THE DMG MORI MAGAZINE FOR CUSTOMERS AND INTERESTED PARTIES 02 – 2022 T E C H N O L O G Y EXCELLENCE WORLD PREMIERE PH Cell Twin AUTOMATION Experience the whole world of DMG MORI automation solutions. Our special automation website can be found at: love-automation.dmgmori.com
CONTENT 42 54 Sandvik Coromant: Automated manufacturing solution of bodies for drilling tools with over a hundred variants in batch sizes from 2 to 80 using the NTX 2000 turn-mill center and MATRIS, the flexible robot system from DMG MORI Pallet handling PH-AGV 5000: The autonomous, driverless transport system for pallet sizes up to 1,600 × 1,400 mm and 5,000 kg handling weight. 08 AUTOMATION – We love Automation – Retrofit – Hintersdorf GmbH & Co. KG – Fr. Aussieker Metallverarbeitung GmbH & Co. KG – PH Cell 2000 22 WORLD PREMIERE – PH Cell Twin 24 AUTOMATION – SPECK Pumpen Walter Speck GmbH & Co. KG – Robo2Go – The best-selling standard automation – STROMBOLI GmbH – NEW: Pallet handling by MATRIS – Nabeya Co., Ltd. – Sandvik Coromant – HYDAC Technology (Shanghai) Ltd. – Interview – AGV / AMR – Pallet handling – PH-AGV 5000 – KIGUCHI TECHNICS INC. – CTS – Central Tool Storage für TH-AGV – Grede Casting Integrity LLC WORLD PREMIERE 2022 2 TECHNOLOGY E XCELLENCE 66 DMG MORI SUSTAINABILITY – Green and efficient with our After Sales – Körting Hannover GmbH – DMG MORI Green Economy – Meindl-Köhle Umform- und Systemtechnik GmbH & Co. KG – NEHER GROUP 82 ADDITIVE MANUFACTURING – Wolfgang Doose Werkzeug- & Vorrichtungsbau GmbH & Co KG SINCE 2021: 100 % CLIMATE- NEUTRAL MANUFACTURING OF OUR MACHINES GREEN MACHINE 22 PH Cell Twin Modular and compact pallet handling for two machines.
EDITORIAL Dr. Eng. Masahiko Mori President DMG MORI COMPANY LIMITED Christian Thönes Chairman of the Executive Board DMG MORI AKTIENGESELLSCHAFT WITH AUTOMATION AND DIGITIZATION TO GREATER SUSTAINABILITY In a challenging market environment, DMG MORI has proven itself to be a firm and reliable partner in global machine tool manufacturing. The world's leading manufacturer of high-precision, sustain- able machines and technologies benefits from its consistent implementation of the strategic triad of automation, digitization and sustainability. Stability is also ensured by the company's global footprint and a wide-ranging product and service port- folio that sustainably integrates forward- looking manufacturing solutions for cus- tomers from a single source. Learn more about the status quo and current innova- tions for the manufacturing industry in the following interview with Dr. Eng. Masahiko Mori, President of DMG MORI COMPANY LIMITED, and Christian Thönes, Chairman of the Executive Board of DMG MORI AKTIENGESELLSCHAFT. With the current campaign “We love automation” DMG MORI emphati- cally addresses the use of automation. Why should users love automation? Dr. Masahiko Mori: Because automation demonstrably creates added value – through increased process productivity and higher quality products as well as through reduced personnel costs and therefore lower costs per unit. Moreover, longer machine run times ensure more efficiency and sustainability, while enhanced transparency and repeat accuracy create the basis for a continuous improvement process. Christian Thönes: Take the utilization rate of a machine as the key indicator for the overall equipment effectiveness as an example. While conventional machine tools achieve a utilization of around 34 percent according to a study from RWTH Aachen in 2020, flexible manufacturing systems are demonstrably able to achieve rates of up to 90 percent. So instead of around 2,600 hours achieved conventionally, our machines can be used for up to 6,000 hours or more in an automated system. Our machines are designed for this and ideally should be used accordingly. » TECHNOLOGY E XCELLENCE 3
EDITORIAL But these arguments are not new … Dr. Masahiko Mori: New is that we have democratized automation so to speak, with massive investments and innovations over the last few years. Flexible manufacturing cells and manufacturing systems have now become economically viable for companies of all sizes. Today a unique range of modular equipment puts DMG MORI in a position to perfectly map the entire spectrum of flexible automated production from a single source – from simple to complex, for work- pieces, pallets and tools as well as from large series to single part production. Christian Thönes: Our innovative automation portfolio comprises in total 57 automation solutions in 13 production lines for machine- specific, universal and scalable solutions – including the entire hardware and software. We thereby can already equip or upgrade more than 150 different machine models for our customers, often even as a retrofit option. The levels of our automation offer range from machines with tool and pallet change, through flexible manufacturing cells to automatic tool provision and from driverless transport vehicles to different turnkey expansion stages of flexible manu- facturing systems. Dr. Masahiko Mori: Another basic topic is the extensive central control computer techno- logy. The new CELL CONTROLLER LPS 4 is not only able to integrate all single machines, but also manufacturing cells and manufacturing systems on the shopfloor to a flexible manufacturing network. Moreover, the intelligent new development can, where necessary, also control the automatic pro- vision of material, tools and operating resources. Integration to ERP, MES or APS systems and tool management is also reliably solved by means of adequate interfaces. Customers thus receive their entire tailor- made system consisting of high-tech machines, automation plus control intelli- gence and central control computer techno- logy from a single source and under a single responsibility. This gains in importance the higher the degree of automation, a fact reflected in our sales success. In the past few months we managed to place dozens of systems with a Linear Pallet Pool (LPP) and systems from the MATRIS building blocks successfully on the market. In addition, there are several hundred Robo2Go and PH Cell solutions – plus the standard auto- mation solutions. What innovative highlights can visitors at the international DMG MORI fall trade fairs expect? Dr. Masahiko Mori: We are currently expanding the successful series of Robo2Go models for turning and milling to include the Robo2Go Max as a solution for workpieces up to 115 kg and small until medium batch sizes. This model can also be prepared for its tasks quickly and simply directly from the CELOS control without any programming knowledge. In addition we are expanding the Matris family for modular entry into the world of manufacturing automation with the highly flexible and compact MATRIS Light for workpieces up to 5 kg. The handling system can be connected to the machine in less than 5 minutes, operated intuitively and, as a collaborating robot solution, needs no safety fence. For entry into automatic pallet handling, DMG MORI will also present the PH 50, an entry model that is both compact and economical. In the medium range, the PH Cell 300 offers space for up to 40 pallets of varying sizes of 320 × 320, 400 × 400 and 500 × 500 mm for transfer weights up to 300 kg on a footprint of just 10.7 m2. And finally, the PH Cell 2000 expands the port- folio with the flexible handling of work- pieces up to 2,000 kg on 21 pallets. The democratization of manufacturing has been DMG MORI's focus for years, so today automation is accessible and economical for companies of all sizes. Dr. Eng. Masahiko Mori President DMG MORI COMPANY LIMITED 4 TECHNOLOGY E XCELLENCE
GLOBAL FULL-LINER FOR AUTOMATION DMG MORI CELL CONTROLLER LPS 4 EDITORIAL SET-UP TIME TURNING MILLING G N I L D N A H E C E I P K R O W G N I L D N A H T E L L A P NEW NEW NEW NEW NEW MACHINE-SPECIFIC UNIVERSAL (1 MACHINE) SCALABLE (≥ 1 MACHINE) COMPLEXITY DMG MORI's portfolio consists of 57 automation solutions in 13 product lines for machine-specific, universal and scalable solutions, including the complete hard- and software: from machines with tool and pallet changer, flexible manufacturing cells, automatic tool supply (CTS), driverless transport vehicles (AGV & AMR) to the various turnkey expansion stages of flexible manufacturing systems, such as LPP or MATRIS, completed by the DMG MORI CELL CONTROLLER LPS 4. Christian Thönes: In particular at the AMB in Stuttgart, DMG MORI will exhibit the RPS 14 rotary pallet storage system, the Robo2Go Max for turning and the Robo2Go Milling. There will also be two very compact auto- mation solutions on show – the WH 3 Cell and the MATRIS Light. Another absolute AMB highlight is the new PH Cell Twin, via which two DMU 50 machines are linked on the smallest of spaces. You will find reports on many of the highlights mentioned in this magazine. Although automation is booming on a broad front, studies show that especially small and medium sized enterprises in manufac- turing technology are still reticent where digitization is concerned. Does this disparity surprise you? Christian Thönes: Automation and digitization are the strategic pillars for cost-efficient and sustainable manufacturing technology. Every change always begins where innovation for customers demonstrably creates value. In this respect the automation of production today creates the cost-effective, transparent and reactive environment in which the sustainable effect of industrial digitization can better evolve. To be more specific: the current situation does not indicate disparity, but perfectly normal customer behavior. » TECHNOLOGY E XCELLENCE 5
EDITORIAL DIGITIZATION DIGITAL TWIN 1. PLANNING 2. PREPARATION 3. PRODUCTION 4. MONITORING 5. SERVICE 62 Technology Cycles 27 CELOS APPs DMG MORI's connectivity solutions open up a holistic portfolio of digital tools and applications for the immediate workshop environment. This portfolio of digital end-to-end solutions supports our customers from planning with ISTOS, through work preparation and production, to the optimization of maintenance and service processes, for example with my DMG MORI. … which according to the studies comes at the expense of digitization! Dr. Masahiko Mori: The value of digital products and services is not measured on the basis of visions but by predictable customer benefits. Wherever this is the case, digitization will take place. This is proven by the enormous acceptance of our customer portal my DMG MORI, where al- ready today more than 30,000 customers with over 140,000 machines are connected to our service organization. As a result, we already receive 67 percent of all service ueries via the customer portal. To what do you ascribe the success of the customer portal? Christian Thönes: my DMG MORI quite simply makes digitization worthwhile. We use it to offer our customers direct access to all relevant production and service information. In addition we open up a direct digital communication channel for them in our worldwide service organization, which we are currently expanding to include another 100 service technicians. All these digital and real measures accelerate the processes holistically and convincingly enhance the service quality. Meanwhile, the term “triad” referred to at the beginning can also be found in the sustainability offensive from DMG MORI. What elements interact here? Dr. Masahiko Mori: In this case the triad reflects the holistic nature of our climate measures. By avoiding, reducing and com- pensating, DMG MORI has achieved both a CO2-neutral “Company Carbon Footprint” and a climate-neutral “Product Carbon Footprint”. This includes direct and indirect emissions from our own value creation as well as indirect emissions from upstream processes along the supply chain. Energy experts refer here to scope 1, 2 and 3 upstream. Christian Thönes: More specifically, all machines delivered since January 2021 have been produced completely climate-neutral. For this, DMG MORI was recently awarded the Platinum Medal in the Sustainability Rating by the internationally renowned institute EcoVadis. This means that we are among the TOP 1 % of over 35,000 companies evaluated worldwide. 6 TECHNOLOGY E XCELLENCE
EDITORIAL Automation and digitization are the strategic pillars for cost-efficient and sustainable manufacturing technology. Christian Thönes Chairman of the Executive Board DMG MORI AKTIENGESELLSCHAFT Does the energy-efficiency of the DMG MORI machines play a role here? Christian Thönes: Not directly. The machines and their utilization by customers have been a key pillar of our sustainability strategy for many years. This topic has again gained momentum in view of the price develop- ment on the energy market. Various studies indicate just how elemental this field of action is; they estimate the share of machine tools and production processes in the electrical power requirement in industry worldwide to be around no less than 5 to 10 percent. Dr. Masahiko Mori: Efficient starting points in this respect can be found especially in the optimization of the main and auxiliary units of our machines – in particular, within the framework of new developments, but also wherever possible in the re-engineering of existing series. At the same time, we are pushing the consistent use of consumption- optimized components (e. g. for lighting), the recovery of braking energy as well as the energy-efficient control and regulation of units. For example, customers save up to 20 % of energy in machine usage with the CELOS app “ENERGYSAVING”, while simultaneously reducing process times. « GREEN ECONOMY 100 % GREEN MACHINES CLIMATE-NEUTRAL MACHINE PRODUCTION GREEN MACHINE 1. Neutral Product Carbon Footprint (Scope 3 Upstream) 2. Neutral Company Carbon Footprint (Scope 1 + 2) GREEN MODE RESOURCE-EFFICIENT MACHINE USAGE (Scope 3 Downstream) TECHNOLOGY EXCELLENCE FOR GREEN TECHNOLOGIES GREEN TECH TOP 1 % FROM MORE THAN 35,000 COMPANIES! DMG MORI's sustainability strategy covers the entire life cycle of the machines. From climate-neutral machine manufacturing through resource-efficient machine operation to a machine recyclability of > 99 %. In addition, we support our customers in the field of green technologies, such as wind & water power, recycling and e-mobility. For this, DMG MORI recently received the Platinum Medal in the Sustainability Rating from the internationally renowned EcoVadis Institute. This means that DMG MORI is among the top 1 % of over 35,000 companies rated worldwide. TECHNOLOGY E XCELLENCE 7
AUTOMATION GLOBAL LEADER IN AUTOMATION: 13 PRODUCT LINES AND 57 PRODUCTS SET-UP TIME TURNING NEW Robo2Go Max NEW MATRIS Light SR (WASINO) IMTR (NTX 1000) MILLING Robo2Go Turning / Vision Robo2Go Milling WH Cell 1 PH Wheel 3 NEW PH Cell 2000 / PH Cell 300 G N I L D N A H E C E I P K R O W G N I L D N A H T E L L A P AWC (NMV / CMX V) RPS 2 PH 150 PH 50 MACHINE-SPECIFIC UNIVERSAL (1 MACHINE) NEW 8 TECHNOLOGY E XCELLENCE
AUTOMATION DMG MORI CELL CONTROLLER LPS 4 Technology expertise, machine and automation from a single source. Future-proof your production with DMG MORI. Harry Junger Managing Director GILDEMEISTER Drehmaschinen GmbH GX / GX T MATRIS WH Flex WH-AMR (AGV) NEW PH Cell Twin CPP LPP SCALABLE (≥ 1 MACHINE) 1 DMP, CMX V, CMX U, DMU, DMU monoBLOCK, DMU eVo, LASERTEC 2 NHX, DMC H linear, monoBLOCK, duoBLOCK, Portal 3 DMC 65 monoBLOCK, DMU 65 H monoBLOCK PH-AGV TH-AGV COMPLEXITY TECHNOLOGY E XCELLENCE 9
AUTOMATION WE love AUTOMATION Specialists to load machines? No night shifts due to staff shortages? Lack of process integration for quality control? Our automation solutions make these a thing of the past. This will leave you free to deploy your experts where they are really needed. Your machines will be better utilized and not only produce large quantities impressively quickly but also work flexibly from a batch size of 1. The biggest benefit: A fully automated machine can replace three stand-alone solutions. The advantages are obvious: Lower costs, fewer downtimes, less space require- ments, ensuring the long-term success of your company. And don’t forget – you can upgrade almost every one of your machines. « WHY YOU SHOULD ALSO LOVE AUTOMATION + Simple to operate: unified and integrated user interfaces + Proven technology: All solutions are optimized and tested in our factories! + Night shifts and weekends: Let the machine work! + Become more competitive: Reduce the cost per part with workpiece and process optimization! + Flexibility: From large batches to individual pieces! + Sustainability: Optimization of footprints and energy resources including minimization of CO2 emissions! DMG MORI supplies automation and turnkey solutions for every machine from a single source. Get in touch with us, we will take care of your production requirements. Ralf Riedemann Director and CTO DMG MORI EMEA GmbH 10 TECHNOLOGY E XCELLENCE
AUTOMATION PORTFOLIO Did you know that we offer an automation solution for almost every one of our machines? → Find out more in our web special! FIND AN AUTOMATION SOLUTION! Our special automation website can be found at: love-automation.dmgmori.com TECHNOLOGY E XCELLENCE 11
AUTOMATION – RETROFIT RETROFIT now AMORTIZATION OF YOUR RETROFITTED AUTOMATION EXAMPLE: DMU 75 monoBLOCK WITH PH Cell 300 E R ATIO E R ATIO N N P P 8 h 8 h T O T O F F I I H H S S - - 1 1 R A T I ON AUT R A T I ON AUT O O E E M M A A T T E E D D T O P T O P IF IF H H S S - - 3 3 24/7 24/7 1-shift operation = 1,560 spindle hours per year* YOUR CONTACT PERSON: Torsten Zwerenz Head of Global Service Systems email@example.com Tel. +49 (0)83 63 89 29 17 WE AUTOMATION Our special interactive website not only offers you information on technical details but also allows you to see how quickly our automation solutions pay for themselves based on calculated examples. We are not talking about years here but just months! Do you already have a machine? We can help you find a suitable automation solution: love-automation.dmgmori.com AMORTIZATION < 6 MONTHS (AUTOMATION) 24/7 operation = 6,552 spindle hours per year* + 2 × additional unmanned shifts per day (< 19 months for machine & automation) + 6 × additional unmanned shifts at the weekend (< 12 months for machine & automation) AMORTIZATION < 9 MONTHS (AUTOMATION) 3-shift operation = 4,680 spindle hours per year* + 2 × additional unmanned shifts per day (< 19 months for machine & automation) CHECK EXISTING MACHINES 12 TECHNOLOGY E XCELLENCE * DMU 75 monoBLOCK with PH Cell 300 stack magazine, 20 pallets – simplified calculation with 75 % spindle hours: 1-shift: 52 weeks × 5 days × 8 h × 0.75 = 1,560 h/a; 3-shift: 52 weeks × 5 days × 24 h × 0.75 = 4,680 h/a; 24/7: 52 weeks × 7 days × 24 h × 0.75 = 6,552 h/a
AUTOMATION THROUGH RETROFITTING INSTEAD OF A NEW INVESTMENT CUSTOMER STORY – HINTERSDORF GMBH & CO. KG A T I ON AUTO M A T E D R E T O P IF H S - 3 24/7 After moving to a new plant, DMG MORI retrofitted the DMU 60 eVo linear with a PH Cell 300. As a result, Hintersdorf can now produce unmanned during night and weekend shifts. AMORTIZATION < 1 YEAR (AUTOMATION) The production process runs autonomously for long periods and can even be maintained throughout the weekend. This means that investment in the PH Cell 300 can pay for itself in less than one year! Holger Hintersdorf Managing Director of Hintersdorf GmbH & Co. KG » TECHNOLOGY E XCELLENCE 13
CUSTOMER STORY – HINTERSDORF GMBH & CO. KG RETROFIT NOW PH Cell 300 RETROFITTABLE PALLET HANDLING FOR UP TO 40 PALLETS + Up to 300 kg transfer weight (workpiece incl. pallet) + 10.7 m2 footprint + Separate setup station for ergo- nomic and simultaneous loading and unloading of pallets + Handling of different pallet sizes in one system Retrofittable and available for 9 series, e. g. monoBLOCK, DMU, eVo etc. The PH Cell video on modular pallet handling: https://youtu.be/_W3KjhMykqo 14 TECHNOLOGY E XCELLENCE just a few years Hintersdorf GmbH & Co. KG was founded in 2014 in Rahden as an engineering company. In it has established itself as a reliable service provider for manufacturing blow molds, casting molds and extrusion tools as well as for assembly and measuring devices, prototype construction and small special- purpose machines. International customers, particularly from the automotive industry, chemical industry and heating engineering put their trust in the expertise of the almost 30-strong team. A high-performance array of machines is a part of the total range of services and includes new machining centers and from DMG MORI. The machine tool manufacturer had already provided considerable support during the founding of the company by offering attractive financing solutions from DMG MORI Finance. The latest investment was a DMU 60 eVo linear, which was retrofitted with a PH Cell 300 to ensure that Hintersdorf can continue to produce even more efficiently – around the clock. turning machines Integral range of services “After founding the engineering company, it quickly became clear to us that an on-site manufacturing facility would be the perfect complement to these services,” says Holger Hintersdorf looking back at his company’s first year. As a toolmaker with specialist training as a mechanical engineering technician, the experienced designer reco- gnized that an integral range of services would be more flexible and would also deliver the best quality at all times. “Existing colleagues were won over by the idea and put all their support behind my team.” Skilled specialists as the backbone of success Holger Hintersdorf still considers skilled engineers to be the backbone of the company: “We have toolmakers that are not responsible for machining but instead understand every detail of the complicated design and who also assemble the tools themselves.” The team is thus able to work extremely independently and over and again contribute ideas for optimization. Holger Hintersdorf maintains the high level of manufacturing with an in-house training program, but has also noticed that skilled staff and trainees are getting harder to find: “This is the reason we need to continuously optimize our manufacturing strategies to remain competitive.” This begins with the development and design of new tools. “Our customers ask us to get involved very early on in the process to ensure we can find the best possible solutions,” according to Holger Hintersdorf. Sophisticated jigs are used to make machining more efficient during the manufacturing process. Hintersdorf has already invested in nine machining centers and turning machines from DMG MORI with the support of DMG MORI Finance.
