NEW FEATURES FOR LARGE PART MACHINING · Panels Steel construction Compressor housing Precision...

MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING 1

NEW FEATURES FOR LARGE PART MACHINING

AGENDA


DMG MORI

Product Portfolio

Target Markets

Applications (Aerospace, Die&Mold, Energy, Engineering)

Preferred spindles

Mill-Turn + Grinding

Automation

Cutting Solutions

WORLDWIDE PRESENCE IN 79 COUNTRIES


14 PRODUCTION PLANTS WORLDWIDE

MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 4IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING

PRODUCTION FACILITY XXL CENTER


PRODUCT OVERVIEW 2019 WITH 168 PRODUCTS*

MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019 6

*w/o Taiyo Koki

IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING

TECHNOLOGY EXCELLENCE


TARGET MARKETS


Gantry Portal

Ae

ros

pa

ce

Die

& M

old

En

erg

yE

ng

ine

eri

ng

Carbon components Bulkheads and structure parts Turbine components Large landing gears

Monocoque Complete processing, mainly finishing Complete processing, mainly roughing

Gears and Pelton turbines CrankcasePump housingCarbon blade Turbine housing

Compressor housingPanels Steel construction Precision components Machinery components


AEROSPACE – APPLICATIONS


HIGH STRESSED & TITANIUM STRUCTURE COMPONENTS

ROTATION SYMMETRIC ENGINE PARTS

ALUMINIUM STRUCTURAL PARTS & COMPOSITES


AEROSPACE – A380 TORQUE LINK: TI10V2FE3AL


Machining facts Customer BenefitCustomer request

Part name: Airbus A380 Landing

gear torque link

Objective/

requirements:

1) Reduction of

machining time

2) High process stability

regarding tool life and

chattering

3) High position accuracy

Branch: Aerospace

Dimension: h/w/l: 209 / 605 / 1075 mm

Material: Titanium Ti10V2Fe3Al

Set-ups: 3 (Green Button Process)

Number of tools: 21

Machining time: 23 hours

Key facts: DMC 160 U dB, Gearbox

spindle: 6.300 rpm, 1100

Nm / 32 kW (40%dc)

HSK-A100; B-Axis, Active

damping package

43% time reduction (33 23 hours)

5 µm positioning accuracy

Ra 0,4 µm surface quality

Cutting speed of 180 m/min (35 m/min

previously) thanks to innovative CBN

inserts

High process reliability thanks to damping

package (no tool breakage)


Finished workpiece Area of applicationClampingTooling

AEROSPACE – COMBUSTOR CASE – INCONEL 718+


Finished workpiece Area of applicationIn-Process MeasuringSetup


Part name: Combustor case

Objective/

requirements:

1) Reduction of

machining time

2) High raw material

costs require high

process stability

(25.000€)

Branch: Aerospace

Dimension: h/w/l: 686 / 500 / 360 mm

Material: Inconel 718+

Set-ups: 5 set-ups (Green Button

Process)

Number of

tools:

49 tools plus sister tools

1. Ceramic, Carbide partly

2. Carbide, CBN partly

Machining: 60 hours

Key facts: Motor spindle: 12.000 rpm, 430

Nm / 52 kW (40% dc), HSK-

A100; in-process probing,

accuracy package

67% time reduction (180 60 hours)

Reduction of machines (2 1) by one

mill-turn machine = high flexibility

Reliable green button process for high

volume production

High process reliability due to the use of

measuring features

Ceramic roughing (turning, milling)

Fixture concept with rigid clamping,

supports and damping elements


AEROSPACE – COMBUSTOR CASE – INCONEL 718+


OP10

Pre-Turning outside +

Milling

OP20

Pre-Turning inside + Milling

OP25

Heat Treatment

OP30

Turning

OP40

Finish-Turning

OP50

Finish-Turning +

Milling

Raw part

pre-machined forging

Finished part

Combustor Outer Case

DMC 125 FD duoBLOCK

5-Axis Mill-Turn Machine

OP 10 OP 20 OP 40 OP 50

Tools: 49 different tools plus sister tools Roughing: Ceramic, Carbide partly Finishing: Carbide, CBN partly

OP 30 (=OP 20)

Total Machining Time: ~ 60 hours

DIE&MOLD – APPLICATIONS


MOBILITYINDUSTRY &

INFRASTRUCTUREHUMANS & ENVIRONMENT


+ Information Technology

+ Mechatronics and Automation

+ Energy Technology, etc.

