Pfronten event, Mori Seiki mill-turn machines were highlighted in there DMG colours – the CTX delta 4000 TC mill-turn, which "roughly corresponds" to the NT 6000 from Mori Seiki; the CTX delta 6000 TC, which is Mori Seiki's NT6600; and the CTX 450 alpha TC mill-turn, which is Mori Seiki's NTX 1000.
Image: The NTX1000 looks similar, because it is essentially the same machine as the CTX alpha 450 TC
Assembly of these Mori Seiki-designed 'DMG' machines is undertaken in Germany to varying degrees, using some Mori Seiki supplied pre-assembled modules plus local parts. This helps to avoid delivery delays introduced by a 40-day sea journey and eliminates the costs of shipping and insurance for equivalent Mori Seiki machines, which Dr Mori puts at 10-15%.
(Mori Seiki also supplies machine parts to Gildemeister for its own machines, including spindles, ballscrews and turrets.)
In return, Mori Seiki offers DMG machines in the markets where it sells on behalf of DMG ( see box item 1). Dr Mori said that his company had sold 250 DMG machines in 2010 and that this year that figure would rise to 450. The sales focus is on DMG's eco machines (lathes and machining centres) made in Gildemeister's Shanghai, China, factory, but which are sold in either Mori Seiki or DMG/Mori Seiki clothing. Gildemeister's Shanghai factory will make 2,000 eco machines this year, more next – 2,500 to 3,000, said Dr Kapitza.
In a slightly different vein and into the future, Mori Seiki's new Californian factory, anticipated to be up and running by mid-2012, is expected to support the manufacture of DMG machines, with Dr Mori particularly highlighting the DMU 50 eco 5-axis machines. Again, the shipping delay/cost burdens will be avoided, he underlined. (Dr Mori also suggested that DMG could use its Japanese factories, but nothing specific was said).
When the Californian factory is up and running, the pair will have manufacturing facilities in the USA, Japan, China and Europe, which will allow them to shorten delivery times, cut costs and hedge currency risks, it was underlined. On the latter, with the Euro currently weak and the Japanese Yen strong, Dr Mori said that he intended to purchase more parts from Europe (although two years ago, this would have been the reverse situation, in fact). Currently, the company buys components to the value of €50 million – its sells parts to the value of €300 million the other way - and Dr Mori was to meet suppliers at the Pfronten event to move this initiative forward.
Nearer term, the first machine designed co-operatively between Gildemeister and Mori Seiki will get its outing at the forthcoming EMO exhibition, it was revealed. The pair will have a major presence at the biennial exhibition, to be held this year in Hanover, Germany from 19 to 24 September.
There will be 16 DMG innovations introduced this year, 10 at EMO (see box item below), but the combined design model was not highlighted, if it was, indeed, listed at the Pfronten event.
Launched at the Bavarian event in February, however, were the CTX delta 4000 TC, CTX 6000 TC (not shown) and CTX beta 1250 TC 4A mill-turns; the DMU 85 monoBLOCK and DMU 80 eVolution 5-axis verticals; and the huge DMU 600P gantry machine. Also, from Gildemeister's Sauer Lasertec operation came the DMU 210 Shape – a surface texturing machine, while automation innovations were the preserve of DMG Automation. (See box item for details.)
To be launched at the company's Bielefeld factory Open House was the CTX gamma 3000 TC mill-turn, while March will also see the official opening of the high speed machining competence centre at Geretsried, Germany.
Energy efficiency was again highlighted, with several machine features pointed up to ram this message home – DMG GreenMODE; minimal slideway forces, minimal friction, regenerative drives, regulated motors, and AUTOshutdown (see last year's feature for details on some of these).
In addition, a spindle protection system – Machine Protection Control – was unveiled. It offers machinery monitoring, machinery protection (10 ms response) and data logging. This joins Collision Monitoring, which is standard for Heidenhain iTNC 530 controls; quickSET, which verifies kinematic accuracy of 5-axis machine tools and is available for Siemens and Heidenhain CNCs; and Application Turning Cycle, which allows users to prioritise speed, finish, or accuracy during a program, and which is again available for Siemens or Heidenhain CNCs.