Company founded with support from DMG MORI Finance When it comes to CNC technology, Hintersdorf has relied on DMG MORI since the begin- ning – as a machine supplier and as a finance partner. “DMG MORI Finance made our start easier with attractive con- ditions,” says Holger Hintersdorf looking back. Sven Stolle, an experienced Area Sales Manager (ASM), was also a great help in choosing the machines. To start with, they comprised a DMU 75 monoBLOCK, a DMC 850 V and a used NL 3000. Hintersdorf has continued to invest since then and added a DMU 60 eVo linear in 2019. “The speed, acceleration and precision of the machine is ideal for our applications and we are also able to utilize our work space optimally for our range of components,” is the opinion of Holger Hintersdorf regarding the 5-axis universal machine. Due to space restric- tions, he was initially unable to automate the DMU 60 eVo linear. FLEXIBLE MANUFACTURING DURING UNMANNED SHIFTS As there was already a new plant in plan- ning when the DMU 60 eVo linear was being purchased, Holger Hintersdorf ordered the machine prepared for automation: “There was really no way to avoid this, as we need to utilize our machines to the maximum while also tackling a shortage of skilled labor.” Although it is also possible to ret- rofit a machine that has not been prepared, the approach significantly alleviates the effort. This was confirmed when moving into the new plant. DMG MORI retrofitted the DMU 60 eVo linear with an PH Cell 300 within one week. Double the spindle runtime The investment in the PH Cell 300 paid off quickly, explained Holger Hintersdorf: “Pro- duction continues autonomously for long periods and can even be maintained over the weekend. We have someone come in from time to time to exchange the parts.” It was possible to double the spindle runtime. Another argument in favor of the PH Cell 300 was its flexibility: “We mainly produce individual parts, prototypes or very small series.” With 20 spaces for pallets up to a size of 320 × 320 mm, the configuration of the storage racks is ideal. Automation and digitization for flexible work planning The next investment is proof that Holger Hintersdorf is more than satisfied with the automation. Another DMU 60 eVo linear with a PH Cell 300 will be installed in 2023. Moreover, sustainability and digitization are becoming increasingly important for the future. “A solar power system means that we will be able to cover the majority of our power requirements ourselves. Deliveries are made with an electric vehicle and we use regional suppliers as much as possible.” Digitization has meant that Hintersdorf is well on its way to networked manufacturing. When machine service is needed, the team relies on fast and transparent interaction through my DMG MORI. Holger Hintersdorf sees further potential: “Digital solutions for work planning will enable us to react more flexibly in the long term.” « HINTERSDORF FACTS + Founded in Rahden in 2014 as an engineering company + Reliable service provider for the manufacture of blow mold tools, prototype construction, extrusion tools, fixtures and mechanical engineering + International customers, particularly from the automotive industry, chemical industry and heating engineering + 30 employees Hintersdorf GmbH & Co. KG Carl-Zeiss-Str. 3 32369 Rahden, Germany www.hintersdorf-inform.de CUSTOMER STORY – HINTERSDORF GMBH & CO. KG The setup station of the PH Cell 300 enables the next job to be prepared while production continues. By retrofitting a flexible PH Cell 300, Hintersdorf can now produce unmanned during night and weekend shifts. TECHNOLOGY E XCELLENCE 15
CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG CAPACITY PLUS THANKS TO AUTOMATION The company Aussieker Metallverarbeitung GmbH & Co. KG from Preußisch Oldendorf was founded in 1969 as a classic subcontract manufacturer. Right up to the present day, customers in the general machine and plant engineering sector and the medical industry place their trust in the competence of the 30-strong team. For producing its high quality workpieces, Aussieker uses modern machine tool among which since 2019 are four models from DMG MORI – including two automated machines: a DMU 50 with PH 150 and a DMU 95 monoBLOCK with PH Cell 300. Combating the skills shortage with automation “The challenge we face has always been to produce complex and high-precision work- pieces as economically as possible”, explains Frank Aussieker. He has led the company of the same name as the second generation Managing Director since 2003. Production requires both modern CNC technology and well-trained engineers. Although Aussieker trains its own future employees in-house, it nevertheless recognises how it is becoming ever more difficult to find good staff. “This makes it difficult to fulfil a healthy order book over the long term – in particular when we sometimes have to work three shifts.” In view of the growing lack of skilled staff, the company decided to invest in an Prototypes and small series are part of our daily business. Thanks to the PH 150 and PH Cell 300 pallet handling systems, we can respond flexibly. Frank Aussieker (left), Managing Director, and Jan Kleine-Beek, authorized representative Fr. Aussieker Metallverarbeitung GmbH & Co. KG 16 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG Aussieker entered into automated 5-axis machining in 2019 with a DMU 50 and a PH 150 pallet handling system. The ten pallet places of the PH 150 are sufficient to allow an unmanned night shift. automated manufacturing solution in 2019. A authorized representative Jan Kleine-Beek recalls the purchase of the DMU 50 with PH 150: “Based on the positive experience we have had with a DMU 100 P duoBLOCK since 2004 and a DMF 260 | 7 since 2018, it was clear to us that DMG MORI was the right partner for this investment.” The move UNMANNED SHIFTS AND MULTI-MACHINE OPERATION towards unmanned production has helped enormously. “All our employees have to do now is set up new orders, load the automation and then unload the finished parts.” This leaves them enough time to operate other machines. If necessary, the PH 150 is loaded at night or at the weekend. “This only takes a few minutes and ensures that we can more or less produce around the clock and so meet tight delivery times”, says Frank Aussieker. High capacity utilization and flexible production thanks to pallet handling The good experience with the first automation ultimately led to the purchase of the DMU 95 monoBLOCK with PH Cell 300 in 2022. “Compared to the PH 150, the PH Cell 300 offers us additional capacity”, explains Jan Kleine-Beek regarding the purchase of the automation solution, which DMG MORI launched onto the market in 2020. The pallet storage system is modular in design and can be configured specifically for each customer. The version at Aussieker is equipped with a shelf module for 19 pallet storage places – 15 for pallets of up to 300 × 300 mm, and four for pallets of up to 400 × 400 mm. “The storage system is designed in such a way that we can load components that protrude a little over the end of a pallet”, Frank Aussieker goes on to tell us. This means that the large work area of the DMU 95 monoBLOCK can The ten pallet places of the PH 150 are sufficient to allow an unmanned night shift. PH 150 THE UNIVERSAL PALLET HANDLING SYSTEM FROM DMG MORI + High variability of the available configurations of 24 round pallets of ø 148 mm and up to four pallets measuring 500 × 500 mm + Up to 250 kg workpiece weight (150 kg as standard) + Possibility of prioritizing orders + EROWA clamping system as standard, optionally SCHUNK + Optimal accessibility to machine and automation Retrofittable & available for the 10 series, e. g. CMX V / U, DMU etc. The video of the DMU 50 3rd Generation: https://youtu.be/57vl-BgHKzw be exploited during automatic production. Another innovation: Control of the PH Cell 300 is directly via the CELOS interface of the DMU 95 monoBLOCK. “And if we wish to increase our capacity, we can expand the system in the future with another shelf module.” » TECHNOLOGY E XCELLENCE 17
CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG AUTOMATED SMALL SERIES PRODUCTION With the PH 150 and the PH Cell 300, Aussieker has confirmed that automatic production is certainly not limited to large series. Quite the opposite: ”Prototypes and small series are part of our daily business”, is how Jan Kleine-Beek describes typical orders. “Thanks to pallet handling we can respond flexibility certainly not.” PH Cell 300 MODULAR PALLET HANDLING FOR UP TO 40 PALLETS IN A FOOTPRINT OF 10.7 m2 + Up to 300 kg transfer weight (workpiece incl. pallet) + Separate setup station for ergonomic loading of the pallets during production + Handling of different pallet sizes in one system Retrofittable & available for 9 series, e. g. monoBLOCK, DMU, eVo, etc. The PH Cell video for modular pallet handling: https://youtu.be/_W3KjhMykqo 18 TECHNOLOGY E XCELLENCE The PH Cell 300 is loaded via an ergonomic setup station. The PH Cell 300 is equipped with a shelf module with 19 pallets positions – 15 for pallets up to 300 × 300 mm and four for pallets up to 400 × 400 mm. Aussieker expanded automated production in 2022 with a DMU 95 monoBLOCK with PH Cell 300. ø 500 mm 500 mm PH Cell 300 kg Max. workpiece dimensions Pallet size 500 × 500 mm 400 × 400 mm 320 × 320 mm Workpiece height 500 mm* 300 mm Max. number of pallets 18 24 30 24 32 40 *No limit to component height on the top shelf
CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG Reliable production thanks to digital products from DMG MORI Aussieker also works with digital products from DMG MORI to ensure automatic production runs smoothly. “The DMG MORI Messenger informs us of any unscheduled stoppages during the night and weekend shifts, so someone can drive to the plant and restart the automation”, mentions Jan Kleine- Beek as just one example. We rarely have any serious problems thanks to the integrated tool breakage monitoring. Digitization has also benefited our service, adds Frank Aussieker: “my DMG MORI enables technical problems to be sent to the the DMG MORI service team at the press of a button, so help can be provided via the NETservice or hotline, reducing stoppages to a minimum in many cases. In view of the good order situation, the company depends on reliable production. Fast amortization The path to automated production soon paid for itself, sums up Frank Aussieker: “It is quite clear that it has allowed us to combat the skills shortage effectively.” A the same time, machine utilization has increased significantly. “Against this background, auto- mation solutions will play a key role in future investments”. « FR. AUSSIEKER FACTS + Founded in Preußisch Oldendorf in 1969 + 30 employees + Subcontractor for demanding applications + Wide range of customers from the general machine and plant engineering sector and the industry, sectors among others Fr. Aussieker Metallverarbeitung GmbH & Co. KG Am Alten Markt 30 32361 Preußisch Oldendorf Germany www.fr-aussieker.de PRECISION ENGINEERING MEETS DIGITIZATION September 13 – 17, 2O22 Come and visit us at AMB in Stuttgart! Hall 1, Booth # 1F5O Tooling Technology Shrinking Technology Balancing Technology Measuring- and Presetting Technology www.haimer.com TECHNOLOGY E XCELLENCE 19
PH Cell 2000 PH Cell 2000 MODULAR ROTARY PALLET STORAGE FOR UP TO 21 PALLETS TRANSFER WEIGHT 2,000 kg Retrofittable! Connection to existing machines possible if automation interface already integrated CONSTRUCTION KIT Modular concept for individual customer requirements with 2 different sizes and 2, 3 or 4 shelf levels handling device shelf storage setup station Compact! up to 21 pallets in a 16.5 m2 footprint + Fast pallet change in under 45 seconds + Heavy loads possible with 2,000 kg due to integrated twinFORK gripper per storage location + Rotatable setup station as standard + High precision FD setup station + Handling device for pallets from + Fast commissioning. The shelf optionally available 500 × 500 mm to ø 1,100 mm storage system is transported as a whole including the handling device + Setup station optionally available in conjunction with clamping hydraulics + Maximum 21 pallets on 4 levels in the overall system 20 TECHNOLOGY E XCELLENCE
Available for: – DMU 65 H monoBLOCK – DMU 85 H monoBLOCK – DMU 80 P / FD duoBLOCK – DMU 90 P duoBLOCK – DMU 100 P / FD duoBLOCK – DMU 125 P / FD duoBLOCK PH Cell 2000 Celos / Joblist en 0 PH Cell MAX Joblist Projects NEW: Pallet Master Software 9 5 1 10 11 12 6 2 7 3 8 4 1 2 3 Aluminium rocker arm Device holder Steel Mold forge Number Name Home Pocket 6 3 1 L0 Shuttle L1 Machine L2 Setup 1 2 1 1 Objects per page: 10 1 - 3 from 3 WORKPIECE SIZES + Transfer weight up to 2,000 kg HIGHLIGHTS ø 1,100 mm PH Cell 2000 2,000 kg 1,350 mm + 12 to 21 pallets in system, pallet size 500 × 500 mm to ø 1,100 mm + Fast pallet change time < 45 seconds due to integrated twinFORK gripper + Can be retrofitted with machine preparation + Short commissioning time within 3 days due to defined interface and modular principle PH Cell 2000 VS. RPS A DIRECT COMPARISON PH Cell 2000 + Retrofittable for machines with automation interface + Also available for DMU machines + Up to 21 pallets can be handled and stored in the system + Modular design with different pallet sizes + Integrated pallet changer in the handling device 25 % SMALLER FOOTPRINT AREA COMPARISON + 16.5 m2 footprint of the PH Cell 2000 with up to 21 pallets on 4 levels + 25 % reduction in footprint compared to the RPS with 12 pallets 4,700 mm (PH Cell 2000) 5,240 mm (RPS 12) RPS + Machine-integrated solution for DMC machines with pallet changer + Maximum number of workpieces corresponds to the machine + Very fast pallet change times due to the machine pallet changer + Also for DMC 160 U / FD and Portal machines ) 0 0 0 2 l l e C H P ( m m 0 9 4 , 3 ) 2 1 S P R ( m m 0 6 0 , 4 RPS 12 PH Cell 2000 16.5 m2 RPS 12 21.3 m2 TECHNOLOGY E XCELLENCE 21
PH Cell Twin WORLD PREMIERE 2022 Available for: – DMU 65 / 75 monoBLOCK – DMU 65 H monoBLOCK – DMU 50 3rd Generation – DMU 40 / 60 eVo – CMX 50 / 70 U Machine combination possible PH Cell Twin with DMU 50 and DMU 65 H monoBLOCK Retrofittable! Connection to existing machine with already integrated automation interface possible Extendable! Subsequent connection of a second machine possible PH Cell Twin MODULAR AND COMPACT PALLET HANDLING FOR TWO MACHINES HIGHLIGHTS + Proven PH Cell 300 pallet handling as Twin solution now for two machines + One pallet handling device for 2 machines + Up to 30 pallets in a 12.9 m2 footprint due to double row pallet storage on each level + Workpieces up to 500 × 500 × 500 mm + Up to 300 kg transfer weight (workpiece incl. pallet) + Retrofit of a second machine possible + Separate station for ergonomic setup of pallets during production + Short installation time due to defined interface and modular concept PH Cell Twin with DMU 50 and DMU 65 H monoBLOCK + Attractively priced automation in DMG MORI VERTICO design 22 TECHNOLOGY E XCELLENCE
PH Cell Twin PH Cell Twin OPERATING PRINCIPLE PALLET HANDLING DEVICE Up to 300 kg transfer weight (workpiece incl. pallet) SEPARATE SET-UP STATION + Ergonomic setup + Optionally rotatable Machine 1 Machine 2 Maximum workpiece dimensions 500 mm PH Cell 300 kg 30 pallets 24 pallets 18 pallets 500 mm 500 mm 320 × 320 / 345 × 345 mm 400 × 400 mm 500 × 500 mm TECHNOLOGY E XCELLENCE 23
CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG INVESTMENT & INNOVATION – AUTOMATION & COMPLETE MACHINING The history of SPECK Pumpen Walter Speck GmbH & Co. KG from Roth goes back to the year 1909. At that time – still located in Nuremberg, Daniel Speck started man- ufacturing piston pumps. With over 600 employees worldwide, the SPECK Group is an internationally successful company that produces its extensive and highly individual range of pumps for customers in every conceivable sector. SPECK has been work- ing with CNC technology from DMG MORI for decades. There are around 75 machines in operation alone in Roth, with twelve more used in its Chinese facility. What all models have in common: They are among the most modern machines that DMG MORI has on offer – as are the most recently acquired DMC 65 H monoBLOCKs – one with an RPS 12 pallet changer, the other with amill-turn table. Solutions and further developments tailored to customer needs A strong customer focus, high levels of expertise and the development of cus- tomized solutions have always set SPECK apart. Orders come from a diverse range of industries and from a multitude of customers. “Our specialized products are principally used in the medical, chemical and pharma- ceutical industries, in cooling and tempering appliances and in the plastics industry”, says Dr. Thomas Krüger, Member of the Manage- ment Board, giving us an impression of the product portfolio. Its customized orientation has resulted in the consistent expansion of a wide range of variants, which continue to gain in importance. 1 2 1. Machining of gray cast iron and stainless steel components for the vacuum housing of pumps. 2. Evacuation of chips under gravity on the horizontal machine enables reliable production. Thanks to the RPS 12 with 12 pallets, the DMC 65 H monoBLOCK is used optimally for several hours. Setup is carried out in parallel to machining. 24 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG Torsten Hahn (left), Authorized representative Dr. Thomas Krüger (center), Member of the Management Board Dieter Meier (right), Head of Mechanical Engineering SPECK Pumpen Walter Speck GmbH & Co. KG “We help our customers move forward with new solutions and further developments to our existing products.” from the machine tool manufacturer as well multifunction machine models – both turn- mill centers and mill-turn machines. Reliable processes thanks to horizontal mill-turn machining The latest acquisitions include two DMC 65 H monoBLOCK centers. SPECK uses the 5-axis horizontal machining centers among other things to machine gray cast iron and stainless steel components. Vacuum hous- ings for pumps are produced on these, which are used in the sterilization of hospital beds, for example. » LATEST MANUFACTURING TECHNOLOGY FROM DMG MORI With the high standards it sets on its own quality management, SPECK guarantees perfect products. The many years of experi- ence of its employees plays a significant role, as does its use of the latest manufacturing technologies. Authorized representative Torsten Hahn adds in this respect: “Invest- ments in new machine tools are made primarily with a view to expanding capacity. We boost our productivity at the same time by continuously purchasing the most advanced manufacturing technologies.” DMG MORI plays a key part in this. For over ten years, SPECK has been using automation solutions RPS 12 MACHINE- INTEGRATED AUTOMATION + Unmanned shifts due to circular storage system with up to 12 pallets + DMU / DMC 65 H monoBLOCK: Workpieces up to ø 800 × 700 mm, 600 kg max. + Reduction of non-productive time due to loading and unloading during production + Flexible production of different workpieces + Separate setup station for ergonomic setup of pallets during production TECHNOLOGY E XCELLENCE 25
CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG SPECK Pumpen uses 75 machines for the production of high-precision pump components at its location in Roth. These include a DMC 65 FD monoBLOCK, the new DMC 65 FD H monoBLOCK and a DMC 65 H monoBLOCK with an RPS 12 rotary pallet storage system. “The horizontal machining concept with its optimum chip evacuation is ideally suited for the production of such precision parts”, explains Dieter Meier, Head of Mechanical Engineering. This is especially true of the DMC 65 H monoBLOCK with mill-turn table. “We can position the table vertically during turning, so no water collects in the compo- nent.” The second DMC 65 H monoBLOCK was equipped with an RPS 12 pallet changer, which enabled SPECK to further optimize LOVE OF AUTO- MATION – RPS 12 FOR THE AUTONO- MOUS PRODUCTION OF COMPLETE VACUUM HOUSINGS the manufacturing process for the vac- uum housing. “Each housing consists of six components, which we can now machine completely in sets”, explains Dieter Meier about the application. The pallet changer can, of course, be set up during machining. “So we can make optimal use of the machine for several hours without any long idle times.” Individual machine solutions thanks to DMG MORI’s wide range of products The reason SPECK has maintained such close cooperation with DMG MORI for so many years is due in part to the reliable CNC technology, is how Torsten Hahn judges the quality of the machines. Another aspect is the extensive portfolio, as Dieter Meier goes on to tell us: “We always find solutions that are both individual and innovative, which ensure sustainable optimization of our processes.” « DMC 65 FD H monoBLOCK MILL-TURN TECHNOLOGY FOR COMPLETE MACHINING HIGHLIGHTS + Complete machining thanks to milling and turning in a single setup on one machine + Direct Drive technology for up to 1,200 rpm + Lower investment costs and reduced space requirements thanks to the use of just one machine You can find the video on the DMC 65 FD H monoBLOCK here: https://youtu.be/0twEUGh8eYE 26 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG SPECK PUMPEN FACTS + 1909 founded in Nuremberg, headquarters now in Roth + Over 600 employees worldwide + Development and production of pumps tailored to customer needs + Competent partner in a multitude of industries, including medical, chemical and pharmaceutical SPECK Pumpen Walter Speck GmbH & Co. KG Regensburger Ring 6–8 91154 Roth, Deutschland www.speck.de All from a single source. Fortunately, DMG MORI has a full line-up of automation systems in addition to a comprehensive machine programme. This enables us to serve our wide range of industries. Torsten Hahn, Authorized representative SPECK Pumpen Walter Speck GmbH & Co. KG DMG MORI ROUND STORAGE SYSTEMS – MACHINE-INTEGRATED AUTOMATION WITH MINIMAL SPACE REQUIREMENTS System Advantages RPS PH CELL 2000 Machine-integrated solution for one machine type Usable for different machine types For DMC machines with pallet changer For DMU machines without pallet changer thanks to the integrated twinFORK gripper Ex-works in combination with a new machine Ex-works & retrofittable for various machines with automation interface Maximum workpiece size and pallet dimensions depending on the machine Modular design with different pallet sizes Short pallet change time thanks to rotary pallet changer in the machine 25 % smaller footprint thanks to the integrated pallet changer Machine 1 DMC monoBLOCK DMC duoBLOCK 2 DMC Portal 3 NHX DMU / DMC H monoBLOCK 4 DMU duoBLOCK DMU H monoBLOCK Number of pallets 3 / 6 6 / 7 / 12 4 / 5 5 / 7 / 9 / 12 12 / 14 / 21 12 / 17 / 21 Max. workpiece size* mm ø 800 × 590 Max. load* 800 kg *depending on the machine ø 1,600 × 1,350 ø 3,400 × 2,400 ø 630 × 700 ø 800 × 1,000 ø 1,100 × 1,350 4,000 10,000 600 700 2,000 2 4 1 3 TECHNOLOGY E XCELLENCE 27 TECHNOLOGY E XCELLENCE 27
Robo2Go – THE STANDARD AUTOMATION Robo2Go – THE BEST-SELLING STANDARD AUTOMATION RETROFITTABLE CHECK EXISTING MACHINE NOW love-automation.dmgmori.com THE Robo2Go APP: ONE FOR EVERYONE! Turning, Vision, Milling and Max 1. Integrated app for uniform control – no adaptation of the existing NC programs 2. No robot programming knowledge required 3. Process creation based on predefined program modules 4. Setting up a new workpiece < 5 minutes 5. Multijob function: different jobs on one workpiece tray, ideal for small and medium batch sizes. 6. Home function for simple retraction and system setup AVAILABLE FOR 38 DMG MORI MACHINES Z. B.: CLX, CLX TC, CTX, CTX TC, NLX, NZX, NTX, DMU, DMV, CMX NEW AVAILABLE FOR DMU 65 / 75 mB Robo2Go Milling Robo2Go Turning + Handling of workpieces up to 200 × 200 × 200 mm as standard. Other dimensions on request + Now with alignment and turning station For automated 6-sided complete machining + Full accessibility to the machine thanks to loading from the side + Handling of shafts ø 20 – 170 mm and chuck parts ø 20 – 175 mm + Laser scanner with automatic restart + Now with alignment and turning station + Enables the gripping of long shaft workpieces 28 TECHNOLOGY E XCELLENCE
Robo2Go Jobs + Paperless job management + Easiest processing of orders using checklists + Definition of various orders in the job queue + Multijob: Different workpieces possible in one order NEW AS STANDARD Robo2Go – THE STANDARD AUTOMATION 1. Basic module Robot, control cabinet, cover 2. Storage module Basic variant for two EU pallets with roller shutter: – Rotate the module by ± 90 degrees to change the loading direction – AGV-compatible 3. Flexible tower and safety system – Telescopic door for easy access to the machine and automation – Left- or right-sided installation possible 4. Extensions Space for upcoming options such as: Alignment station, turning station NEW OPTION 1 1. Zero point detection of the workpiece LENGTH REFERENCE DETECTION + Increased process reliability during shaft machining + Ensuring a defined clamping length + Detection of axial position deviations, e. g. due to slippage of the shafts during transport TECHNOLOGY E XCELLENCE 29 ENTIRE SYSTEM CERTIFIED IS NEW! 210 kg 1 2 3 Telescopic door 4 Loading with standard pallets Robo2Go Max + Strongest version with 210 kg payload and 115 kg workpiece weight + Handling of workpieces ø 40 to ø 400 mm as standard + Free accessibility to the control system and the tool magazine
CUSTOMER STORY – STROMBOLI GMBH HIGH-TECH READY FOR E-MOBILITY FROM THE RUHR DISTRICT The DMP 70 with the WH 3 Cell enables autonomous and flexible production in unattended shifts. Components are fully machined on all 6 sides thanks to the turn-over station. Andreas Köppel Founder and Managing Director STROMBOLI GmbH STROMBOLI produces numerous workpieces on the 5-axis DMP 70; shown here is a component for a battery test bench for electromobility. 30 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – STROMBOLI GMBH STROMBOLI GmbH in Bochum has been manufacturing fine mechanical components and complex assemblies for challenging industries for over 30 years. Customers, including some from the medical sector, semiconductor industry and electromobility, continue to put their trust in the manu- facturing expertise of the 18-strong team. The high quality standard also requires high-performance machines on the shop floor. Eleven models from DMG MORI are in use – including an automated DMP 70 since 2021, which thanks to the WH 3 Cell during unmanned shifts, contributes significantly to overall productivity. From mining to high-tech A disused mine head tower in Bochum- Werne is a reminder that the Ruhr region was dominated by mining until a few decades ago. Since then, many high-tech companies that manufacture innovative products have moved to the region,” explains Andreas Köppel, founder and managing director of STROMBOLI. The subcontractor established itself on the grounds of the former Robert Müser mine and also serves this innovative new marketplace. “We see ourselves as a integral partner – from design to quality assurance and assembly. One of our core focuses is complex niche products.” The challenge lies in producing high-quality precision tools economically. This challenge is tackled by a young and experienced team. “We have two engineers and five fully trained production supervisors. We also train one or two apprentices every year to ensure we can fulfil our specialist requirements,” says Andreas Köppel. » A turn-over station enables workpieces to be machined on all six sides. Included in the eleven DMG MORI machines are two MILLTAP 700s and the DMP 70 with WH 3 Cell, which was installed in 2021. TECHNOLOGY E XCELLENCE 31 TECHNOLOGY E XCELLENCE 31
CUSTOMER STORY – STROMBOLI GMBH DMP 70 WITH WH 3 CELL VERTICAL HIGH-SPEED MACHINING CENTER HIGHLIGHTS + 5-axis simultaneous machining through direct drive table up to 100 kg + 24,000 rpm inline spindle with 20 Nm + 5 µm positioning accuracy thanks to linear scales from MAGNESCALE + Up to 2 g acceleration for 1.5 sec. chip-to-chip time + WH 3 Cell – workpieces up to 300 × 200 × 100 mm and 5.5 kg You can find the online configurator here: https://configure.dmgmori.com 32 TECHNOLOGY E XCELLENCE Thanks to the fast chip-to-chip time of 1.5 seconds and the integrated swiveling rotary table, the DMP 70 is ideal for highly productive production of small workpieces. A flat organization and a modern company culture provide a great motivation for all company members. Flexible shifts, company bicycles and a car fleet with electric vehicles are only three examples of the forward- looking orientation of STROMBOLI. Complete machining for e-mobility and the semiconductor industry The modern orientation is also reflected in the orders, Andreas Köppel says, referring to requests from the futuristic industries supplied. “We work increasingly for customers in electromobility or the semiconductor industry.” The business is becoming ever more international as well. “Requests from China confirm our focus on quality.” To ensure they maintain their quality standards, STROMBOLI invests in pioneering manufacturing technologies from DMG MORI. “A sustained trend is complete machining – whether this is on 5-axis milling machines or turning centers with milling functionality. We have been producing complex components in one setup in this way for several years.” The added benefits are obvious: “Both we and our customers profit from shorter throughput times and improved component quality.” STROMBOLI has taken another step towards the future of manufacturing with their purchase of a DMG MORI DMP 70. The 5-axis, compact machining center is fitted with a WH 3 Cell. Henrik Kieslich, a master precision instruments mechanic who was involved in selecting the machine adds: “The robot
CUSTOMER STORY – STROMBOLI GMBH With automation into the future Automated production has paid off quickly for STROMBOLI. For Andreas Köppel, there is no other way for the future: “We need to increase our economic efficiency to remain competitive internationally.” Extending manufacturing capacity to unmanned shifts is a logical step. DMP 70 WITH WH 3 CELL: UNFAILING, PROCESS RELI- ABILITY AND AUTONOMOUS This also applies to the area of turning, he adds. “Since June 2022 we have been successfully using a Swiss type lathe.” « STROMBOLI FACTS + Founded in 1990 in Bochum + 18 employees + Manufacturing of precision components and assemblies + Customers from future-oriented industries such as medical and electromobility STROMBOLI GmbH Von-Waldthausen-Str. 79 44894 Bochum, Germany www.stromboli.de TECHNOLOGY E XCELLENCE 33 Quality assurance including documentation is an integral part of the range of services offered by STROMBOLI. Depending on the workpiece dimensions and weight, the WH 3 Cell offers space for up to 1,000 workpieces, ideal for unattended series production (30 × 30 × 30 mm aluminum / paternoster system with 15 workpiece carriers measuring 600 × 400 mm). enables autonomous and flexible production during unattended shifts.” After initial training and with a good grasp of programming, he was able to put the automation to work for more complex processes. “We are now able to place the blanks randomly in the relatively large fixture of the magazine trays and the robot adjusts their position them so it can pick them up.” There is also an additional setup station as well as a turn-over station, which makes it possible to invert the component for machining on all 6 sides. STROMBOLI needs this type of flexibility, as the WH 3 Cell is not used for producing large series of certain workpieces. “Depending on the order situation, we want to be able to machine completely different parts automatically one after the other on the DMP 70,” adds Henrik Kieslich. DMG MORI technology cycles for operation with high process reliability: To ensure the DMP 70 operates securely and with high process reliability, DMG MORI equipped it with tool breakage monitoring and the DMG MORI 3D quickSET technology cycle. “A defective tool would have serious consequences in automated operation, but the 3D quickSET enables continuous measu- rement and correction of the position of rotary and swivel axes. This guarantees consistent quality. Moreover, STROMBOLI makes use of the machine measurement cycles, which reduce the effort involved with quality assurance.
