Published 5/24/2017

Making Connections at Innovation Days

Among other highlights, this year’s iteration of DMG MORI’s annual open house event showcased the company’s latest efforts to connect traditionally disparate machining operations, both in the physical sense and the virtual sense.

Matt Danford

Former Senior Editor, Modern Machine Shop

Displayed for the first time in the United States, the DMC 80 FDS Duoblock adds grinding capability to a five-axis machining platform previously limited to turning and milling. Company representatives report that much of the effort to integrate this capability involved configuring the wheel-dressing unit, shown in action here. The system leverages an internal audio sensor, as well as an audio sensor and a torque sensor within the grinding tool itself, to accurately measure and dress the wheel.

Based on a multi-axis turning center platform, the Lasertec 4300 hybrid additive/subtractive machine uses a DED (Directed Energy Deposition) or powder spray additive process.The option for a a laser as powerful as 10 kW helps maximize deposition rates before machining to the required tolerance and/or surface finish.

This display was reportedly targeted largely at small- and medium-sized manufacturing operations seeking an affordable entry into automation. It paired a CTX Beta 800 TC turn-mill with a Robo2Go automation system that’s “taught” directly through functionality in the company’s application-based CELOS operating system. The operator simply enters the dimensions of the workpiece, the chuck and the gripper, then selects one of the pre-defined workpiece tray arrangements to start the process. Thanks to the inclusion of an area scanner, the Robo2Go slows down or shuts down for safety when human beings get too close.

The CELOS application-based control and operating system features various new technology cycles. These include intelligent internal, external and (for the new FDS machines) face grinding. Another example is a “technology library” that enables easy saving and retrieving of hole sequences and tool technologies. A particular highlight at Innovation Days was the CELOS Performance Package. The package includes the Condition Analzyer app for analysis of machines and process signals, and the Performance Monitor app for transparency and monitoring of manufacturing parameters.

Designed for high-precision work in hard, difficult-to-machine materials, the company's ultrasonic machining technology leverages ceramic material within the toolholder that rapidly expands and contracts in increments measured in microns. With the point of interaction between tool and work oscillating ever so slightly, forces and heat are spread over a greater proportion of the cutting edge to improve surface finish and tool life.

The DMU 50 universal five-axis machining center, shown here, is now available with a FANUC CNC.

Industry events have always been about making connections, but making connections these days is about more than just networking. Consider DMG MORI’s recent “Innovation Days” open house, where conversation revolved largely around means of connecting traditionally disparate machining operations, both in the physical sense and the virtual sense.

As for the former, visitors to the company’s Hoffman Estates, Illinois, U.S. headquarters May 15-18 were the first in North America to see a DMC/DMU series Duoblock machine with grinding capability. Grinding is a new addition to the the turning and milling functions previously available on this five-axis machining platform. Another notable example of connecting operations in one platform is the Lasertech line, which integrates subtractive five-axis machining with additive laser deposition technology. Automated means of linking operations were also common, ranging from multi-pallet changers on five-axis horizontal machining centers to robot-fed turn-mills.

Capability for virtual connection was highlighted at more than one of the 35 total machining displays, even those outside an area dedicated specifically to Industry 4.0. CELOS, the company’s suite of front-end CNC applications, offers new machine and process data visualization functions that were demonstrated in various forms throughout the facility. Notably, these applications will reportedly be even more powerful when combined with newly ordered machine tools, which are currently under production and will reportedly contain more embedded sensors (the company maintains manufacturing operations in Japan, Germany, and Davis, California). Among other advantages, strides in data-driven manufacturing technology can help boost capability for taking proactive action rather than reactive action (for example, fixing a problem before it triggers an alarm).

Another U.S. premiere at the event highlighted the company’s drive to further strengthen connections with customers on this continent in the wake of transitioning from distribution to direct sales and service. In response to popular demand, the DMU 50 universal five-axis machining center can now be paired with a FANUC CNC as an alternative to the traditional choice of Siemens or Heidenhain models.

Click through the picture gallery above for more information on these developments and additional examples of technology on display at the event.