Apart from machine tool innovations, GIldemeister's Dr Kapitza underscored the importance of what he called "1:1 simulation" at the February event. The precise simulation of actual reality employing Siemens CADCAM software able to use specific Siemens CNC functions, plus DMG Virtual Machine software incorporating accurate machine models and the Siemens 840D CNC kernel, which allows for faithfull replication of what will happen on the machine tool. This will be a key area in coming years, he offered, and the company has invested some €20 million in this technology.
A smaller innovation at the Pfronten event was the introduction of a new quick change VDI turret tooling system – Trifix, which DMG has exclusivity on till next year. Toolchange time of 5 mins is said to be slashed to 30 secs, with 6 micron positioning accuracy achieved. Together with its Shopturn 3G software, an 80% reduction in set-up time is claimed for turning machines.
As ever, there was almost too much to take in during a fleeting visit, but what was once again confirmed were the relentless expansion of both DMG's worldwide presence and its staggering rate of technology development, both now aided by a major machine tool manufacturing partner, Mori Seiki.
Box items
DMG Pfronten Open House machine/technology launches
Where Mori Seiki and DMG operate
The two are co-operating in many markets, although this is not yet apparent in Europe. Mori Seiki leads the effort in Japan, USA, Thailand and Indonesia, with DMG leading in Turkey, Taiwan, Korea, India and south east Asia (Vietnam, Malaysia, Singapore). The pair have a 50/50 share in Australia, while common sales activities in Africa started in January 2011, led by DMG, with the establishment of a base in Cairo, Egypt.
What's in store for EMO 2011
DMU 105 monoBLOCK; DMU 40 eVolution; and DMU 100 eVolution 5-axis vertical machining centres.
DMC 65 monoBLOCK; DMC 85 monoBLOCK; DMC 60 H linear; and DMC 80 H linear horizontal machining centres.
Sprint 42-8 and Sprint 65 turning machines.
Machines in detail
DMU 85 monoBLOCK
The DMU 85 monoBLOCK is based on the successful DMU 65 monoBLOCK, launched last year. It has a small footprint of 11.6 m² with axis travels of 850, 850 and 650 mm in X, Y and Z, respectively. The 3-axis version can accommodate workpieces up to 1,200 mm long and weighing 2,000 kg. The 5-axis machine supports a 1,040 mm part diameter and a workpiece weight of up to 1,500 kg. For such workpiece optimum accessibility is offered via top loading above the table centre.
Image: The DMU 85 monoBLOCK is based on the successful DMU 65 monoBLOCK
The DMU 85 monoBLOCK is designed for the most demanding milling operations. Its underlying rigidity and stability are achieved via the high resting mass of the monoBLOCK design and a detailed FEM analysis, while the swivel rotary table's 45-size roller guides guarantee the highest level of stability also for the 5-axis version of the DMU 85 monoBLOCK.
In conjunction with its SK50/HSK-A100 toolholder, the DMU 85 monoBLOCK is the only machine in its class that supports heavy machining with 288 Nm/44 kW capabilities.
But there is a choice of spindles - 10,000 rpm, 82 Nm as standard, plus application-driven options of 14,000 rpm (100 Nm), 18,000 rpm (119 Nm) and 24,000 rpm (100 Nm), plus a heavy duty spindle with 10,000 rpm and 288 Nm torque.
The fast swivel rotary table is available either with high torque gear motors or water cooled torque motors, the latter offering more dynamic machining.
Toolchanger capacity is 30, 60 or 90 tool positions chip-to-chip time is 4.9 seconds.
In addition to the universal modular construction kit of the DMU 85 monoBLOCK, there is a special production package with an internal coolant supply of up to 40 bar plus a space-saving chip conveyor on the rear of the machine.
The standard package is rounded off by the DMG ERGOline® Control with a 19" screen and a high-tech 3D controller with an option to choose from either Siemens (Sinumerik 840D solutionline) or Heidenhain (iTNC 530).
The DMU 85 monoBLOCK is designed to offer more flexibility for 5-axis machining, this including integrated turning-milling technology plus the option to use ultrasonics for ultrasound-driven machining of hard/brittle materials, together with Lasertec Shape for milling and laser processing in one machine. These added features will be available prior to this year's EMO 2011.