NEW: PALLET HANDLING BY MATRIS With MATRIS, we offer our customers easy-to-use automation, including secondary processes such as measuring and labeling. What is completely new is that MATRIS can now also be used for pallet handling. Mr. Satoru Kashiwagi General Manager of Technical Sales Department DMG MORI CO., LTD. MATRIS Flexible modular robot system for ≥ 1 machine With innovative developments, DMG MORI has been a pioneer in the automation of machine tools for many years. Its products include highly flexible automation solu- tions such as the modular MATRIS. Satoru Kashiwagi, General Manager of Technical Sales Department at DMG MORI CO., LTD. talks about the versatile robot system in an interview. Mr. Kashiwagi, what prompted you to develop MATRIS*? As the demand for simple robotic automa- tion grew stronger, we needed to create an offering that would allow us to meet our customers' needs quickly and with the high quality they have come to expect. That's why we started standardizing our robot systems in 2016. This has resulted in MATRIS. It is an automated handling system consisting of standardized units and devices. What are the components of MATRIS? The core of MATRIS is a robot, which brings the workpieces into the working area of the machine tool. It is installed on the side of the machine. Peripheral devices can be placed around it to enable further functions – from tool storage and a turnover station to cleaning and tactile or visual measurement. Here, we use only carefully selected products certified by DMG MORI that work reliably. What are the features of the system? Each unit of MATRIS is modular and avail- able in a standardized size of 710 × 710 mm per module. » HIGHLIGHTS + Modular concept with standardized peripheral devices, e. g. washing, measuring or marking + 80 % shorter setup time due to modular, standardized peripherals and robot programs + Flexible adaptation to system changes after installation + Simple and easy operation via the MATRIS controller *MATRIS = MODULAR AUTOMATION TRANSFER ROBOT INTELLIGENCE SYSTEM 34 TECHNOLOGY E XCELLENCE Up to 2 machines in one system
MODULES AND EXPANSION STAGES Transfer Measurement Material table Workpiece quality check NG chute Workpiece turnover Workpiece phase positioning IN / OUT conveyor Stock Other Workpiece stocker Tray changer Manual changer Buffer Robot MATRIS controller NEW: PALLET HANDLING BY MATRIS 1-point measurement 2-point measurement 3-point measurement 3D measurement External checking Deburring Washing Air blowing Marking Transfer weight (single / double gripper): 10 / 20 kg FANUC Kawasaki NACHI YASKAWA ABB + A system controller that offers integrated control of the whole automation system, including robot, each module and machine + Monitoring, schedule management and operational control of the whole automation system possible TECHNOLOGY E XCELLENCE 35
NEW: PALLET HANDLING BY MATRIS The video for the NHX series with MATRIS robot system can be found at: https://youtu.be/vtWcMlJR4H8 MATRIS – WORKPIECE HANDLING HIGHLIGHTS + Handling of workpieces up to ø 200 × 200 mm, 1 × 20 kg or 2 × 10 kg + Stacking magazine: – 14, 20 and 26 pallets: ø 150 × 120 mm, max. 35 kg per pallet – 10 and 20 pallets: ø 200 × 200 mm, max. 75 kg per pallet + Available for 13 series, e. g. NLX, NTX, NHX, DMU, NMV, eVo, etc. → more at: https://love-automation.dmgmori.com Modular concept with standardized peripheral devices, e. g. deburring, washing, air blowing or marking. 36 TECHNOLOGY E XCELLENCE The system can be easily adapted to each customer's requirement. The layout is also completely reconfigurable, allowing flexible response to changes in the range of com- ponents. In addition, the communication format of each unit is standardized, sup- porting Ethernet IP and PROFIBUS. This allows MATRIS to significantly increase setup speed. What about the software? We have developed our own control system to standardize the operation of each robot. The MATRIS controller is connected to the machine tool, the robot and the peripheral devices. In this way, we realize complete control of the entire MATRIS system. The user interface is adapted to that of CELOS, ensuring smooth and efficient operation. In addition, the robot programs and motion sequences (teaching) are already predefined. Whereas previously it was necessary to read and understand complex robot programs, the MATRIS controller uses an intuitive and interactive processing method. What benefits does MATRIS offer you? Typical system packages are available in advance. This means that we can quickly cre- ate layouts based on these packages. Con- sequently, we achieve fast implementation in a short turnaround time. Another advantage of MATRIS is the reduced installation time. Whereas it used to take ten days to install a system, today we only need one to two days. System changes after delivery are also
NEW: PALLET HANDLING BY MATRIS Storage capacity for up to 40 pallets with a transfer weight of 150 kg NEW MATRIS – PALLET HANDLING HIGHLIGHTS + Ideal for the flexible production of 50 to 200 workpieces / day + Space-saving pallet handling for up to 40 pallets + 400 × 400 mm pallet size + 150 kg transfer weight (workpiece designed for pallet handling. The use of pallets and fixtures for workpieces offers even greater flexibility in terms of compo- nent variety and batch sizes. It allows our customers to react more flexibly to the production of different workpieces. « and pallet) + Integration of secondary processes such as deburring or marking possible + Available for the CMX 50 U, CMX 70 U, DMU 50, DMU 65 monoBLOCK, CMX 600 V, CMX 800 V, CMX 1100 V Further machines on request! TECHNOLOGY E XCELLENCE 37 possible within one day. In the past, this took at least five days. We owe this to the oil pan, which is an integral part of the robot frame, so no work is required here either. This also reduces life cycle costs. The customer can independently modify the robot program to take account of additions and changes to the workpieces. This, of course, reduces any travel expenses and labor costs for system integrators. What does the future hold? In addition to the already familiar work- piece handling design, MATRIS is now also
CUSTOMER STORY – NABEYA CO., LTD. HIGHLY PRODUCTIVE 5-AXIS MACHINING IN 24 HOUR OPERATION Nabeya Co., Ltd. is headquartered in Gifu City (Japan, Gifu prefecture) and was founded in 1560 in the midst of the Sengoku period in Japan, the time of warring states. During one of the most notorious battles – the Battle of Okehazama – the ancestors of President Tomohiko Okamoto were granted permission by the emperor to found the family company specializing in casting production. Today, Nabeya continues this tradition, employs around 200 people and dedicates itself to technological innovation. The company uses cutting-edge technology from DMG MORI to manufacture vibration isolators for semiconductor manufacturing equipment and surface plates for precision testing under the widely distributed ERON brand. The design, machining, assembly and inspection of these industrial components are carried out in-house. The combination of Nabeya fixtures and 5-axis machining on the DMU 50 3rd Generation enables different workpieces to be clamped and machined on one pallet or clamping fixture. 38 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – NABEYA CO., LTD. Thanks to MATRIS, we are able to carry out our high-mix, low-volume production of precision components during unmanned night shifts. Shoichi Sakai (center), Managing Director Tomoaki Masuda (left), Plant Manager Ryoma Sonoda (right), Operator in the machining area is probably true Automation and 5-axis machining to combat the lack of skilled workers “The same for other manufacturers, but our company is facing the growing challenge that qualified engineers are becoming ever scarcer. This has led to a lack of personnel who are able to manage complex processes with conventional vertical and horizontal machining centers,” explains Managing Director Shoichi Sakai. “My idea was to integrate the processes as much as possible to simplify process design and to implement automation and unmanned production at night at the same time. 5-axis machines are the perfect solution for this! I wanted to combine 5-axis machines and automation to reduce process steps, improve productivity and enable continuous 24-hour production.” Last year, Nabeya introduced the 5-axis DMU 50 3rd Generation machine and the MATRIS robot automation system with a rack for 20 DMU 50 WITH MATRIS AS PALLET HANDLING SYSTEM Various clamping elements can be used on the pallets during the process as well as different workpieces, depending on the fixture. In the past, the operator had to adjust every fixture for every type of workpiece. Thanks to MATRIS, only minimal setup is required as it can handle different workpieces and fixtures on each pallet for 5-axis machining on the DMU 50 3rd Generation. pallets at their main plant in Motosu, Gifu. The system is being used for the production of machine vices – Nabeya’s main product – as well as clamping units and other similar products. Only one operator is required to operate the automation system. The MATRIS system automatically processes all pallets. » TECHNOLOGY E XCELLENCE 39
CUSTOMER STORY – NABEYA CO., LTD. DMU 50 BESTSELLER! > 10,000 DMU 50 INSTALLED WORLDWIDE + Swivelling Rotary Table for 5-Axis Simultaneous Machining – Table load up to 300 kg – Swivel of the B-axis –35° / +110° for excellent flexibility – Cooled table bearings for maximum precision + 5-Axis Machining with up to 20,000 rpm – speedMASTER 15,000 rpm with 21 kW and 111 Nm in basic version – speedMASTER 15,000 rpm with 46 kW and 200 Nm optionally available – speedMASTER 20,000 rpm with 35 kW and 130 Nm optionally available + High Quality for up to 5 µm Precision – Comprehensive cooling concept for excellent long-term precision – One-piece machine bed – Direct ball screw drives – Linear scales in all axes Visit our online configurator: https://configure.dmgmori.com 40 TECHNOLOGY E XCELLENCE Nabeya Co., Ltd. manufactures a wide range of workholding equipment such as machine vices and clamping units, which contribute to higher machine tool productivity. Use of their own clamping materials What makes this automation system so unique is the use of Nabeya's own fixtures, base elements, pallets and robot grippers. Their fixtures make it possible to clamp more than eight workpieces on one base plate, which can be automatically machined and measured on all sides in the 5-axis machine without retooling. The introduction of this automation solution in combination with in-house products enabled Nabeya to automate its varied production of small batch sizes and achieve highly precise, unmanned production during the night. Increased productivity thanks to unmanned night shifts “The work that used to take four people can today be done by just one operator. We only need to set up the workpieces during the day and the system automatically takes care of the rest during the night. All the workpieces are finished by the time we arrive at the factory in the morning. This means that our productivity has been considerably increased and it is much easier to plan our manufacturing,” says Factory Director Tomoaki Masuda.
It is important when using automation like this that the system runs as reliably as possible. Tomoaki Masuda explains the reason for the successful operation: “Our system runs without any problems at all, thanks to the in-depth advice and troubleshooting provided by DMG MORI. For example, their engineers helped us to avoid downtimes caused by incorrect timing when exchanging the pallets or an accumulation of chips.” CUSTOMIZED PROCESS OPTIMIZATION From ten process steps to one Shoichi Sakai reveals Nabeya’s future plans: “It was the first time that we introduced a 5-axis machine into our production and the positive effects could be felt immediately: The eight to ten work steps that used to be required can now be reduced to just one or two.” In addition, Nabeya is able to use its own fixtures and clamping systems in this automation system. This makes it the perfect showcase for its customers at the same time. “We would also like to show this automation solution to other manufacturers that are battling a lack of skilled labor and automating high-mix, low-volume production – and to support them in increasing their production efficiency.” « CUSTOMER STORY – NABEYA CO., LTD. NABEYA FACTS + Traditional company that has been manufacturing castings for over 460 years. + Precision ERON brand machine vices are valued and used by manufacturers all over Japan. + “Techno-craft”, the combination of technology and craftsmanship, is the hallmark of the company + Continuous improvement of the process design, NC programming and production management through automation, in the spirit of “techno-craft” Nabeya Co., Ltd. Wakasugicho 25, Gifu City Gifu 500–8743, Japan https://eng.nabeya.co.jp The MATRIS robot automation system with a rack for 20 pallets. The clamping devices and robot grippers manufactured by Nabeya are in use here. TECHNOLOGY E XCELLENCE 41
CUSTOMER STORY – SANDVIK COROMANT HOLISTIC AUTOMATION Founded in Sandviken, Sweden, in 1942, Sandvik Coromant has become a global industry leader in tool manufacturing with over 8,000 employees worldwide. Customers from a wide range of industries – including aerospace, Automotive and oil & gas – rely on Sandvik Coromant solutions. The tool experts have a long-standing strategic partnership with DMG MORI, from which innovative machining solutions continue to emerge. Sandvik Coromant also benefits from these in its own production. For exam- ple, two NTX 2000s were installed at the Gimo plant in 2021, each of which operates fully automatically with a MATRIS. The robot handles both the loading of workpieces and the exchange of fixtures and tools. DEVELOPMENT OF 2,500 NEW PRODUCTS PER YEAR “As a market leader, we are required to meet the extremely high expectations of our customers in terms of innovation and quality,” says Philip Eriksson, project manager at Sandvik Coromant, explaining the company’s dependence on development and production. “Gimo is part of our Production Technology Center and is responsible for industrializing 2,500 new products per year.” He says this is done in close cooperation with the R & D departments in Sandviken and Stockholm. » 42 TECHNOLOGY E XCELLENCE 2 1 At the Gimo plant, DMG MORI 2021 has installed two NTX 2000s, each fully automated with a MATRIS. 1. Automatic tool change for the turret 2. Six locations for different tool bodies 3. + 4. Change of centers and chuck inserts
CUSTOMER STORY – SANDVIK COROMANT 4 3 TECHNOLOGY E XCELLENCE 43 The strategic partnership with DMG MORI is a win-win situation. Our individual MATRIS automation is the ideal example of this. Peter Andersén (left), Global Manufacturing Equipment, and Philip Eriksson, Project Manager Sandvik Coromant
CUSTOMER STORY – SANDVIK COROMANT On the two NTX 2000, Sandvik Coromant machines the turned profile of drill bodies. Being a tool manufacturer, Sandvik Coromant has equipped the turrets entirely with its own Coromant Capto C4 tool holders. goal was an automated manufacturing solu- tion that reduces this non-productive time as much as possible.” In the NTX 2000 turn & mill center and the MATRIS, a flexible and modular robot system, they found an optimal solution, he says. “An important point for us was the fact that we got the two manufactur- ing cells from one source.” Fully automated production of over a hundred variants in a range of batch sizes “The challenge in this project was to auto- mate exchange of components and turret tooling as well as the centers and chuck inserts,” says Philip Eriksson, describing the scope of the automation. This is nec- essary due to the large number of different bodies produced. Competitive thanks to automated manufacturing The realization of new products also includes their manufacture. “We need highly efficient technology in order to be able to offer our tools competitively,” explains Peter Andersén, responsible for Global Manufacturing Equip- ment at Sandvik Coromant. For this reason, he says, the company has been using auto- mated manufacturing processes in end-to- end digitalized production for decades. “Even our NC programs for the production of tool bodies are created automatically in Gimo and are new for each order.” The factory received 'lighthouse' recognition by the World Eco- nomic Forums in 2019, he said. MATRIS – modular automation for highly flexible production Using the example of tool bodies for drillis, Philip Eriksson refers to a new manufactur- ing solution that DMG MORI has worked out and implemented with Sandvik Coromant. “We manufacture over a hundred variants here, which involves a lot of setup. So our NTX 2000 / 2500 / 3000 BEST IN CLASS + Turn & Mill – 6-sided complete machining of workpieces up to ø 670 × 1,538 mm + turnMASTER main spindle: 8″ chuck, 5,000 rpm, max. 421 Nm + compactMASTER Turn & Mill tool spindle with 132 Nm torque and 350 mm length + Multitasking: Direct Drive B-axis for 5-axis simultaneous machining of complex workpieces + High flexibility due to X-axis travel up to −125 mm below the spindle centreline + 12-position BMT turret with 12,000 rpm and 80 mm Y-axis + CELOS with MAPPS on FANUC and CELOS with SIEMENS available The video for the NTX 3000 2nd Generation can be found at: https://youtu.be/aUrrM9ZOO0Y 44 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – SANDVIK COROMANT The robot also handles this change reliably.” As a tool manufacturer, Sandvik Coromant took on this part of the project and equipped the turrets with its own Coromant Capto C4 tool holders. STRATEGIC PARTNERSHIP WITH DMG MORI IS A WIN-WIN SITUATION Sandvik Coromant has achieved its goal of realizing more and longer unmanned shifts due to this project, which Philip Eriksson sees as further proof of the good cooperation with DMG MORI: “For us, the strategic partner- ship means that we support each other and achieve a win-win situation for all parties involved.” That is why we all want to main- tain this cooperation, he said. Peter Andersén looks ahead: “Both in Gimo and at our global locations, we are currently working on fur- ther projects with DMG MORI – productive automation solutions will of course remain important in the future.” « Automatic chuck inserts of chucks and centers A look at the MATRIS installation at Sand- vik Coromant reveals the complexity of this automation solution. A total of six carts with bodies can be accommodated in the cell, enabling autonomous production even dur- ing unmanned night shifts. Peter Andersén is pleased with the good capacity utilization: “This significantly increases our production capacity.” The robot takes the raw parts from the cart and turns them through 90 degrees at another station so that it can clamp them in the NTX 2000. The blanks are mainly sup- ported in centers in the main and counter spindles, but there is also the possibility to machine them in a collet chuck. “Since the chuck inserts and centers vary depending on the job, they are also housed in the MATRIS,” says Peter Andersén. The robot replaces them fully automatically when the compo- nents require it, he adds. Automatic tool change for the turret The highlight of the automation solutions of the two NTX 2000s is the automatic turret tool exchange by the robot system. “While the tools for the milling spindle, both milling and turning tools (the magazine of the NTX 2000 has 114 Coromant Capto C6 tool positions) are changed automatically, this is normally a manual process for turret tools,” explains Philip Eriksson. “This ties up a lot of labour because there are only twelve tool stations.” For this reason, he says, a separate tool mag- azine has been integrated into the MATRIS with space for 32 tools. “This allows us to put significantly more tools into the system. SANDVIK COROMANT FACTS + Founded in 1942 in Sandviken, Sweden + Over 8,000 employees worldwide + Development and production of innovative tooling solutions + Customers from demanding industries such as aerospace, automotive and oil & gas Sandvik Coromant Verktygsgatan 11 747 44 Gimo, Sweden www.sandvik.coromant.com Automatic tool change for the turret. Separate tool magazine with space for 32 tools integrated in the MATRIS. The robot in the MATRIS loads and unloads the NTX 2000 with workpieces and changes tools in the turret as well as centers and chuck inserts. Six carts with bodies can be accommodated in the cell, so autonomous production is possible during unmanned shifts. TECHNOLOGY E XCELLENCE 45
CUSTOMER STORY – HYDAC CHINA AUTOMATION MAKES PRODUCTION EASIER HYDAC International GmbH was founded in 1963 in Saarland and, with 9,500 employees worldwide, is a leading provider in the areas of hydraulics and systems technology. The company established a wholly owned sub- sidiary in Shanghai in 1996, which initially focused on the sale of products, particularly hydraulic components such as filters and accumulators. HYDAC China started local production in 2003 in line with the trend towards localization and to shorten delivery times. Expansion took place step by step. The Chinese subsidiary installed the first machine tool from DMG MORI in 2005. Since then, HYDAC and DMG MORI have successively expanded their cooperation with the purchase of several more machines and continued to optimize processes. The latest highlight is automated manufacturing comprising six NHX 4000s and a linear pallet pool. An alliance for top performance HYDAC’s production is based on the principle of guaranteed quality. Consequently, the company has high demands when it comes to manufacturing technology. Both the machines and tools have to be first-class. “We put our trust in leading brands. Machining accuracy and efficiency are particularly important,” explains Qiu Feng, production manager of HYDAC China: “We have been working closely with DMG MORI for a long time.” The machining quality as well as the process stability have been excellent right from the start. Growing together – everything from a single source and hand in hand There is no doubt that the growth of HYDAC China has benefited from the support of DMG MORI, Zhu Min, production manager of HYDAC China, says candidly. “HYDAC and DMG MORI are both leaders in their own industry. The two companies have the same vision when it comes to brand awareness, product quality and development strategy. This provides a solid basis for cooperation.” The central tool storage system offers space for up to 4,000 additional tools. The setting of tools is carried out via a tool setting station (TSS) with a maximum of 60 tools. Here the tools are identified by a DMC reader and loaded and unloaded into the system fully automatically along with the data. 46 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – HYDAC CHINA Automation solution with 4,000 tools and 48 pallet positions, including host computer for overall control of machines, pallets and tool automation. Against the backdrop of increasing digitalization and automation, there are almost no limits to future technical advances. Exactly like the cooperation between HYDAC and DMG MORI, the development will become even more long term and intensive. Zhu Min (right) Production Manager HYDAC China Large fully automated, flexible production line in Asia On the basis of this successful cooperation, DMG MORI also installed the same auto- mated production system in the HYDAC China plant in 2021. This is a fully automated and flexible manufacturing line into which a pallet magazine is integrated. “After a smooth trial run, the system has performed as expected in every respect,” confirms Production ManageZhu Min. At the moment, it is probably the largest fully automated, flexible production line in Asia. “While it quite common to have an automated line with six machine tools, a central tool system (CTS) with 4,000 tool stations along one side of the line is certainly impressive,” adds Manager Qiu Feng. “This is a technically complex production line with a lot of highlights.” It includes the LPP, the CTS, the LPS control computer, a tool presetter and six NHX 4000s. » TECHNOLOGY E XCELLENCE 47 After starting production with a single machine and later adding semi-automated material transfer and automated production cells, HYDAC China has now implemented a fully automated production solution with material handling systems. SIX NHX 4000s WITH LPP AND TOOL MAGAZINE FOR 4,000 TOOLS In 2020 HYDAC installed in its German plant an automated production system from DMG MOR comprising six NHX 4000s, high- performance horizontal machining centers, a pallet pool system with 48 pallets and a central tool store with up to 4,000 tools – everything from a single source. The auto- mated pallet solution completely fulfilled all production requirements.
