ULTRASONIC 65 2nd Generation
ULTRASONIC machining centre in reliable monoBLOCK design
Max. X-axis stroke
29 in.
735 mm
Max. Y-axis stroke
26 in.
650 mm
Max. Z-axis stroke
22 in.
560 mm
Max. workpiece diameter
33 in.
840 mm
Max. workpiece height
20 in.
500 mm
Max. workpiece weight
2,205 lbs.
1,000 kg
Control & software alternatives
SIEMENS
Highlights
ULTRASONIC by DMG MORI
ULTRASONIC technology integration - reduced process forces for higher productivity
- Technology integration via HSK-A63 interface for ultrasonic superimposition of the tool rotation with amplitudes up to 15 µm
- Process forces reduced by up to 50% through ULTRASONIC enable, depending on requirements: higher feed rates, improved surface quality up to Ra <0.1 µm, longer tool life
- Specific coolant treatment systems with centrifuges, optimized for the ULTRASONIC processing of Advanced Materials
ULTRASONIC 3rd Generation - Optimal process control through intelligent controls
- Constant amplitude in the process to ensure reproducibility
- Automatic detection of the working frequency, significantly improved hardware for signal acquisition
- Frequency tracking and simultaneous power control in real time for optimal process stability
- Ensuring the ULTRASONIC advantages even with non-optimal tools
- Fully compatible with 2nd generation ULTRASONIC actuator
Ergonomic
- Large door opening of 1,500 and unique access to the working area, most compact machine with a footprint of just 12 m²
- Unrestricted crane loading of up to 1,500 kg
- Quick and easy to set up thanks to it´s three-point support
Precise
- Comprehensive cooling measures, high-performance coolant unit and multi-sensor compensation as standard
- From 5 µm positioning accuracy in standard
- Stiff construction with high static masses and balanced moving parts
Versatile
- Several table solutions from the 5 axes machining with up to 1,500 kg or complete machining with milling and turning with up to 2,050 Nm
- Widest spindle range on the market with up to 30,000 rpm or with up to 430 Nm
- Machine integrated tool magazines with up to 180 pockets
Stiff monoBLOCK concept
- monoBLOCK – Maximum stability from one casting
- One-piece column with large, stable slideways, 55 mm roller guideways in all axes
- Maximum stability thanks to large ball screws in all axes ø 50 / 50 / 50
- FEM optimisation of all components
- Clamping of the swivelling rotary table
Application Examples
Automation
Standard automation and customized solutions in the VERTICO design
Automation is a key element of digital production. Every DMG MORI machine can be upgraded with standard automation or with a customized automation solution for flexible manufacturing systems:
PH 150
Universal pallet handling from DMG MORI
- Control directly via the machine control system
- High variability of available configurations from 24 round pallets of ø 148 to four 500 × 500 mm pallets
- Up to 150 kg workpiece weight as standard (optionally expandable to 250 kg)
- Possibility to prioritize orders
- EROWA clamping system as standard, SCHUNK optional
- High clamping repeatability (< 0.002 mm for the chuck EROWA UPC-P)
- Optimal accessibility to the machine and automation
PH Cell 300
PH Cell 300 - Modular pallet handling for up to 40 pallets
- Modular automation concept with up to 40 storage locations in a 10.7 m2 footprint
- Handling of different pallet sizes in one system
- Up to 300 kg transfer weight (workpiece incl. pallet)
- Separate setup station for ergonomic and simultaneous loading and unloading of pallets
- Convenient and simple control of the automation directly via the machine control panel
PH Cell 500
PH Cell 500 - Modular pallet handling for up to 32 pallets
- Modular automation concept on just 10.7 m²
- Use of cast iron clamping cone pallets
- Transfer weight up to 500 kg (including pallet)
- Maximum workpiece dimensions 500x500x750 mm
- 400x400 and 500x500 mm pallets
- Modular concept with best ergonomics and accessibility
PH Cell Twin
PH Cell Twin - Modular pallet handling for 2 machines and up to 30 pallets
- One pallet handling device for 2 machines
- Up to 30 pallets on 12.9 m² due to double row pallet storage on each level
- Workpieces up to 500 x 500 x 500 mm
- Up to 300 kg transfer weight (workpiece incl. pallet)
- Retrofit of the second machine possible
- Attractively priced automation in DMG MORI VERTICO design
AMR 2000
Holistic automation on the shop floor
- Collaborative automation solution with free layout design
- Omnidirectional movement for minimal space requirements (turning radius 0m)
- Basis for additional tasks, e.g. B. tool handling, chip disposal, etc.
- Material transport from Euro pallets 1,200 x 800 mm
- Maximum transport weight of up to 2,000 kg
- Security based on Sick and Siemens technology
Highlights
AMR 2000 Material
- Autonomous transport of material pallets
- Transport of different load carriers
- Integration into DMG MORI automation systems for workpiece handling – exchange of finished part and raw part pallets
- Integration into existing processes
- Scalable and expandable at a later date
AMR 2000 chips
- Autonomous transport of chip containers
- Automatic transport order from the master computer
- Extended autonomy of the machine tool
- Material and chip transport can be combined
AMR 2000 tool handling
- Tool identification in the standard
- Autonomous transport and exchange of tools between machines and tool storage systems
- Max. tool dimensions ø 280 / 400 mm
- Max. tool weight 30 kg
- Transport weight 720 kg (24× 30 kg)
- Maximum number of tools: 24 pcs
Robo2Go Milling
Flexible workpiece handling for small to medium batch sizes
- One app for uniform control of all Robo2Go variants, setting up a new workpiece < 5 minutes
- Strong construction for all requirements: load capacity robot optionally 25 or 35 kg
- Handling of components 20 - 200 mm in size
- Full accessibility to the machine is maintained
- Alignment and turning station for automated 6-sided complete processing
Highlights
One app for uniform control of all Robo2Go variants.