DMU 80 eVo linear
The world premier of the DMU 80 eVo linear represents the second model of the new DMU generation. This model also combines the benefits of a universal milling machine with the advantages of a vertical machining centre. This solution has been completely revised and now includes gantry support, significantly increasing its rigidity and precision levels. Robust, dynamic head axes and a fast NC swivel rotary table are further advantages.
Image: A world premier - the DMU 80 eVo linear is the second model of the new DMU generation
The DMU 80 eVo represents perfect interaction between the performance potential of a universal milling machine and that of a vertical machining centre. In contrast to the previous models DMU 50/70, the machine design of the new generation of eVo models has been completely revised and now includes gantry support, significantly increasing the machine's rigidity and precision levels.
Compared to the gantry design, the DMU 80 eVo's 'optimized gantry' (as in the DMU 60 eVo) offers better accessibility, including access from the side, a larger workspace and a smaller footprint. Travels in X, Y and Z are 800, 650 and 550 mm, respectively. The NC swivel rotary table offers a work surface of 800 by 700 mm.
The successful design of the swivel rotary table has been maintained, while the table's load-bearing capacity, its swivel range (now -5/+110°) and its dynamics have all been increased.
The rapid traverse speed is now 50 rpm for the B and C axes when tested with a load weight of 600 kg. This makes the DMU 80 eVo ideal for 5-sided machining, 5-axis positioning and simultaneous 5-axis contour machining. Ball thread gears help to make this machine an inexpensive first option in complex milling.
The swivel rotary table allows for undercuts of up to 20°, again increasing the DMU 80 eVo's range of applications in areas such as toolmaking or machining of highly complex workpieces.
There will be a version of the DMU 80 eVo available that includes an automatic pallet changer with a 10 sec cycle and a high revolution torque table to integrate milling and turning technology. To increase productivity even further, a dynamics package with linear drives for the X and Y axes can be purchased. This will bring rapid traverse speeds up from the standard 50 m/min to 80 m/min.
In combination with fast tool exchange times to ensure shortest chip-to-chip times of less than 5 seconds, these functions and features form a high-tech package.
The new DMU 80 eVo offers even more choice for additional equipment options, including task-driven selection of spindle options with speeds between 14,000 and an optional 18,000 or 24,000 rpm. All spindles can be supplied with SK40 (BT40) or HSK A63 interfaces.
The standard version supports 19 kW and 100 Nm (40% DC), while the new 18,000 rpm motor spindle offers a longer service life, thanks to its oil/air lubrication system; great sturdiness, thanks to its massive shaft with an integrated shaft collar; and a bearing with an increased load rating for a significantly higher load capacity. DMG offers an extra long warranty covering 7,500 hours of operation for this design.
On the control side, DMG ERGOline Control, including a 19" screen and 3D software, is supported by Siemens 840D solutionline with ShopMill or Heidenhain iTNC530.
DMU 600 P
The DMU 600 P offers large travel distances of 1,800, 2,100, 1,250 mm to 6,000 , 4,200, 2,000 mm in X, Y Z and a high table load capacity of up to 40 tonnes, making it possible to process even largest components via 5-sided /5-axis milling and turning in a single setup. Optimum work area accessibility, a variety of spindle choices and other process-optimised options complete the machine.
Image: Large part machining, including mill-turn operations
The DMU 600 P is a universal machine is designed for extremely large and heavy components - be it for tool moulds for the automotive industry or extra large components for the aerospace and power engineering industries.
The possibility of 5-axis simultaneous machining as well as the modular concept of the DMU 600 P, consisting of gantry, machine bed, different tables, magazines and spindle stocks provide the users with the flexibility required for the production of complex moulds and components. For milling operations, users can choose between three interchangeable milling heads, which can be coupled to an integrated C-axis and automatically changed via a magazine.
Apart from a vertical milling head for roughing, a milling head with integrated A-axis and another milling head with integrated B-axis are available for 5-axis simultaneous machining. For highly productive milling operations, a special roughing spindle with 1,000 Nm and a maximum speed of 7,000 rpm is available, while the portfolio also includes a 24,000 rpm spindle with 90 Nm for finishing processes.