CUSTOMER STORY – HYDAC CHINA TURNKEY AUTOMATION COMBINED PALLET AND TOOL HANDLING HIGHLIGHTS + 6 NHX 4000 machines are linked via an LPP linear pallet storage system with 48 pallet positions + 5 setup stations, including two robot setup stations for fully autonomous loading + Integration of a central tool storage system (CTS) for up to 4,000 additional tools + LPS 4 control computer for overall control of machines, pallets and tool automation, incl. interfaces to ERP and tool management systems → More about the LPS 4 control computer on page 53 48 TECHNOLOGY E XCELLENCE Over a width of 33 m, six NHX 4000 are automated with a 48-position pallet storage system. In addition, a central tool storage with 4,000 places has been integrated into the system. 5 setup stations and 48 pallet locations The linear pallet automation system (LPP) at HYDAC China has five setup stations and 48 pallets. Four setup stations have been provided for the machine operator to load fixtures and another for fully automated loading and unloading by robot. The LPP handles the pallets and delivers them to each setup station, storage position and machine. The complete control and mana-gement of the system takes place via a DMG MORI LPS 4 control computer. One system, many machines and one operator The CTS central tool storage system provides 4,000 places and is the most impressive highlight of this automation system. It has the capacity to operate autonomously, 24 hours a day, seven days a week. The image processing camera on the robot arm monitors whether the positions in the tool racks are occupied or free during tool transport. At the same time, the position of the tool racks is checked via the vision system to ensure that neither thermal nor any other influences pose a problem for the safe operation of the system. The LPS control computer acts as the “brain” of the automation. Although the automation system is huge, it can be managed by just one operator. The LPS can assign the machine tool programs, improve productivity and at the same time display the work status of the machine. It offers an overview of the work status of every individual machine. In addition, before each machining operation or LPS 4 CONTROL COMPUTER FOR OVERALL CONTROL OF THE SYSTEM transport to a machine tool, it checks whether the tools are available and if their service life is sufficient. This is a significant advantage in combination with the CTS (central tool storage), as missing tools and expired service lives are automatically reported to the tool room so replacements can be prepared.
The tool presetter is connected with the LPS to enable the tool data to be automatically written to the database of the cell computer. Should the machine operator need to load the tool, its QR code is first read by the TSS (tool setting station) and the tool is loaded into the magazine. The robot then automatically transports the tool to the correct position in every machine or into the magazine. Essential automation solutions “Although the range of parts is extremely diverse, this automation system is perfectly suited to fulfil our requirements. The manu- facturing system currently handles 70 percent of HYDAC China orders,” comments Zhu Min. HYDAC is very satisfied with the performance of the installation. “The advantages are obvious, whether in reference to staff deploy- ment, process reliability, technical support, error rate, stock ratio or the proportion of good parts produced.” It has been possible to reduce the six people that were needed to operate the manufacturing line per shift to just three operators, one for each shift. Zhu Min adds: “In light of increasing labor costs and difficulty in finding staff, there is no doubt about the attractiveness of these benefits for our company.” > 97 % good parts and savings in raw materials Once again it shows that high efficiency and reliability can be achieved by automated machining. “Our yield used to be approximately 85 percent. In a very short time, it is now over 97 percent, thanks to the new production line and it continues to improve.” says Zhu Min. “We also profit from the associated savings in raw materials along with a reduction in stock levels and many other advantages.” Technological advances for the future Within the context of increasingly tough competition, the automation solution from DMG MORI has enabled HYDAC China to maintain and build on its advantages. Recently, cooperation between HYDAC and DMG MORI has increased and an additional LPP automation line with four machines Shuttle of the 48-position LPP system. CUSTOMER STORY – HYDAC CHINA and connection of the existing CTS are in planning or have been ordered for Hydac Sulzbach. “Against the backdrop of increasing digitization and automation, there are almost no limits to future technical advances,” is the opinion of Zhu Min. “Exactly like the cooperation between HYDAC and DMG MORI, the development will become even more long term and intensive.” « HYDAC CHINA FACTS + Founded in 1996 in Shanghai as a wholly owned subsidiary of HYDAC INTERNATIONAL + Initially a sales company for hydraulic components such as filters and accumulators + Local production since 2003 HYDAC Technology (Shanghai) Ltd. Lvchun Rd 271 Economic & Technological Development Zone 200245 Minhang, Shanghai, China www.hydac.com.cn TECHNOLOGY E XCELLENCE 49
INTERVIEW – AGV / AMR 3 1b PH-AGV PALLET AUTOMATION Pallet automation with maximum flexibility through versatile layout design – our PH-AGV solutions transport pallets from 500 × 500 mm to 1,600 × 1,250 mm weighing (workpiece and pallet) up to 5,000 kg and ø 1,600 mm. 1 1a 1b The video for the PH-AGV can be found at: https://youtu.be/_evyeQ8LFUQ 50 TECHNOLOGY E XCELLENCE PH-AGV 950 + Pallet sizes: 500 × 500 mm, 630 × 630 mm, ø 800 × 630 mm PH-AGV 3000 + Pallet sizes: 1,000 × 800 mm PH-AGV 5000 + Pallet sizes: 1,250 × 1,000 mm, 1,600 × 1,400 mm
CTS – Central Tool Station INTERVIEW – AGV / AMR 1a 3 2 AGV / AMR – DRIVERLESS TRANSPORT SYSTEMS FOR THREE APPLICATIONS DMG MORI is driving forward integrated automation on the shop floor with Autonomous Mobile Robots (AMR) and Automated Guided Vehicles (AGV). 2 3 WH-AMR* WORKPIECE AUTOMATION TH-AGV TOOL HANDLING The solution for handling workpieces up to ø 150 × 120 mm and 10 kg. The WH-AMR travels autonomously, does not need rails and can automatically avoid people and obstacles that it detects using laser sensors. Driverless transport system for the autonomous transport of tools between the central tool magazine (CTS = Central Tool Station) and the machine tool. The TH-AGV can transport up to 16 tools with a maximum total load of 480 kg. The video for the WH-AMR 5 can be found at: https://youtu.be/aR3brPXRMSY The video for the TH-AGV can be found at: https://youtu.be/WqNlOOemktg *AMR = Autonomous Mobile Robots (“WH-AGV” was renamed “WH-AMR” from July 2022) TECHNOLOGY E XCELLENCE 51
INTERVIEW – AGV / AMR PH-AGV PALLET AUTOMATION → more on page 54 WH-AMR WORKPIECE AUTOMATION → more on page 56 TH-AGV TOOL HANDLING → more on page 60 52 TECHNOLOGY E XCELLENCE HOLISTIC AUTOMATION ON THE SHOP FLOOR Within the context of manufacturing pro- cesses, which are becoming increasingly automated, more and more driverless transport systems, so-called Automated Guided Vehicles (AGV), are taking over the shop floor. DMG MORI supports its customers in this area with products in its AGV portfolio. The vehicles collaborate with people in one working environment to transport workpieces, pallets or tools from external storage loca-tions to the machines. The layout of this modular concept can be freely designed and quickly adapted to changing production environments if necessary. Michael Trenkle, Head of Special Construction at DMG MORI and Hideki Nagasue in the AMR Development Office at DMG MORI discuss how WH-AMR, PH-AGV and TH-AGV contribute to process automation and digitization of production. Mr. Trenkle, Mr. Nagasue, DMG MORI is regarded as a pioneer in automated production. You have also been concentrating on processes outside the machine tool since last year with the introduction of automated guided vehicle systems. What was the reason for this? takes a Michael Trenkle: DMG MORI holistic view of the subject of automation. Autonomous production on machines is only a part of the overall picture. The demand for flexible processes is increasing at the same time. This means that a wide range of workpieces, pallets and tools have to be stocked in large quantities. Many machines do not have the necessary capacity, meaning that external storage has to be installed. We provide economical decoupling of the machine from the workpiece, pallet or tool storage with our automated guided vehicle systems. Hideki Nagasue: The AGVs from DMG MORI drastically reduce the use of manual pallet trucks and forklifts. This gives engineers time to concentrate on demanding tasks such as planning and programming. DMG MORI started with the PH-AGV. When is it advisable to use autonomous pallet handling systems? Michael Trenkle: The modular concept of the PH-AGV makes it possible to have a flexible layout design, which is an advantage in situations where there is not enough room for a system consisting of a machine and a pallet store, for example. The pallet rack of the PH-AGV is also to extend at a later date. and additional machines may be integrated. The machine also remains completely accessible to operators. Pallet sizes up to 1,600 × 1,250 mm and with a total weight of up to 5,000 kg also guarantee that a wide range of components can be handled. Material pallets can also be transported. However, the speed must be taken into consideration. Classic linear pallet storage (LPP) has clear advantages in this case. With the LPP, cycle times should be more than 5 minutes. With the PH-AGV it is at least 20 minutes. Hideki Nagasue: Production is similarly made more flexible when the TH-AGV assists in tool management. The TH-AGV can transport up to 16 tools, each with a maximum weight of 30 kg. It has an interface to the tool loading station of the DMG MORI wheel magazine and is supplied with tools via a central tool store (CTS, see page 60). The WH-AMR (Autonomous Mobile Robot) differs from these two AGVs in that it has a robot which clamps workpieces in a machine. This process is significantly more complex than simply loading pallets or tools. Hideki Nagasue: That is correct. Workpiece clamping in particular requires technologies which are significantly more precise. For workpiece handling we have combined the principle of the AGV with a collaborative robot, which transports the workpieces into and out of the machine. The robot of the WH-AMR has an optical system with a positioning accuracy of ± 1 mm, which permits loading with sufficient precision into any fixture. We have standardized the WH-AMR to such an extent that it can interact with any machine on the shop floor. AMR is able to travel autonomously and reroute itself when an obstacle blocks its path. It is so flexible that deployment in production environments
E H A N D L I N G C P I E K R O W DLING N A T H E L L A P TOOL MANAGE M E N T A G V C O N T R O L FOR CPP, LPP, MATRIS, WH Flex and AGV (PH, WH & TH) and combinations thereof outside of the machine tool industry is also feasible. This means that we are in a position to develop new markets. How compatible are the AGV's in a production environment? Hideki Nagasue: All AGVs generally have to drive over uneven floors and cable ducts some of the time and are able to do so. Obstacles are bypassed with the aid of a laser scanner, meaning that safety fences are not required. A laser makes it possible to scan the environment and react to changes in the layout in a flexible way. The sensors and scanners of the AGV make safe opera- tion possible at speeds of up to 9 km/h (WH-AMR: 4 km/h). What about flexible layout design and control of the AGV? Michael Trenkle: The basis for the flexible layout lies in the modularity of the system. The storage and the setup stations can be freely positioned, regardless of whether this is for pallets, workpieces or tools. A buffer is also available as an option for achieving faster changeover times. The entire system can be integrated into an existing production envi- ronment and extended at a later date – and other machine types can be added. Modern lithium-ion batteries make continuous operation for eight hours possible. The vehicles have their own stations for auto- matic charging. Hideki Nagasue: The AGV is controlled using the DMG MORI LPS 4 central computer, with which DMG MORI successfully optimizes the entire production process. In other words: INTERVIEW – AGV / AMR LPS 4 THE MASTER CONTROLLER FOR ALL AUTOMATION SOLUTIONS + Pallet, workpiece & tool handling + Tool administration and tool management + Fixture management + AGV control + ISTOS PRODUCTION PLANNING & CONTROL + CELOS Job Manager + Reporting & evaluation functions such as OEE >> Modular software modules can be precisely adapted to any customer requirement THE BASIS OF THE FLEXIBLE LAYOUT LIES IN THE MODULARITY OF THE SYSTEM Customers who wish to fully automate their production can obtain everything from a single source at DMG MORI. « Michael Trenkle Head of Special Construction DECKEL MAHO Pfronten GmbH AMR and AGV are the ideal solution for auto- mating existing produc- tion. And in a completely collaborative way. TECHNOLOGY E XCELLENCE 53 Hideki Nagasue AMR Development Office General Manager
PALLET HANDLING – PH-AGV 5000 PH-AGV AUTONOMOUS PALLET HANDLING UP TO 5,000 kg DMG MORI has already presented the first AGV (Automated Guided Vehicle) solution for pallet handling (PH) at EMO in Hanover in 2019. The PH-AGV automated guided vehicles move autonomously and collaboratively with people on the shopfloor and transport pal- lets from external storage facilities to the machines. They ensure even more flexible production processes with unrestricted machine accessibility at the same time. Thanks to its free layout design and simple expandability, the AGV system can also be effortlessly integrated into existing produc- tion areas and quickly adapted to a changed production environment if required. NEW is the PH-AGV 5000 for pallet sizes up to 1,600 × 1,400 mm and 5,000 kg handling weight. “The automation solution enables maximum flexibility through free accessi- bility to the machines and freely program- mable travel paths for the handling unit”, says Cornelius Nöß, Managing Director at DECKEL MAHO in Pfronten. The configura- tion of the pallet rack and the set-up stations is modular. “The number and positioning can thus be completely adapted to suit the specific requirements of the customers.” The control and the management of the system is taken on by the DMG MORI CELL CONTROLLER LPS 4, which optimizes all processes in production. « PH-AGV 5000 for pallet sizes up to 1,600 × 1,400 mm and 5,000 kg handling weight. 54 TECHNOLOGY E XCELLENCE
PALLET HANDLING – PH-AGV 5000 Large vertical stroke of 2,010 mm for pallet storage in racks up to 3 m high. The PH-AGV 5000 connects the machine and the material into a perfectly coordinated value chain. The autonomous, driverless trans- port system for up to 5,000 kg enables efficient and collaborative work between the material store and the machine with free layout design. Access to the machine remains unrestricted in the process. Cornelius Nöß Managing Director DECKEL MAHO PFRONTEN GmbH PH-AGV PALLET AUTOMATION + Modular concept with flexible layout design – Automated guided vehicle systems without guide rails or tracks – Collaborative: Man and machine in one system – Maximum safety thanks to area scanners – Laser navigation + Pallet sizes from 500 × 500 mm to 1,600 × 1,250 mm + Workpieces weighing up to 5,000 kg (including pallet) and with a diameter of up to ø 1,600 mm + Used for machine pallets and material pallets A video of the PH-AGV 5000 can be found at: https://youtu.be/4CGHswmO_EA TECHNOLOGY E XCELLENCE 55
