Dominant position

This performance places the company in number one spot as the world's largest manufacture of metalcutting machine tools, ahead of Yamazaki Mazak and then Mori Seiki, Dr Kapitza observed. Gildemeister manufactures turning centres, machining centres, plus ultrasonic and laser cutting machines under the Deckel Maho and Gildemeister brand names. Machines are sold through its DMG sales operations worldwide – DMG UK, Luton, in the UK. It is also involved in the manufacture of systems to carry and guide solar panel arrays – a fast growing business. This latest sales performance is a feat that will not be bettered for some time, Dr Kapitza added, but underlined the fact that during the current difficult economic conditions, Gildemeister will be winning market share "by getting the orders that others are not", adding that there will be industry consolidation at a record level during the next two years. He said that Gildemeister had some 10 per cent of the global potential customer base, which he put at more than 333,500, implying that the company had much yet to aim for. The introduction of the low-cost Eco Line of machine tools is clearly helping to expand its user base, since it is claimed that 80 per cent of the 1,000 machines sold during 2008 went to new customers.This line of machines, currently taking in lathes plus vertical and horizontal machining centres, will be expanded later this year with the introduction of a 5-axis (positional, not simultaneous) machining centre – a CNC update to incorporate Gildemeister's ERGOline control will also take place during the coming year. The company expects to deliver another 700-or-so Eco Line units this year (Image: CTX 310 Eco), with the chief executive reporting that these machines are priced on a day-to-day basis to match competitors: "There will be no space for others." AROUND THE MACHINE But it is not only machine tools that are of interest to Gildemeister. Dr Kapitza also underlined that the company wants to be a "dominant supplier in equipment that surrounds machine tools", instancing specifically the introduction of the company's first bar feed system: the company also introduced a performance-leading linear motor driven tool presetter at the Open House. These were among a number of product unveilings (see box, below), but real-world applications were underlined heavily at the event. Aerospace and power generation, together with medical engineering are three key target areas for Gildemeister this year. For the latter, a number of events are planned around the world to promote this. In the power generation area, a DMC 125FD duoBLOCK universal machining centre, capable of 5-axis milling plus turning, via its 30 rpm table, was demonstrated machining a stainless steel blade base for a gas turbine centrifugal compressor. The important point being that with this machining method the manufacturing time has been slashed from 16 hours to just two, in two clampings. A larger component, a 1.6 m guide ring for a steam turbine, was shown being machined on a DMU 200P 5-axis, pallet-type universal machining centre. Here, the main pointers are that the 5-axis milling capability of the machine means that there is no need to employ the time-consuming EDM eroding process, it is claimed, with this positively impacting on surface integrity and eliminating the need for any manual finishing. In addition, the constant geometry of the impeller blades within the guide ring improves efficiency. The precision machining of a planet gear carrier for a wind generator weighing 3,500 kg on Gidemeister's largest machine, the DMC 340 FD 5-axis mill-turn machine, was another highlight. And for parts that won't fit on even this – other wind turbine parts, for example – the company plans to adapt it to meet individual components. Necessary, since today's 5 MW wind turbines will, in time, give way to those boasting generating capability of 10 MW, it was suggested. Additionally, Gildemeister also has a special gear package for its machines to support the manufacture of very large gears as used in the power generation industry. Software to support the creation of NC programs from gear parameters is under development. AEROSPACE EXCELLENCE In aerospace, it was a similar theme, but this event also marked the anniversary of the launch of the company's Aerospace Centre of Excellence, which is based at Pfronten. Last year, the ambition was to double the value of aerospace sales from €50 million to €100 million. That has been achieved, reports newly installed UK managing director at DMG UK Richard Watkins, who previously headed up the company's European aerospace efforts. Further aggressive growth is now on the cards (see also the Aerospace Supplement with this issue). Demonstrating its aerospace part credentials, at the Open House, in parallel with a seminar programme, machining solutions included high speed turning on a DMC160 FD duoBLOCK 5-axis machining centre with 30 rpm A-axis, the subject part being a compressor component for an aircraft engine; the machining of a complex helicopter gearbox on a DMC 125 FD duoBLOCK fitted with high torque spindle, plus the demonstration of high speed titanium machining; a flexible solution to the machining of long turbine blades based on a DMU 100 monoBLOCK universal 5-axis machine fitted with 'vario' table, aimed at sub-contractors requiring flexibility; and the world premiere of the DMC 60 FD duoBLOCK 5-axis milling plus turning centre was highlighted by the complete machining of an aluminium control case in a single clamping. Box item Open House product launches · The 5-axis DMU 60 FD duoBLOCK has the same machining compartment dimensions and basic milling and turning functions as its sister model, the DMU 60 FD. X, Y and Z-axis travels are 600, 700 and 600 mm, respectively. The main difference between the two is the latest model's integrated pallet system for parts up to 630 mm diameter, height 695 mm, and weighing up to 500 kg. Turning speed is 1,200 rpm max. · The DMC 210 U universal gantry machine has been updated in keeping with the company's other machines, so, high visibility windows, plus ERGOline CNC, for example. But it also offers a longer Y axis, a larger Z path, higher clearances, faster rotary and linear axes with increased dynamics, a larger swivel range in the B axis, bigger and heavier tool dimensions, as well as a higher table load and faster pallet changes. X, Y and Z-axis travels are 1,800, 2,100 and 1,250 mm, respectively; weight capacity is 5,000 kg. The integrated pallet changer can also integrate with the RS3 triple pallet system. · The Ultrasonic 5-5 linear ultrasonic and high speed machining centre has also been updated to the latest design look. Linear drive in X now offers 1 G acceleration, while linear rapid traverse rates are 80/min. X, Y and Z-axis travels are 500, 450 and 400 mm, respectively. · A new series of tool presetters featuring linear drives offers repeatability of +/- 0.001 mm, with a 25 per cent increase in productivity claimed. The new VIO linear supports tools up to 1,000 mm diameter and up to 1,000 mm in length. · The DMG Loader 65-1 magazine bar loader weighs 1,500 kg – 50 per cent more than others – and so will tolerate bent bars to a better degree. It can support bars up to 80 mm diameter (69 mm hexagon) and 3,300 mm in length, with maximum rpm set at 6,000, depending on diameter.