Apart from a fixed table, there is the option of an integrated NC rotary table or a milling-turning table (FD), which, apart from milling operations, also makes turning machining of the workpiece in the same setup possible.
On the control-side, DMG ERGOline control panel with 19" display is employed with either Heidenhain iTNC 530 or Siemens 840D.
CTX beta 1250 4A TC
The latest addition to the successful CTX family is CTX beta 1250 4A TC, a model for medium-sized workpiece dimensions that completes the DMG portfolio of turning-milling centres. This machine fits in well between the smaller CTX alpha 450 TC and the larger CTX gamma TC models on one side and the new CTX delta 4.000 TC and CTX delta 4000 TC mega machines on the other.
With its powerful turning-milling spindle, bottom DirectDrive turret and 2-channel control technology, the new CTX beta TC 4A sets new standards for productivity and flexibility.
"The CTX beta 1250 TC 4A marks the new top model in the field of medium-sized workpieces in the diameter range up to 390 mm and for turning lengths up to 1250 mm," says the company. The new development differs from the CTX beta 1250 TC with B-axis, mostly due to the additional bottom turret. Both tool mounts work autonomously and without restrictions, with this making it possible to either work on one spindle four-axis, with two tools, or to work on both sides in parallel (on the version with counter-spindle).
DMG estimates that the overall degree of productivity has been increased by up to 50% in the new CTX beta 1250 TC 4A, compared to the purely B-axis version. And for customers undertaking turning, deep-hole boring, gear milling, out-of-round turning, turning/milling, 4-axis roughing, high performance milling, off-centre turning and milling or even simultaneous 5-axis milling," the CTX beta 1250 TC 4A is the first choice for the future", says the company.
The CTX beta 1250 TC 4A has a B-axis that swivels by ±100° and has a 12,000 rpm motor spindle, while the bottom VDI 40-DirectDrive turret has 12 driven stations and speeds of up to 10,000 rpm for driven tools. The turret additionally has a Y-axis (±40 mm) and all tool stations, even in the standard version, are equipped with the DMG Trifix precision interface for reduced set-up times and increased tool precision as well as stability. (See main feature for Trifix information.)
For the turning-milling spindle, the standard version has a disk magazine with 24 positions. However, this can be increased with the option of an 80-position chain magazine.
The new ShopTurn 3G control features multi-channel programming with freely selectable DIN or graphical programming.
CTX delta 4000 TC
Gildemeister is developing its CTX delta TC series in co-operation with partner Mori Seiki, based on the NT6600 for a turning length of up to 6,000 mm.
Image: Its GIldemeister's CTX delta 4000 TC, Mori Seiki's NT 6000
The CTX delta 4000 TC is the first member of the new product family of so-called XXL turning machines and it opens up a new dimension for the machining of large components – for complete turn-mill machining up to a turning length of 6 m, as well as for 5-axis machining.
The CTX delta 4000 TC and CTX delta 6000 TC have turning lengths of 4,150 mm or 6,150 mm, respectively, and a maximum turning diameter up to 1,070 mm.
There are tailstock and counter-spindle versions, while the robust travelling column with solid slide guided quill, the highly accurate gantry drives in the X- and Z-axis are the basis for high accuracy, as well as the B-axis of the turning-milling spindle with DirectDrive, which can be swivelled by +-120°. Another advantage of the CTX delta TC series is the tool magazine with tool shuttle, which supplies the spindle in the work area with tools and whose standard version provides space for 50 large C8 or HSK100 tools. DMG will offer optional chain magazines, with 100, 140 or even 180 tools. Tools can be up to 600 mm in length and weigh up to 30 kg.
Laser surface structuring - DMU 210 Shape
Gildemeister's Sauer Lasertec had a world premiere in the shape of the DMU 210 Shape. Using a laser, it can generate surface textures on metal parts. Laser texturing can be used together with 5-axis simultaneous milling to process complex 3D moulds, and it can create virtually any type of surface structure, it is claimed.