CUSTOMER STORY – KIGUCHI TECHNICS INC. 24-HOUR PRODUCTION THANKS TO WH-AGV 5* By connecting the NTX 1000 2nd Generation to a pallet warehouse via the WH-AGV 5*, we were able to sustainably optimize our processes. Tatsuya Kanou Production Department Manager KIGUCHI TECHNICS INC. 56 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – KIGUCHI TECHNICS INC. WH-AGV* WORKPIECE AUTOMATION HIGHLIGHTS + Modular concept with flexible layout design – Autonomous Mobile Robot systems without guide rails or tracks – Collaborative: man and machine in one system + The vision sensor enables robot arm accuracy of less than ± 1 mm + Workpieces with a diameter of up to 150 × 120 mm and a weight of 10 kg + Compact design (700 × 1,035 mm) + Laser sensor + High performance and stability, including on uneven surfaces The video for the WH-AGV 5* can be found at: https://youtu.be/aR3brPXRMSY The WH-AGV 5* does not need rails and can automatically avoid people and obstacles In Shimane Prefecture, known since ancient times for its iron production, KIGUCHI TECHNICS INC. has its headquarters in Yasugi. Japanese sword polisher Hisashi Kiguchi founded the company in 1961 and today KIGUCHI TECHNICS' core business is quality control of metals and other materials. Since 2021, test specimens have been processed on two NTX 1000 2nd Gen- eration machines that are connected to a pallet warehouse via the WH-AGV 5*, an autonomous transport system. This allows KIGUCHI TECHNICS to have a fully auto- mated process from the transport of raw parts to 6-sided complete machining and return of the finished test specimens. Inspection of industrial materials “Defects in components can lead to serious accidents and endanger people’s lives,” explains Takahiro Kiguchi, Executive Vice President KIGUCHI TECHNICS INC. This applies to cars, airplanes and power plants, for example, he said. “Quality control of *“WH-AGV” was renamed “WH-AMR” from July 2022. industrial materials used in production is therefore essential to ensure human safety.” KIGUCHI TECHNICS came to material inspection when a steel company asked the then Kiguchi Polishing Company to polish the surface of the high-grade special steel Yasuki-Hagane to a high gloss. It was then to be inspected under a microscope. » TECHNOLOGY E XCELLENCE 57
CUSTOMER STORY – KIGUCHI TECHNICS INC. Metal inspection specialists – more demanding tasks through automation Since then, KIGUCHI TECHNICS has consist- ently refined its expertise in metal inspection. Today, the company has an integrated sys- tem to perform everything from making test specimens to testing and evaluating them in-house – primarily in the aerospace, auto- motive, energy and medical sectors. As part of its 60th anniversary celebration, KIGUCHI TECHNICS has been working for two years to automate test specimen machining. Tat- suya Kanou, head of the production depart- ment responsible for this anniversary project, recalls, “We aimed to eliminate human error and increase productivity. At the same time, we wanted to use automation to reform our work processes so that our employees could concentrate on more demanding tasks.” HIGH-MIX, LOW-VOLUME PRODUCTION KIGUCHI TECHNICS' testing business is characterized by high-mix, low-volume pro- duction. The company cuts the materials received from customers, machines them into the optimum shape for testing and performs strength and fatigue tests. Finally, KIGUCHI TECHNICS provides the test data. The iron, stainless steel, aluminum or tita- nium test specimens each have to be molded into dozens of shapes. “Sometimes engines that have broken down due to metal fatigue are brought to us as they are,” Tatsuya Kanou said. “Our job then is to process such ‘irre- placeable specimens’ flawlessly and with the highest precision.” DMG MORI excels with autonomous and collaborative automation concept After evaluating several suppliers for the plan- ned automation solution, KIGUCHI TECHNICS opted for the concept from DMG MORI. The innovation leader combined two NTX 1000 2nd Generation – compact turn & mill centers – with an autonomous transport system, the WH-AGV 5*, enabling linkage to the pallet warehouse. The WH-AGV 5* takes the work- piece from the warehouse and trans-ports it to the two NTX 1000 2nd Generation. One takes over the pre-machining, the other 58 TECHNOLOGY E XCELLENCE On the two NTX 1000 2nd Generation machines, KIGUCHI TECHNICS processes around 50 different material types and 200 variants of specimens. KIGUCHI TECHNICS INC. (from left): Hiroyuki Uchida, Division Manager, Production Division 2, Production Department Shohei Yamaura, Section Chief, Section 1, Production Division 2, Production Department Takahiro Kiguchi, Director / Vice President Tatsuya Kanou, Department Manager, Production Department Tatsuhiro Okamura, Section Leader, Section 1, Production Division 2, Production Department The city of Yasugi in Shimane Prefecture has been known in Japan for its iron production since ancient times. KIGUCHI TECHNICS has its headquarters here.
CUSTOMER STORY – KIGUCHI TECHNICS INC. Measurement of thread dimensions is performed in the machine with a small diameter stylus of ø 1 mm. Connection to the pallet storage system enables unmanned production of a large number of workpieces over 24 hours. KIGUCHI TECHNICS FACTS + Founded in 1961, one of the largest independent testing labo- ratories for metals and other industrial materials in the country + Evaluating the quality and performance of materials used in the aerospace, automotive, energy and medical industries + A complete quality control system from machining speci- mens to performing the tests + Nadcap certification: Quality assurance considered essential for the manufacture and testing of aerospace products worldwide KIGUCHI TECHNICS INC. 114–15, Enoshima-cho, Yasugi-shi, Shimane, Japan https://kiguchitech.co.jp 門 柱 サ イ ン TECHNOLOGY E XCELLENCE 59 more demanding tasks. “Operators used to work two shifts to run the machines, but now automated production is possible around the clock.” Looking to the future, Tatsuya Kanou adds, “With the increasing use of hydrogen as an energy source, the need for metal testing will certainly increase even more.” This is because hydrogen embrittlement could reduce the strength of metallic materials. “As the overall labor force in Japan decreases, there will still be areas where manual labor is required as in this type of metal testing. Based on the automation solution we have now introduced, we intend to further auto- mate such processes and increase their precision.” « The WH-AGV 5* transports workpieces to the two NTX 1000 2nd Generation. The workpiece length is measured automatically on the workpiece tray. the finishing. The WH-AGV 5* then returns the test specimen to the warehouse. Unlike its predecessor, the autonomous transport system does not need rails. It can avoid peo- ple and obstacles automatically. “Since the NTX 1000 2nd Generation is equipped with 76 tools, we can machine a wide range of work- pieces without much setup effort,” adds Tat- suya Kanou. In addition, he says the system also improves machining accuracy. “This is because manual grinding used to be required after finishing.” 0.5 operators and 2 NTX 1000s instead of 4 operators and 4 machines The automated system is able to measure the length of the workpiece and the thread dimensions independently, eliminating the need for manual operations. “DMG MORI was the only manufacturer able to implement this automatic measurement,” Tatsuya Kanou looks back on the decision-making phase. In addition, he says, the system adjusts the machining program based on the meas- urement results. “The automation solution has been fully operational since January 2022. Processes that used to require four machine tools and four operator can now be performed by just 0.5 operator.” There- fore, he said, employees can be assigned to *“WH-AGV” was renamed “WH-AMR” from July 2022.
CTS – CENTRAL TOOL STORAGE FOR TH-AGV CTS – CENTRAL TOOL STORAGE MODULAR FLEXIBLE TOOL MAGAZINE FOR UP TO 1,440 TOOLS UP TO 1,440 TOOLS IN 29 m2 3,300 mm TLS – Tool loading station 100 % from the wheel magazine station HIGHLIGHTS + Modular concept with the option of expanding in stages by 360 / 240 tools (taper 40 / 50) + Very small footprint with only 29 m2 for 1,440 / 960 tools (taper 40 / 50) + Integrated tool loading solutions for portal tool handling or AGV tool loading + High transport capacity with portal tool rack handling + Taper cleaning and TDS tool identification optional + Proven wheel magazine technology with over 1,600 installations worldwide 60 TECHNOLOGY E XCELLENCE 4,450 mm 6,500 mm FLEXIBLE PLACEMENT IN PRODUCTION
CTS – CENTRAL TOOL STORAGE FOR TH-AGV Wheel element with 360 (ISO 40) or 240 (ISO 50) tools Storage and drive 100 % provided by the wheel magazine 80 TOOLS PER HOUR Tool changer 100 % from wheel magazine station TH-AGV TOOL HANDLING + Autonomous transport of 16 tools (2× 8 sets) between the CTS (Central Tool Station) and the machine + Tool Loading Station (TLS) – Transfer station to the CTS and the machine for handling 8 tools in sets – Tools weighing up to 50 kg and 650 mm in length PORTAL TOOL HANDLING SYSTEM + Portal tool handling for maximum efficiency, transport of up to 80 tools per hour + Transport of 16 tools (2 × 8 sets) + Fast tool exchange by rotatable rack + Max. linear speed: 80 m/min + Tool Loading Station TLS interface at machines and CTS Shuttle To transfer the tools, the Tool Loading Station (TLS) moves up to the shuttle, which is used to change the tools. TECHNOLOGY E XCELLENCE 61
CUSTOMER STORY – GREDE CASTING INTEGRITY LLC Thanks to the combination of machining speed, stability and accuracy, the NHX 5500 is the ideal machine for fully automated processes. The entire system of 18 machines manufactures reliably and safely to an accuracy of ± 0.01 mm. Mike Latwesen, Plant Manager (left) Chris Pegelow , Engineering Manager (middle) Dan Woyak, Project Manager (right) at Grede in Menomonee Falls FULLY AUTOMATIC, SAFE AND PRECISE Grede Holdings LLC has its origins in a foundry established in 1920 in Wauwatosa, Wisconsin. Today, with 3,000 employees at ten locations in North America, the company is one of the leading experts in the field of metal casting. As a first-tier supplier to the automotive and commercial vehicle industry, Grede manufactures safety-critical compo- nents for the powertrain or chassis, among others. For this purpose, the team has more than 40 machining centers and lathes from DMG MORI at its disposal. 62 TECHNOLOGY E XCELLENCE At its machining and assembly facility in Menomonee Falls, Wisconsin, the machine tool manufacturer optimized the production of steering knuckles in 2019. The result is impressive: Over 650,000 steering knuckles are produced per year in a fully automated production line comprising 18 NHX 5500s. Holistic manufacturing from casting to ready-to-install component “As a full-service provider, we cover the entire process chain from design and cast- ing to final machining and quality control,” explains Mike Latwesen, General Manager at Grede in Menomonee Falls. He says the focus is primarily on safety-critical compo- nents for customers in demanding industries. “To remain competitive, we have to manufac- ture high-quality products and deliver them on time.” The fact that Grede has been one
CUSTOMER STORY – GREDE CASTING INTEGRITY LLC Production line with 18 NHX 5500s and 10 robots. One robot feeds 2 NHX 5500s. The tenth robot feeds the blanks and transfers the finished parts into a separate washing & measuring cell. The Grede team has more than 40 machining centers and lathes from DMG MORI at its disposal of the leading suppliers in the industry for decades is a direct result of continuous pro- cess optimization. Particularly in machin- ing – which accounts for up to 50 percent of the value chain – there is a lot of potential for savings, says Mike Latwesen: “Today's machining centers are more versatile, faster and more precise.” Grede has been using machine tools from DMG MORI since 1980, so he knows the technology very well. Turnkey project for complete machining of 650,000 steering knuckles per year Recent installations at Grede include a pro- duction line for steering knuckles, which was installed in Menomonee Falls in 2019. “In DMG MORI, we found a partner for this turn- key project that, offers leading manufacturing technologies. Additionally, their engineers have the necessary competence to implement such an extensive project in the allotted time,” says Mike Latwesen. In view of the order sit- uation, the capacity expansion had already been planned. The project took six months to complete. Since then, the plant has been producing over 650,000 steering knuckles for passenger cars per year in a fully auto- mated and highly flexible process – a complete set for one vehicle per process operation. » TECHNOLOGY E XCELLENCE 63
CUSTOMER STORY – GREDE CASTING INTEGRITY LLC 18 NHX 5500s for reliable one-hit machining The production line in Menomonee Falls consists of 18 NHX 5500s that perform a total of four milling operations. Ten robots load and unload the machines with heavy knuckle parts. This removes the risk of injury to the operators, while ensuring the machines are always supplied with raw parts. The operator loads the raw parts at one loca- tion and the intelligent parts conveyor trans- ports them to all 18 machines. The DMG MORI Messenger monitoring software allows status monitoring of the machines, which enables the operators to address issues such as tool change in a timely manner. “After the steering knuckles have passed through the production line, only final quality control follows,” adds Mike Latwesen. The fully automated process naturally requires absolute reliability – one reason for acquisition of horizontal machin- ing centers: “Efficient chip evacuation makes the NHX 5500 an ideal machine tool for such The same applies to the powerMASTER spin- dles, on which DMG MORI offers a 36-month warranty with no hourly limit, thanks to their robust design. According to Mike Latwesen, reliable hori- zontal machining was just one of several arguments in favor of the NHX 5500: “The combination of machining speed, stability and accuracy made the decision easy.” The sys- tem machines to an accuracy of +/- 0.01 mm. Another advantage was the small footprint in relation to the large work area. “It offers sufficient space for the required fixtures.” RELIABLE PRODUCTION IN THE HUNDREDTHS RANGE automated processes.” The integrated tool breakage sensing and the high-pressure coolant system are also crucial for the relia- ble operation of the production line, he adds. 2 1 3 1. Feeding of the blanks 2. Turnover station 3. Discharge of finished parts 64 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – GREDE CASTING INTEGRITY LLC Up to 650,000 steering knuckles are automatically processed by the production system, consisting of 18 × NHX 5500s. In addition, CELOS played a role, adds Mike Latwesen: “We've been using the intuitive control interface since 2014 on NLX 2500s installed at the time, so in the case of the NHX 5500, our team was already familiar with its operation.” Turnkey project perfectly implemented With the turnkey solution, DMG MORI met all Grede's productivity and machining qual- ity requirements, and Mike Latwesen looks back positively at the entire project imple- mentation: “In a project of this size, there are always hurdles to overcome. DMG MORI mastered the installation professionally and on schedule at all times.” « GREDE FACTS + 1920 founded in Wauwatosa, Wisconsin + Today, one of the top foundries in North America + Design, engineering, validation and manufacturing of safety-critical components for passenger, industrial and commercial vehicles + 10 facilities across North America with a team of 3,000 employees Grede Casting Integrity LLC Menomonee Falls, WI W 139 N 5470 Oak Lane P. O. Box 300 Menomonee Falls USA WI 53052–0300 www.grede.com TECHNOLOGY E XCELLENCE 65 Thanks to the LPS 4 master computer control system, the entire manufacturing system can be centrally controlled and monitored. The finished steering knuckles are then washed and automatically measured.