+ Automotive

+ Railway

+ Logistics, etc.

+ Nutrition (e.g. Packaging)

+ Consumer Electronics

+ Medical, etc.

DIE&MOLD – FORM PLATE


Finished workpiece Final productMachiningSetup


Part name: Vehicle Components

Objective/

requirements:

1) Surface quality below

Ra 0.4

Branch: Die&Mold

Dimension: h/w/l: 310 / 240 / 170 mm

Material: 1.2312 40CrMnNiMo8-6-4

Set-ups: 1

Number of tools: 8

Machining time: 51:44:23

Key facts: Technology cycle 3D

quickSET


Surface quality Ra 0.3 achieved

Precision better than 0.01 mm achieved

DIE&MOLD – RADIATOR GRILL MOLD


Workpiece Machining


Part name: Radiator Grill Mold

Objective/

requirements:

1) Machining time

reduction

2) Elimination of EDM

processes

3) Reduction of polishing

time

Branch: Die&Mold

Dimension: h/w/l: 578 / 970 / 1.570

mm

Material: S55C (JIS)

Set-ups: 1 set-up

Number of tools: 11 tools

Machining time: 8 hours

Key facts: 5-axis simultaneous

milling, Aqueous coolant

25% total machining time reduction

Complete elimination of EDM

processing time of 136 hours

Reduction of polishing time of 14 hours

Reduction the number of tools due to 5-

axis machining


DIE&MOLD – NEW BENCHMARK AT VW GROUP


Requirements:

+ Programmed machining feed rate: 10,000mm/min and 15,000mm/min

+ Contour accuracy: max. permissible deviation from given contour at TCP = 0.01mm

+ Surface quality: visual and tactile inspection

Results to the DMU 600 Gantry linear

+ Elapsed time 25% faster compared to all other machines at Audi Tool Shop

+ Contour accuracy deviation < 10µm at TCP

+ Linear drive technology: minimum vibration compared to ballscrew and/or rack & pinion

+ Best surface quality, no irritations and perfect transitions


HIGHER PERFORMANCE WITH LINEAR DRIVE


Tim

e [s]

0.0

0

5

10

40

0.0

5

0.1

0

0.1

5

Distance [mm]

0.2

0

0.2

5

0.3

0

Tim

e [s]

0.0

0

3.0

linear

conventional drive

0.0

5

0.1

0

0.1

5

Acceleration [m/s²]

0.2

0

0.2

5

0.3

0

0.3

5

0.4

0

0.4

5

0.5

0

Time to max.

acceleration9× shorter

5,000 mm/min 6,500 mm/min 7,500 mm/min 10,000 mm/min

Rack & Pinion / Ballscrew

Advantages

+ Highest surface quality

+ Significant reduction of the machining time

+ Long-term precision and maintenance-free

+ Highest contour accuracy

35

30

15

20

25

0.5

1.0

1.5

2.0

2.5

Acceleration time

around 3× shorter

linear

conventional drive


ENERGY – APPLICATIONS


GEARS & PELTON TURBINES CRANKCASES INDUSTRIAL GAS TURBINE


ENERGY – DRILLING HEAD


Finished workpiece Final productMachining


Part name: Drilling head

Objective/

requirements:

1. Reduction of

processing time by

75 %

2. Machining of

negative angles with

angular head

3. Complete machining

in one setup

Branch: Energy

Dimension: h/w/l: 330x400x400 mm

Material: 1.6523 (21CrNiMo2)

Set-ups: 1

No. of tools: 20

Machining time: 18 h

Key facts: Motor spindle:

12.000 min-¹, 288 Nm / 44

kW (40% ED)

75% machining time reduction

from 70 18 hours

Achieved surface quality of Ra 1 μm

Complete machining in one setup


ENERGY – LEDSKENESEGMENT A STEG3 SGT-800


Finished workpiece Final productPicture 2 “Machining”Picture 1 “Machining”


Part name: Gas Turbine

Components

Objective/

requirements:

1) Machining the gas

turbine component

without manual

intervention

2) Reduction of

processing time

3) In-process measuring

4) Programming with

NX

Branch: Energy

Dimension: h/w/l: 1.060 / 690 / 160

mm

Material: 1.4305 X8CrNiS18-9

Set-ups: 6

Machining time: 4 h

Key facts: Alternate spindle speed,

Probing

33% machining time reduction

from 360 240 min

Processing without manual intervention

In-process measuring with automatic tool-

correction

Program was created with NX

In-process measuring was programmed

via CAD/CAM-system – NC-CAM / Janus


ENGINEERING – APPLICATIONS


STEEL CONSTRUCTION MACHINERY COMPONENTS COMPRESSOR HOUSING


ENGINEERING – GEAR WHEEL


Finished Part Final ProductPicture 2 “Machining”Picture 1 “Machining”


Part name: Drive Technology

Objective/

requirements:

1) Technology integration

of milling, turning and

grinding in one machine

2) Reduction of setups

3) Grinding an internal

cone of length 444 mm

Branch: Engineering

Dimension: h/w/l: 1.510 / 459 / 472

mm

Material: 18CrNiMo7-6 EN10084

No. of set-ups: 2

Number of tools: 24

Machining time: 8 hours 10 minutes

Key facts: Hard turning, Grinding

and pallet station

Reduction from 3 1 machine

Reduction from 5 2 set-ups

Grinding a cone inside with a length of

444 mm (grinding tool length = 560 mm)

Milling slots inside 90 mm with angle head

and three different tools

Automatic measuring and correction of

tools and positions with 3D-touch probe

and L-touch probe

Mill-turn the hardened outside diameter

over the gearing for more process stability


PRODUCTIVITY & EFFICIENCY


Zero clamping systems

Increase of Productivity (Increase the utilization of machine tool)

Complete

5-axis-machining

High availability Tool magazine Best ergonomics

Increase of Efficiency (Increase the output of machine tool at high utilization)

Powerful gearbox

spindles

High speed

motor spindles

Linear drives Endless C-axis

rotationTechnology Cycles

∞IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING

MILL-TURNING (FD) TECHNOLOGY


Mill-Turn (FD) package

› Automatic balancing cycle

Display of size and position of the counterweight

› Covering for the work space as safety cabin

with safety glass screen

› Speeds up to 250 rpm (210) / 200 rpm (270) / 120rpm (340)

› Moment of inertia

up to 2.900kgm² (210) / 9.000kgm² (270) / 8.000kgm² (340)

› Unique technology integration

› Tool taper HSK-A100

Direct

measuring

system

Rotary encoder

in table center

Hydraulic table

clamp

Direct drive


TECHNOLOGY INTEGRATION: GRINDING



› 4 x DMC340U

› 18 pallet locations

› 2 loading stations

› Long set up times due to

complex components

› Vacuum clamping

AUTOMATION – CUSTOMER PROJECT


DMG MORI LARGE PART MACHINING


Project Scope:

• 3x DMC 210 U (incl. 2x µPrecision)

• LPP – 22 No. of pallets

• 3x DMC 340 U

• 2x DMU 600 P


CUTTING SOLUTIONS


THANK YOU FOR YOUR ATTENTION

MATTHIAS WOELFL & JOSE VARGHESE | 23/01/2019IMTEX 2019 | NEW FEATURES FOR LARGE PART MACHINING

NEW FEATURES FOR LARGE PART MACHINING · Panels Steel construction Compressor housing Precision...

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Transcript of NEW FEATURES FOR LARGE PART MACHINING · Panels Steel construction Compressor housing Precision...