- Integrated in the machine control operation via CELOS APP: No need to change your NC programs!
- Intuitive usability thanks to dialog-guided software
- Creation of the process through predefined program modules via drag & drop: No robot programming knowledge necessary
- Setting up a new workpiece < 5 minutes
Robo2Go Milling
- Strong construction for all requirements: Robot payload optionally 25 or 35 kg
- Handling of components 20 – 200 mm in size
Details
Exchangeable workpiece trays for maximum flexibility
Flexible gripper system, for workpieces up to 200 × 200 × 200 mm
PH-AMR
Pallet automation with maximum flexibility through free layout design
- Modular concept with flexible layout design
- Driverless transport systems without guide rails or tracks
- Collaborative: Man and machine in one system
- Navigation through natural navigation
- Pallet sizes from 500 × 500 mm to 1,600 × 1,250 mm
- Workpieces up to 5,000 kg and ø 1,600 mm
Highlights
Free accessibility
- Best visibility into the workspace at any time
- Manual or crane loading still possible
- Collaborative system – man and machine in one system
Modular concept with free layout design
- No safety housing for the automation system necessary
- Free positioning possibility of the individual modules
- Subsequent integration into existing production
Simple expansion of automation system
- Additional shelf modules to increase the number of storage places
- Additional AMRs can be integrated in the system
- Machines with an automation interface can be integrated very quickly afterwards
Minimum space requirement
- Free pallet handling system without fixed installation requirements on hall floor
- AMR paths remain walkable and passable
- Laser scanners guarantee personal protection in driving direction
- Omnidirectional movement for minimum space requirements (turning circle 0m)
- Flexible automation concept - Automation of different machine types with one system
Control & Software
MPC 2.0 – Machine Protection Control
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
Highlights
Customer Benefits
MPC Graph: current and learned process values. / MPC Diagnostics: stock condition, number of impact and crash.
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
intoolSENSOR
- Automatic detection of contact with the workpiece
- Tool breakage detection without additional measuring device
- Self-learning algorithm for precise contact detection
Highlights
Customer benefits
- Precise drilling depth independent of tool wear
- Time saving due to automatic recognition of the workpiece contact
- Increased process reliability due to closed control loop
Left: The ULTRASONIC system reacts to external load; Right: Tool contact detected
ULTRASONIC feedCONTROL
- Automatic reaction of process changes (materials, tool abrasion) by adapting the feed rate in the process
- Directly evaluates the signals (frequency and power) of the ULTRASONIC system
- Optionally also takes the spindle utilization into account
Highlights
Customer Benefits
- Always optimal process performance
- Process control through predefined parameter windows
- Safety for fragile workpieces made of brittle-hard materials
Left : ULTRASONIC feedCONTROL sets limit values “Upper / Lower Limit” for the machining process and monitored in real time. This determines the optimum “Operating Range” of the process. / Right : Via an intuitive user interface, ULTRASONIC feedCONTROL can be set up quickly. Parameters and required reactions are defined in this way.
ULTRASONIC axialGRINDING
- Grinding of rotationally symmetrical structures and in particular 3D contours in hard-brittle materials with maximum performance
- Production of bearing rings, wafer chucks, microwave windows for many areas of the semiconductor industry, optics and technical ceramics
- Grinding of spheres possible
Highlights
Customer Benefits
- Simple programming of complex 3D contours* and rotationally symmetrical geometries using intuitive operator screens
- Selection of different cutting edges and setting angles of the grinding tool
- Automatic adjustment of the tool contact point depending on the contour
*Only the ULTRASONIC axialGRINDING cycle can grind 3D contours. The standard grinding cycle from DMG MORI for FDS machines cannot grind 3D contours.
Left : Different tool settings for changing the engagement point of the of the ULTRASONIC grinding tools. / Right : Simple setup of the grinding tools including edge radii.
Sealing ring, SiC
Ring, quarts glass
Resonator, quartz glass
3D quickSET
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
Highlights
Turning Customer Benefits
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
Dialogue-guided measurement of the B- and C-axis.
Milling Customer Benefits
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
Define kinematics head
ULTRASONIC microDRILL
- With ULTRASONIC 3rd Generation and 32.000 rpm for micro drilling with highest process safety
- Fully integrated regulation of the drilling force in the preset- spindle down to smaller 1 N – independent from the z-axis of the machine
- ICS with seperate fine filtration and flow rate control starting from 1 l/min
- Automatic ejector mechanism for drill cores from the diamond hollow drills
Highlights
Customer Benefits
- Drilling diameter from 0.1 mm – 2.0 mm
- Several thousand holes per part possible without manual interaction
- Applicable for diamond hollow drills and spiral drills
Left : Fully integrated into the display in the CELOS SideScreen / Right : Precise regulation of the drilling force incl.
Service & Training
Downloads & Technical Data
Workpiece
Max. workpiece diameter
33 in.
840 mm
Max. workpiece height
20 in.
500 mm
Max. workpiece weight
2,205 lbs.
1,000 kg
Work Area
Max. X-axis stroke
29 in.
735 mm
Max. Y-axis stroke
26 in.
650 mm
Max. Z-axis stroke
22 in.
560 mm