DMG MORI SUSTAINABILITY GREEN AND EFFICIENT WITH OUR AFTER SALES Mitigating the effects of global climate change is the greatest challenge that we can only overcome together. As a global manufacturer of CNC machines, we take our environmental responsibilities seriously: DMG MORI offers its customers sustainable services and products for the complete machine lifecycle, allowing you to reduce your CO2 footprint to a minimum – and in a way that conserves resources and energy while at the same time saving costs and maintaining competitiveness! Often all that is needed are small changes to achieve great success: Join us in shaping the future of a green industry for a more sustainable world! « DMG MORI focuses on sustainable value creation including in the after-sales area. Dr. Thomas Froitzheim Managing Director firstname.lastname@example.org 66 TECHNOLOGY E XCELLENCE GREEN MODE RETROFITTING, REFURBISHMENT AND RECYCLING We bring your machine back to its original performance level. Like a new machine for absolute competitive ness. Our solutions for retrofitting, replacement spindles and repairs are environmentally friendly and inex- pensive – coupled with the highest DMG MORI quality.
LIVE DATA AVAILABLE ANYWHERE MAXIMUM MACHINE EFFICIENCY WITH A MINI- MUM CARBON FOOTPRINT 1 LESS TRAVEL WITH DIGITAL SERVICES Monitoring solutions: + Increase the efficiency of your machines + Detect and avoid unplanned downtimes at an early stage Digital remote solutions: + Sustainably reduce work travel and CO2 emissions with our NETservice my DMG MORI customer portal: + Free your company from working with an ineffective jumble of paper and save the raw material with our digital customer portal INSTEAD OF NEW PURCHASES AND DISPOSAL 3 LIKE NEW MACHINES – RETROFIT & OVERHAUL + Retrofit: Bring your machine up to the state of the art + Overhaul: Restore 100 % of the performance of your machine DMG MORI SUSTAINABILITY AVOID TRAVEL EMISSIONS 2 ALMOST LIKE ON SITE – HoloLens TRAINING + Innovative remote solution for digital practical training with mixed-reality technology + Your employees are always available in the company + More sustainability for training The DMG MORI Academy was awarded E-Learning AWARD 2022 with its concept, “Use of HoloLens for practical training within the scope of blended learning”. 4 LIKE NEW SPINDLES – OVERHAULED & REPAIRED + 60 % of all spindles are refurbished and reused + 50 % of our customers decide on an overhauled replacement spindle or the repair of their spindle + 50 % of all spindle components are refurbished and reused TECHNOLOGY E XCELLENCE 67 4SUSTAINABLE SERVICE PRODUCTS
CUSTOMER STORY – KÖRTING HANNOVER GMBH DMG MORI USED MACHINES – RETROFIT AND OVERHAUL INSTEAD OF DISPOSAL GREEN MODE + Retrofit: Return your machine to the state-of-the-art + Overhaul: Restore the your machine to 100 % capacity The overhaul of a DMU 125 FD duoBLOCK by DMG MORI Used Machines allowed Körting to add many years to the operation of its mill-turn center. OVERHAUL – COST EFFICIENT AND SUSTAINABLE In 1871, Ernst Körting invented the steam jet injector as a boiler feed pump and founded the company Gebrüder Körting in Hannover with his brother Berthold. Today Körting Hannover GmbH has subsidiaries in Brjzil, China, India, Malaysia and Poland and ranks as a leading manufacturer in the develop- ment and production of application-specific jet pumps as well as vacuum engineering products and environmental technology. The principle of fluid dynamics applied then is still valid today. With around 300 employ- ees, Körting is an important partner in the processing and chemical industries and the vacuum technology and environmental tech- nology sectors. The company manufactures its demanding components on CNC machine tools from DMG MORI, among others. They include a DMU 125 FD duoBLOCK installed in 2006, which was made fit for at least another ten years thanks to a general over- haul carried out at the end of 2021 / begin- ning of 2022. Development of integrated products through collaboration with partners “As an expert in engineering services, com- ponents and systems, we develop integral solutions in partnership with our customers”, explains Dr. York Fusch, Chairman of the Board of Directors at Körting. This leads to consistent further development of the prod- ucts and ever more innovative fields of appli- cation. “Our expertise ranges from develop- ment and construction to manufacturing and on to include measurement of our jet pumps.” With this unique selling point, Körting can guarantee outstanding quality and process reliability. Jet pumps for economic and energyefficient wastewater treatment Jet pumps require very little maintenance and are designed to operate for decades. “So although we have only a negligible spare parts business, more and more companies are replacing old jet pumps and vacuum systems with more energy-efficient ones in order to increase economic efficiency and improve their environmental footprint”, explains Dr. York Fusch. The wastewater treatment business is gaining in importance. Körting develops and produces wastewater systems with ejectors whose design is similar 68 TECHNOLOGY E XCELLENCE
CUSTOMER STORY – KÖRTING HANNOVER GMBH to that of a jet pump. These, too, are dimen- sioned according to requirements, require virtually no maintenance and offer high oxy- gen efficiency, which is needed for purifying the water. DMU 125 FD duoBLOCK: efficient milling-turning operations since 2006 The ejectors are made of polypropylene and have been produced on a DMU 125 FD duoBLOCK from DMG MORI since 2006. “Milling and turning in one work area was even then the perfect manufacturing solu- tion”, recalls Jürgen Sack, plant manager at Körting. In addition, the work area offers sufficient space for long tools. “This means we can carry out many machining steps in a single clamping, which has reduced through- put time significantly.” In 2021 Körting considered investing in a new machining center. “However, the DMU 125 FD duoBLOCK was technically suited to our requirements, so we decided to commission OVERHAUL: THE NEW OLD MACHINE – COST EFFICIENT AND SUSTAINABLE DMG MORI Used Machines to overhaul our existing model”, says Jürgen Sack. This brought many benefits: “Firstly, we would have had to invest at least twice as much for a new model. Secondly, the overhaul did not require any changes on the shop floor and we were able to continue using our existing tools and equipment, such a fixtures and NC programs.” Overhaul with original spare parts in DMG MORI quality When carrying out a machine overhaul, DMG MORI Used Machines first records the actual condition of a machine, dismantles it and transports it to Geretsried. After dis- assembly and cleaning, all components are overhauled and reassembled. » Having the machine overhauled by DMG MORI Used Machines after 15 years brought decisive benefits for us. We saved 50 % of the costs of a new machine and thanks to the manufacturer's more moder, high quality parts, the accuracy of the machine is improved. Jürgen Sack, (left) Plant Manager at Körting Hannover GmbH Lars Günther, Head of Mechanical Production TECHNOLOGY E XCELLENCE 69
CUSTOMER STORY – KÖRTING HANNOVER GMBH OVERHAUL OF A DMU 125 FD AT KÖRTING IN HANNOVER – FACTS + 1,150 working hours + 3-month lead time + approx. 9,100 replacement parts The Körting ejectors are completed in assembly. OVERHAUL + 6-month warranty on the entire scope of the service + Attractive pricing with exclusive manufacturer expertise + Short lead times for the refurbishment + At least 10-year availability of spare parts and service You will find a demo video of the DMC 200 U at: https://youtu.be/Z65wssdGx4w 70 TECHNOLOGY E XCELLENCE The paintwork is also renewed. Then comes a test run, acceptance and pre-delivery inspection before the machine is reinstalled at the customer’s premises. “Having the machine overhauled by DMG MORI was important for us, because the manufacturer knows the machine best and uses only orig- inal, high quality parts”, Jürgen Sack goes on to tell us. An overhaul after 15 years also means that DMG MORI uses far more modern components. “This again further boosts the accuracy of the machine.” Three-month machine overhaul with timely completion Punctual completion was also important for Körting. “We were able to plan the three- month overhaul and produce a large number of ejectors in advance, yet the DMU 125 FD duoBLOCK is essential for our production”, explains Dr. York Fusch regarding the urgency. The mill-turn center has a multitude of appli- cations – it can also be used for the demanding machining of components made of chrome- nickel alloys. “DMG MORI documented We take care of your machine, from the last machining operation before it is dismantled through to the first machining operation after the overhaul and recommissioning. Lothar Sommer Managing Director of DMG MORI Used Machines GmbH email@example.com
CUSTOMER STORY – KÖRTING HANNOVER GMBH JET PUMPS – CONSISTENT APPLICATION OF FLUID DYNAMICS The jet pump is a device in which the pumping action is achieved by a decrease in the pressure of the fluid, steam or gaseous medium together with a high nozzle exit velocity and delivery of the suction medium by the jet pump. The application and condition of the medium determine the individual shape and cross-section of the flow channels in order to ensure pumping is energy efficient. It requires no mechanical drive and thus has no moving parts. Thanks to milling-turning operations, it was possible to reduce throughput times drastically. everything with interim reports and put the machine back into operation punctually as agreed”, say Dr. York Fusch and Jürgen Sack, obviously more than satisfied and impressed. Reliability with 10-year availability of spare parts and service The DMU 125 FD duoBLOCK was predestined for a machine overall, concludes Jürgen Sack: “Large, complex, new machines always involve large investments, which are only feasible if you can optimize your processes sustainably with a leap in technology.” As this had already been achieved in 2006, the benefits of the overhaul far outweighed the optio of buying new. Dr. York Fusch goes on to add: “What is more, our engineers were able to carry- ing on working seamlessly on their familiar machines – plus we benefit from a six-month warranty and 10-year availability of spare parts and service.” KÖRTING HANNOVER FACTS + 1871 founded in Hannover + Approximately 300 employees + Subsidiaries in Brazil, China, India, Malaysia and Poland + Development and manufacture of application-specific jet pumps as well as vacuum engineering products and environmental technology « Körting Hannover GmbH Badenstedter Straße 56 30453 Hannover, Germany www.koerting.de TECHNOLOGY E XCELLENCE 71
DMG MORI GREEN ECONOMY 100 % GREEN MACHINES GREEN ECONOMY CLIMATE-NEUTRAL MACHINE PRODUCTION GREEN MACHINE 1. Neutral Product Carbon Footprint (Scope 3 Upstream) 2. Neutral Company Carbon Footprint (Scope 1 + 2) Through avoidance, reduction and compensation, DMG MORI has both a CO2-neutral “Company Carbon Footprint” and a climate-neutral “Product Carbon Footprint”. This includes direct and indirect emissions from our own value creation as well as indirect emissions from upstream processes along the supply chain. Specifically, all machines delivered since January 2021 have been produced completely climate-neutral. + Neutral product carbon footprint + Neutral company carbon footprint + Machines > 99 % recyclable Sustainability initiatives award DMG MORI TOP 1 % RATING In 2022, DMG MORI was rated among the top 1 % of over 35,000 participating companies worldwide as part of the EcoVadis Sustainability Rating. 72 TECHNOLOGY E XCELLENCE
DMG MORI GREEN ECONOMY RESOURCE-EFFICIENT MACHINE USAGE (Scope 3 Downstream) All DMG MORI energy efficiency measures, such as the CELOS Energy Saving App, are of course standard on DMG MORI machines. GREEN MODE ENERGY SAVING Up to 30 % energy savings compared to the predecessor machine, e. g. + Regenerative braking + Demand-oriented control of process parameters and components + Energy Saving App TECHNOLOGY EXCELLENCE FOR GREEN TECHNOLOGIES GREEN TECH DMG MORI supports its customers in the area of the GREEN ECONOMY using e. g. recycling, wind & hydropower or electromobility as important levers against climate change. Renewable energy Hydropower E-Mobility TECHNOLOGY E XCELLENCE 73
CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG RA UP TO 0.4 μm CIRCULARITY UP TO 5 μm IT4 AT ø > 300 mm Exclusive technology cycle 360° TECHNOLOGY COMPETENCE MILLING, TURNING AND GRINDING + Milling, turning and grinding in a single setup + Grinding cycles for internal, external and face grinding, and dressing cycles + Stationary or rotating dressing unit for dressing a wide range of tool materials using structure-borne sound sensors + AKZ nozzle unit for best possi- ble flushing of the grinding gap optionally available Available for: CTX TC (4A) // DMU / C monoBLOCK // DMU / C duoBLOCK // DMU / C Portal A video of DMG MORI – Milling, Turning & Grinding can be found at: https://youtu.be/83DTxnlVxSc 74 TECHNOLOGY E XCELLENCE FIT FOR THE FUTURE WITH TECHNOLOGY INTEGRATION Meindl-Köhle Umform- und Systemtechnik GmbH & Co. KG from Landsberg am Lech developed out of a precision toolmaking company, which was founded by Georg Meindl in 1928 in Munich. With core expertise in the areas of engineering, toolmaking, CNC technology and sheet metal working and punching, the 70-strong team is a reliable partner for customers in a wide range of industries – from automotive and aerospace to mechanical engineering and the con- struction sector. The company recently entered the field of charging technology for electric vehicles with their own products. Meindl-Köhle has been using a DMC 80 FDS duoBLOCK for their production since 2022. The 5-axis mill-turn center by DMG MORI features a grinding function that allows the manufacturing process to be optimized. incentive for producing A combination of aspiration and enthusiasm “Joy in perfection” is a guiding principle practiced by Meindl-Köhle and is also the best an possible products. “We maintain very close partnerships with our customers and are involved early on in complex projects,” explains Matthias Müller, the authorized company representative. With many years of experience and specialist expertise, the team implements reliable processes and a
CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG TECHNOLOGY EXCELLENCE FOR GREEN TECHNOLOGIES + Integrated manufacturing processes save time and conserve resources + Development and production of components to optimize the charging infrastructure of electric vehicles + E-mobility: Manufacture of mold for conduits in cable ducts zero-error strategy. While partners placing orders profit from this customer-oriented philosophy, Meindl-Köhle has long since used its know-how and the possibilities offered by DMG MORI to implement its own ideas. Innovative solutions for charging technology “We would like to contribute by expanding the charging infrastructure in the strongly growing market of electromobility,” Matthias Müller makes reference to their MEVOLT electric charging system, which was deve- loped in-house. The special feature of the premium charging stations is a patented motorized cable extension and retraction system. “This means it is protected from the weather and remains clean. Nobody has to dirty their hands these days. The latest development is the MEVOLT MK4 ROOF CHARGER, a roof charging system with a 13-meter-long cable, which is ideal for car-ports or underground car parks, for example. Toolmaking for electromobility The order situation at Meindl-Köhle is proof of the major importance of electromobility. The company produces molds for the production of plastic conduits, for example. “Amongst other things, these are used as cable ducts in cars – and naturally increasingly in electric vehicles too,” says Matthias Müller. The conduits are extremely individual in design and different for almost every vehicle. “A complete set of these molds comprises 200 pairs.” For months, Meindl-Köhle has been producing these components almost 24/7. IMPRESSIVE THROUGHPUT TIMES THANKS TO COM- PLETE MACHINING INCL. GRINDING “The challenge associated with these molds is that they need to be ground on all sides after being milled,” Matthias Müller describes the process that he would like to make more efficient. » MEVOLT MK4 “ROOF CHARGER” is a ceiling-mounted charging solution for garages, carports, multi-storey car parks and similar types of parking spaces. Joy in perfection is a guiding principle. We need reliable machines and partners like DMG MORI to achieve this. Matthias Müller Authorized company representative Meindl-Köhle Umform- und Systemtechnik GmbH & Co. KG TECHNOLOGY E XCELLENCE 75
CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG 76 TECHNOLOGY E XCELLENCE Special tools such as a gear cutter, for example, are used for machining the mold. “In DMG MORI, we have found a partner that can offer all the machining technologies we need in one working area.” The machine tool manufacturer offers grinding integrated into its duoBLOCK series. “The DMC 80 FDS duoBLOCK with its integral grinding function was the perfect solution for us as it allows the throughput time per component to be reduced significantly compared with production on several machines.” Joint process optimization for 3-shift operation The development of the machining concept took place in close cooperation right from the beginning says Matthias Müller looking back: “For example, we built the devices for the two process steps ourselves in such a way that the grinding wheel was able to rotate all around twelve clamped workpieces.” For their part, DMG MORI selected special tools such as a gear cutter. “The success of this cooperation is demons-trated by the fact that the machines were able to be put into operation after just nine months and have been working without any problems since then – and this in 3-shift operation. RELIABLE GRINDING THANKS TO INTEGRATED MEASUREMENTS The internal measurements are the reason why the grinding process is so reliable. “The machine analyses the measurement data and calibrates the tools automatically,” Matthias Müller explains. In addition, there is always a sister tool in the tool magazine, which has 123 positions. Another feature is setup in parallel with production by means of a pallet changer. To all intents and purposes, idle times are a thing of the past.”
CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG Meindl-Köhle has been using a DMG 80 FDS duoBLOCK with grinding function since 2022. Flexibly and securely into the future with DMG MORI technology cycles Meindl-Köhle purchased the DMC 80 FDS duoBLOCK fully equipped to enable them to react flexibly for future orders. “We will soon be machining larger mold and will be able to make use of the turning function,” says Matthias Müller looking to the future. The same applies to the more complicated grinding operation. “We will be able to rely on DMG MORI technology cycles for this.” Countering the lack of skilled staff with technology integration The decision to invest in process integration for the DMC 80 FDS duoBLOCK quickly proved to be the right path for Meindl-Köhle – for capacity reasons, but also when it came to the lack of skilled staff, as Matthias Müller explains: “We are able to deploy our personnel more flexibly, as the machines can work autonomously for long periods. « MEINDL-KÖHLE FACTS + Founded in Munich in 1928, now with headquarters in Landsberg am Lech + 70-strong team + Comprehensive skills in engi- neering and tool making + Their own product range in the charging technology sector Meindl-Köhle Umform- und Systemtechnik GmbH & Co. KG Justus-von-Liebig-Straße 14 86899 Landsberg am Lech Germany www.meindl-koehle.de DMC 80 FDS duoBLOCK COMPLETE MACHINING: MILLING, TURN- ING AND GRIND- ING ON ONE MACHINE HIGHLIGHTS + 800 rpm Direct Drive table for 5-axis milling and turning in one setup + Workpieces up to ø 900 × 1,450 mm and 1,200 kg + powerMASTER motor spindle with 1,000 rpm and 77 kW + 5X torqueMASTER Spindle with 1,300 Nm and 37 kW + High surface quality thanks to grinding technology integration You can find the video on the duoBLOCK series here: https://youtu.be/Ql0LzkJXUAY TECHNOLOGY E XCELLENCE 77
CUSTOMER STORY – NEHER GROUP PCD TOOLS FOR E-MOBILITY APPLICATIONS At the NEHER GROUP in Ostrach, which was established in 1990, 110 experienced engineers develop and manufacture high- quality special tools for metalworking and woodworking, as well as molds, gages and other devices. The company's customers come mainly from the automotive industry, the aerospace industry and general mechanical and plant engineering. A special focus is currently on electromobility applications, which repeatedly present the team with new challenges. The NEHER GROUP has been implementing its production for many years using innovative manufacturing technolo- gies from DMG MORI – from demanding machining and additive manufacturing on LASERTEC SLM machines to cutting blanks on a LASERTEC 20 FineCutting machine to automated processing on machines from the LASERTEC PrecisionTool series. Customized PCD and CVD tools for e-mobility “Our core competence lies in the complete development of sophisticated PCD or CVD special tools,” explains Gerd Neher, who is the second generation to manage the NEHER GROUP. Polycrystalline diamond is a very hard cutting material which gives tools a long service life. “If a customer wants to manufacture a specific component, we implement the optimum tool for precisely that application.” A sector which is rapidly expanding is special tools for electromobility applications. The precision machining of a stator housing, i. e. the housing in which the rotor of the electric motor rotates, requires comparatively long and therefore heavy tools. “The weight is too much to ensure low-vibration and precise machining for numerous existing machines in the way that the cutters are normally used,” says Tobias Niess, who is responsible for developing the tools, describing the challenge. The weight can be reduced in two ways: “By using lighter materials such as titanium and new production methods, but above all with the aid of innovative manufacturing technologies from DMG MORI.” E-MOBILITY: GREEN TECHNOLOGY WITH NEW CHALLENGES FOR TOOL DESIGN LASERTEC SLM: bionic structures using powder bed AM One such technology is additive manufac- turing. The NEHER GROUP uses powder bed The NEHER GROUP develops and produces top-quality PCD and CVD precision tools for innovative applications in a wide variety of industries, including electromobility in an increasing number of cases. 78 TECHNOLOGY E XCELLENCE
TECHNOLOGY EXCELLENCE FOR GREEN TECHNOLOGIES + Machining the stator housings of electric motors requires tools that are both long and light + Additive manufacturing makes innovative methods possible in tool development + Bionic structures with a weight saving of up to 70 percent can be realized by powder bed additive manufacturing CUSTOMER STORY – NEHER GROUP Additive manufacturing on the LASERTEC 30 SLM gives you absolute design freedom – be it cooling channels close to a contour for durability or bionic structures that provide outstanding rigidity and optimum vibration behavior. And what's more, the weight saving compared to conventional tools is between 30 and 70 percent. Gerd Neher, owner and managing director (right) and Tobias Niess, development NEHER GROUP Changeover between different powders on the LASERTEC SLM models is quick and easy with the aid of rePLUG exchangeable modules. technology from DMG MORI to manufacture tool bodies – a LASERTEC 30 SLM and a LASERTEC 30 DUAL SLM. “The layer-by-layer build-up takes place directly on a previously milled interface,” says Tobias Niess. Additive manufacturing gives you complete design freedom. “On one hand we can integrate cooling channels close to the contour, which improves the durability of the tool. On the other hand, we can use the Finite Element method to create bionic structures inside the tools which provide maximum stability and optimum vibration behavior.” You also get a weight saving of between 30 and 70 percent compared to conventional tools. » TECHNOLOGY E XCELLENCE 79
CUSTOMER STORY – NEHER GROUP The video for the LASERTEC 50 PrecisionTool can be found at: https://youtu.be/1dzmrlNjcJ4 LASERTEC 50 PrecisionTool 210 % FASTER AND 56 % LOWER UNIT COSTS IN COMPARISON TO EDM! + Diamond tool laser finishing at up to 3.0 mm/min + Individual cutting edge processing: – < 1 μm sharp cutting edges – 3, 6, 9, 12, 15 μm defined cutting edge radii – negative chamfering + The service life of the tools is increased by a factor of up to 2.5 using laser processing PH 50 – PALLET HANDLING + Small footprint of just 2.7 m2 + Modular system with different tool pallet configurations such as: – 6 × tools ø 355 × 370 mm – 22 × tools ø 90 × 440 mm 80 TECHNOLOGY E XCELLENCE The two 5-axis LASERTEC PrecisionTool machines can economically produce 1 µm sharp cutting edges, defined cutting edge radii of 3, 6, 9, 12 or 15 µm and negative chamfers. LASERTEC Precision Tool: Precision cutting edge machining The cutting segments of the tools are first cut out of PCD or CVD blanks and are then brazed on. The NEHER GROUP uses a LASERTEC 20 FineCutting from DMG MORI for cutting. “The laser penetrates through blanks up to 3.8 mm thick,” says Tobias Niess. The diamond tools get their final “finishing touch” in the form of laser finish-ing. A LASERTEC 20 PrecisionTool and a LASERTEC 50 PrecisionTool from DMG MORI are used in this case. The two 5-axis pre-cision laser machines can economically produce 1 µm sharp cutting edges, defined cutting edge 1 µm SHARP CUTTING EDGES radii of 3, 6, 9, 12 or 15 µm and also negative chamfers. Thanks to High Speed Mode 3.0, the laser can operate at speeds of up to 3.0 mm/min. The technology is therefore up to 210 percent faster in comparison to spark erosion (EDM) and unit costs are reduced by 56 percent. The service life of the tools is increased by a factor of 2.5 thanks to laser processing.
CUSTOMER STORY – NEHER GROUP The LASERTEC PrecisionTool machines operate automatically in unmanned night shifts, e. g. with a PH 10 handling system for 54 HSK tools on the LASERTEC 20 PrecisionTool. The PCD and CVD cutting edges get their final “finishing touch” in the form of laser finishing on a LASERTEC 20 PrecisionTool and a LASERTEC 50 PrecisionTool from DMG MORI. User-friendly software for programming cutting edges DMG MORI has implemented the industry standard GTR as a programming solution for cutting edge machining, which allows the importing of EDM projects and requires little training when you switch to laser processing. Special software features also make it easier to program rotary and fixed tools, chip breaker geometries and negative chamfers. Unmanned shifts thanks to automated laser processing The cutting edges are processed even more economically thanks to the automation solutions installed by DMG MORI. For ex- ample, the LASERTEC 20 PrecisionTool has a PH 10 handling system with space for up to 54 HSK tools. The LASERTEC 50 PrecisionTool is equipped with automation that can change tools weighing up to 30 kg. “In this way, we can utilize both machines unmanned at night and at the weekend,” adds Tobias Niess. Optimum solutions across the entire process chain As far as Gerd Neher is concerned, the integrated product portfolio of DMG MORI is an important argument for long-term cooperation: “Tool manufacturing is an excellent example of how we have installed innovative manufacturing solutions from The NEHER GROUP manufactures tool bodies on machining centers and lathes from DMG MORI. The PCD and CVD elements of the tools are cut from blanks on a LASERTEC 20 FineCutting. DMG MORI across the entire process chain.” With a new DMU 200 Gantry for mold pro- duction and a DMU 50 3rd Generation and a CLX 350 for the training workshop, it emphasizes the good collaboration. He goes a step further: “We would like to organize our production so that it is paperless in future – with PLANNING & CONTROL from ISTOS.” « NEHER GROUP FACTS + Founded in Ostrach in 1990 + 110 skilled workers + Development and manufacture of PCD and CVD special tools for applications in the automotive, aerospace and mechanical engi- neering sectors, among others NEHER GROUP Am Sägebach 6, 88356 Ostrach Germany www.neher-group.com TECHNOLOGY E XCELLENCE 81
CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG LASERTEC – ADDITIVE MANUFACTURING: NOTHING IS IMPOSSIBLE 82 TECHNOLOGY E XCELLENCE
Image left: Laser deposition welding and 5-axis machining in one clamping. The LASERTEC 125 DED hybrid is ideally suited to the repair of large components. CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG An important pillar of success is innovative technologies such as additive manufacturing. We rely on machines from DMG MORI to ensure we can continue to write the successful history of the company. Dr. Ing. Hartmut Frerichs Managing Director Wolfgang Doose Werkzeug- & Vorrichtungsbau GmbH & Co KG The history of Wolfgang Doose Werkzeug- & Vorrichtungsbau GmbH & Co KG began in a garage in Henstedt-Ulzburg in 1999. With the goal of realizing solutions that are as precise and customized as possible, the current 30-strong team supplies customers in the automotive, medical and other demanding industries. The dynamic development of W. Doose is illustrated by the modern, fully air-conditioned production plant comprising an area of 2,300 m2. It houses TO ACHIEVE THE POSSIBLE, WE MUST ATTEMPT THE IMPOSSIBLE AGAIN AND AGAIN LASERTEC 125 DED hybrid, W. Doose makes full use of the possibilities offered by metal 3D printing. According to Dr. Hartmut Frerichs, managing director of W. Doose, the quote below left by Hermann Hesse perfectly describes the inspiration behind his team and the company. Dr. Frerichs took over from the company founder, Wolfgang Doose, in 2016. The company has a very customer-focused working style. “We take sufficient time to understand the customer’s problem as best we can at the beginning of every job.” This understanding, combined with the specialist’s many years of experience forms the basis for a holistic and quality-conscious approach. The range of services offered by W. Doose includes traditional tool making as well as prototype and small series production. What all orders have in common: “They are demanding projects that require both a high level of expertise and high-performance, innovative manufacturing technologies.” 18 CNC machines, including two turning cen- ters from DMG MORI. W. Doose carries out precision machining to an accuracy of up to 2 µm across the entire production chain. Its range of services was expanded in 2021 to include additive manufacturing – again with technology from DMG MORI. With two LASERTEC 30 DUAL SLM machines and a Acquisition of additive manufacturing technologies W. Doose retains its competitive edge with regular investment in manufacturing technologies. The best example is metal 3D printing. “We very often received orders where we had to rely on suppliers of additive » LASERTEC 125 DED hybrid COMBINED LASER DEPOSITION WELDING AND 5-AXIS MILLING IN A SINGLE CLAMPING HIGHLIGHTS + Workpieces up to ø 1,250 × 745 mm and 2,000 kg + Automatic changeover between additive and milling operations in a single setup + Complete hybrid CAD / CAM process chain + AM assistant: Adaptive process control, powder feed-rate sensor, AM Evaluator, AM Guard for the highest quality and process safety A video on the LASERTEC 125 DED hybrid can be found at: https://youtu.be/ruTo9hIYQGw MAINTENANCE REPAIR Punching tool – up to HRC 63 without heat treatment Die-cast core – 3 times longer tool life by using multi-material SPARE PARTS NEW PRODUCTION Valve – minimal system downtime thanks to a 90 % reduction in lead time Closed impeller – 10 % higher performance thanks to new design TECHNOLOGY E XCELLENCE 83
CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG LASERTEC 30 DUAL SLM GENERATIVE MANUFACTURING IN A POWDER BED WITH A 300 × 300 × 350 mm BUILD VOLUME + Highly complex components with function integration + Internal conformal cooling channels + Weight reduction due to topology optimization, lattice and honeycomb structures + Powerful DUAL-laser system (2 × 600 W) + rePLUG – the powder module for automated powder management and fast material changeover < 2 hours + Material-independent filtration system with filter subscription for 3,000 h The video on the LASERTEC 30 DUAL SLM can be found at: https://youtu.be/Ne9myMGpj9I 84 TECHNOLOGY E XCELLENCE Material changeover within two hours thanks to the innovative rePLUG powder module, resulting in optimal flexibility. W. Doose manufactures light components such as this robot gripper in the LASERTEC 30 DUAL SLM powder bed. manufacturing,” says Dr. Hartmut Frerichs, looking back. Over time, an in-house facility became increasingly interesting for W. Doose. “After market research in 2021, we made a decision to work together with DMG MORI.” The good experience with the existing machine tools was just as decisive as the supplier's extensive portfolio in the area of additive manufacturing. High-quality repairs using laser deposition welding and 5-axis machining in one clamping With products for the powder bed process and laser deposition welding, DMG MORI is considered to be a comprehensive provider of additive manufacturing machines. “We were able to integrate both technologies into our processes perfectly,” says Dr. Hartmut Frerichs. W. Doose now uses both a LASERTEC 125 DED hybrid as well as two LASERTEC 30 DUAL SLMs Thanks to its hybrid functionality, the former really shows its strengths especially when it comes to the repair of tool components, says Jens Retzlaff, plant manager at W. Doose: “Worn areas can be built up with the powder nozzle, which can be combined with 5-axis milling in the same setup, so that the original condition can be restored.” This process is considerably less expensive and more precise than manual welding with subsequent machining. The service life of the repaired mold is also increased 3-fold by the new process.
CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG Less space requirements: two machines in one An additional advantage of the hybrid machine – which is based on the monoBLOCK concept – is its versatility: “We also use the LASERTEC 125 DED hybrid for machining large base plates, for example.” This has a positive effect on the production space required. LASERTEC 125 DED hybrid, 3D printing in a powder bed normally requires post-pro- cessing of the components. “This means that our CNC machines are a fixed part of the additive process chain. Nevertheless, we can often reduce post-processing to a minimum, such as for drill holes and fits,” says Jens Retzlaff explaining the process. LASERTEC 30 DUAL SLM: productive small series manufacturing in a powder bed W. Doose uses the two LASERTEC 30 DUAL SLMs to achieve functionalities that would be impossible or difficult to implement using conventional machining. “This includes con- formal cooling channels in tools or light component structures,” says Jens Retzlaff with reference to a delicate but nevertheless stable robot gripper. “Conventionally pro- duced grippers are entire assemblies made up of many individual parts. These come out of the powder bed almost complete.” W. Doose mainly processes tool steel powders, but materials such as aluminum and titanium are also possible. “In this case we need to introduce argon instead of nitrogen as the shielding gas.” The material changeover itself takes less than two hours thanks to the inno- vative rePLUG powder module and thus offers optimal flexibility to enable the company to react to different customer requests. Complete process from the powder bed to finish machining Equipped with two 600-watt lasers, the LASERTEC 30 DUAL SLM is extremely pro- ductive when it comes to the deposition of individual parts or small series. Unlike the Spare parts on demand by means of additive manufacturing One other area where additive manufacturing makes an important contribution at W. Doose is for manufacturing replacement parts. “We are able to faithfully reproduce the respec- tive parts based on the component data – the LASERTEC 30 DUAL SLM is ideal for small workpieces, while the larger ones fit on the LASERTEC 125 DED hybrid,” Jens Retzlaff describes the possibilities. If no data is avail- able, the team uses a scan box that optically measures the old part with high precision. Investment in expertise and technology Innovative technologies such as additive manufacturing as well as training and further education of skilled workers are important pillars of success at W. Doose. “We invest equally in both areas to ensure we can con- tinue the successful history of the company,” emphasizes Dr. Hartmut Frerichs. “After all, we would like to continue in the future to optimize quality, costs and productivity for our customers.” « Complex tool components, small series and individual parts are produced in the LASERTEC 30 DUAL SLM powder bed. WOLFGANG DOOSE FACTS + Founded in Henstedt-Ulzburg in 1999 + 30 experienced engineers + Production of tools, jigs, prototypes and small series + Customized solutions for customers, including from the automotive industry and medical sector Wolfgang Doose Werkzeug- & Vorrichtungsbau GmbH & Co KG Tiedenkamp 19 24558 Henstedt-Ulzburg Germany www.wdoose.de The manufacture of conformal cooling channels in moulds requires advanced technologies such as additive manufacturing. TECHNOLOGY E XCELLENCE 85
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