Competitive production with CNC milling machines

From 3-axis milling to 5-axis simultaneous machining

In their simplest design, milling machines are set up for 3-axis machining: the tool moves over the workpiece in the X, Y and Z direction. A rotary axis, in the headstock or the table for example, extends the range of machining because components can also be positioned at an angle. But this is only a precursor to 5-axis milling, which machine tool manufacturers achieve by means of a second rotary axis. This makes it possible to align the workpiece in almost any position, so that it can be machined from five sides in one clamping process, which makes it possible to produce metal components with complex geometries too. The workpiece only needs re-clamping if you intend to machine a sixth side. 

The king of milling disciplines – 5-axis simultaneous machining – is a further development of 5-axis technology: in this process, all the axes are interpolated, which gives the milling machine the maximum machining versatility. The kinematics of the CNC machine is usually housed in a swivel-type indexing table, which continuously moves the component as the milling tool cuts away the material. An alternative to this is head kinematics. Here the milling head has two rotary axes which allow it to move freely around the workpiece. 5-axis simultaneous milling makes it possible to produce so-called free-form surfaces, which are common in mould construction, for example.

Milling machines for various applications

Optimal vertical milling machines for any size of workpiece

Typical features of vertical machining centres from DMG MORI include reliable milling spindles, powerful motors and innovative cooling and tool systems in all standard sizes, including a quick changer for the milling tools. The machines also have a stable design, ensuring long-term high repeat accuracy. High-tech control systems from SIEMENS, HEIDENHAIN, MITSUBISHI and FANUC ensure precise completion of challenging jobs, combined with ease of operation.

The variety of machinery and cutters in the product range ensures that users of vertical milling machines can always find the size they need – from the compact DMP 35 with a minimal footprint to the DMV 185 for components over 2,000 mm in length. In addition, the range includes entry-level models such as the M1 or the vertical milling machines in the CMX V series and the NVX models for high-precision machining of the most complex components.

• Strong design and innovative cooling systems for maximum precision
• Future-proof production thanks to modern control systems and digitalisation features
• High-quality components for reliable and productive manufacturing

Horizontal milling machines for economical series production

Whether it’s for precision machining of series components or powerful milling with high cutting volumes – horizontal machining centres from DMG MORI are versatile. Large working spaces offer sufficient room for clamping towers, so that even large volumes can be produced cost-effectively in conjunction with a pallet changer and automation solutions.

The series of products in the horizontal machining centre segment from DMG MORI offer a seamless range for horizontal CNC machining. From the extremely robust NHX series for maximum precision, to the DMU/DMC H monoBLOCK models for reliable universal processing, the high-tech range offers customised complete solutions for every need: from universal milling of various workpieces to highly automated series production of engine components in the automotive industry.

• Maximum utilisation of the working space
• Perfect for series production of precision parts
• Optimal chip fall with very high cutting volumes

Productive complete machining with 5-axis milling

As a world market leader in 5-axis milling, DMG MORI offers the entire spectrum of universal milling machines. Consistent development of numerous models always results in innovative manufacturing solutions to meet the highest quality requirements. Volumetric precision down to less than 15 µm, workpieces of up to 120 t in weight and movements of up to six metres can be achieved in this segment. Process integration with equipment options for milling-turning and grinding is also available.

5-axis machining centres from DMG MORI offer great flexibility, maximum cutting and carving performance, dynamic precision and the highest accuracy. Individual equipment options allow optimal configuration for any application. The CMX U series is the entry level for 5-side machining, while the DMU 50 facilitates applications in the premium class of 5-axis simultaneous milling. Meanwhile, the numerous DMU eVo, DMU monoBLOCK and DMU duoBLOCK models meet a wide range of requirements in terms of component size, precision and speed. The DMU Gantry models and portal machines add the finishing touch to the portfolio for XXL machining.

• Precision, dynamics and productivity of the highest quality
• Wide variety of machines, from 5-axis machining to 5-axis simultaneous milling
• Integrated production solutions for complete machining, including integration of various technologies

Greater productivity with automated manufacturing solutions and process integration

With varied and innovative automation solutions, DMG MORI supports its customers in remaining competitive on the global market over the long term. The range covers everything from standard automation such as the PH 150 pallet handling system, the WH 3 Cell workpiece handling system and Robo2Go milling as a flexible robot solution, through to round pallet stores (RPS) and linear pallet pools (LPP). Driverless transport systems in the AGV series also move workpieces, pallets and tools autonomously from A to B. With its expertise in automation, DMG MORI can find an integrated solution for any application.

Process integration is also part of the design of integrated solutions at DMG MORI. Here the machine tool manufacturer combines various machining processes in one working space, so that complex workpieces can be completed. Thus, milling machines are also able to turn components, cut teeth in them and grind them – process stages for which separate machines are used conventionally. Production in one clamping process means that the component quality increases significantly, and cycle times are drastically reduced.