DMG offers laser-based surface texturing both as a standalone solution and as technology integrated into its 5-axis universal milling machines of the DMU/DMC machines. The DMU 210 Shape can tackel workpieces of up to 8,000 kg.
DMG Automation
DMG Automation unveiled two world premieres - the new linear system PH 200, designed to provide fast and reliable handling of heavy pallets; and the dynamic restacking system WH 3 U.
For tool and mould making customers, as well as the automotive and aerospace industry, the PH 200 automation solution can be easily implemented and will safely and reliably moves heavy palettes, having a maximum handling transfer weight of 200 kg. Thanks to a 3-axis linear system with a 350 degree rotational axis, the PH 200 is completely flexible. Pallet changing is about 22 seconds.
Image: The PH 200 system can be fitted to a number of DMG machines
A 12-position pallet magazine is available as standard (Ph 200|12), with standard pallets 400 by 400 mm (larger as option). The PH 200 system is modular, so storage capacity can be quickly and easily increased with additional shelves – for example a circular storage shelf and/or additional travel distances.
DMG job manager supports the users in pallet prioritisation as well as pre-programming – also in combination with a central manufacturing system.
The PH 200|12 measures 4,200 by 5,460 by 2,360 mm and is loaded via a crane. The system is compatible with: HSC 75/105 V linear, DMU 50/70, DMU 40/60 monoBLOCK, DMU 80 monoBLOCK, DMU 50/70 eVo and DMU 60/80 P duoBLOCK.
WH 3 U: Dynamic restacking system for maximum storage
The WH 3 U is based on the WH 3, a tried and tested solution from DMG Automation for turning machines, and uses stackable containers to support easy workpiece handling. Each container has standard dimensions of 400 by 600 mm and accommodates workpieces of up to 3 kg. The system is designed for both flexible side loading and front loading, using a loading trolley. The maximum stacking height for baskets (using a trolley) is 1,100 mm. DMG Automation offers component-specific container design and modification.
The system measures 1,030 by 2,050 by 2,190 mm. The robot moves the components, which can weigh up to 3 kg, reliably through the work area within an 859 mm radius. Changing containers takes 20 seconds.
The WH 3 U is compatible and ready to use with: CTX alpha/beta 300/500/800, CTX 310/410, CTV160/250, MSL 42/60, and Sprint 42 linear. It can also be adapted to work with other Gildemeister systems or third-party machines on request. And the WH 3 U system can easily be incorporated into existing systems.
Machine tool business outlook
Referring to German VDW/Oxford Economics figures – VDW is the German machine tool makers' association - Dr Kapitza gave a market overview of the machine tool industry, highlighting that markets recovered in 2010, with the Americas seeing consumption rise by almost 28%; Europe 27.5%; and Asia 17.4%. Within each area, there were highlights, with USA growing 36%, Germany 30% and India 26%.
Worldwide consumption was put at €41.8 billion (+16.1%), with this expected to grow to €51.8 billion (+19.8%) this year and €59.8 billion (+19.3%) in 2012. Five countries – China (€13.6 billion), Germany (€4.8 billion), USA (€3.1 billion), Japan (€3 billion) and Korea (€2.7 billion), are predicted to account for 54% of consumption this year.
Demonstrating the change in pattern of consumption, in 1999, Europe was top consumer, with 44%; America was second, with 31%; Asia was 16%, with China 9%. In 2014, the prediction is that China will consume 44%, followed by Europe (26%), then the rest of Asia (18%), with America last at 14%.
And DMG's order intake reflects the changing pattern – 89% of it was in Europe in 1999, while in 2010 this had dropped to 68%; China went from 1% to 10% in the same period. Co-operation with Mori Seiki to gain market access in Asia is clearly sensible from all this.
Machine tool production, which fell from €52.1 billion in 2008 to €36.3 billion (-30.3%) in 2009, recovered to €38.3 billion (+5.5%) last year and is expected to grow by almost 20% to €45.9 billion this year and then to €54.8 billion (19.4%) next.
Dr Kapitza said that DMG's order growth target was 20% for this year - similar for Mori Seiki – and that 2012 would see a return to 2008 levels of business.
First published in Machinery, March 2011
