DMG Mori Innovation Days 2014

U.S. Premiere NLX 3000Y/1250: Accurate efficient turning and milling with BMT® turret up to 1,250 mm (49.2 in) turning length
Next to the general advantages of the NLX series from DMG MORI, the new NLX 3000Y/1250 provides the additional highlight of a Y-axis with turning lengths up to 1,250 mm (49.2 in) and a bar capacity of 111 mm (4.4 in). BMT® (“Built-In Motor Turret”) refers to the integrated direct tool drive, which provides optimum conditions also for heavy milling operations with up to 10,000 rpm and the high torque of up to 54 Nm (39.8 ft/lb). Even large threads up to M4 x P3.0 can be optimally machined. The wide flat guides provide ideal machining conditions for complex  turn-mill complete machining. The coolant circuit of the NLX 3000Y/1250 through the machine body and machine bed also guarantees high precision, ensuring a consistent temperature of the whole machine.

U.S. Premiere NLX 4000 BY/1500: Efficient complete machining of large workpieces of up to 500 mm (19.7 in) diameter and 1,500 mm (59.1 in) turning length
Characteristic highlights of the NLX 4000BY/1500 are the large traverse path in the X-axis of 1,500 mm (59.1 in) on the one hand and, on the other hand, steady rests of up to 310 mm (12.2) diameter can be mounted for supporting workpieces. The maximum turning diameter is 600 mm (23.6 in) for the version with driven tools (MC). For the model with integrated Y-axis, the turning diameter measures a maximum of 500 mm (19.7 in), and the Y-axis in turn provides a traverse path of 120 mm (4.7 in). The machine is optionally available with a 145 mm (5.7 in) or 185 mm (7.3 in) Y-axis, depending on the bar capacity. This U.S. premiere also impresses with the BMT® turret.

NLX 2500SY/700: Efficient complete machining
One of the top models in the NLX range is the NLX 2500SY/700. As well as the main and counter spindles, which are obligatory in this performance class, the standard BMT® turret provides space for 12 driven tools, which can cut material at speeds of up to 10,000 rpm (10 or 20-station turrets are available as an option). The Y-axis travel is 100 mm (3.9 in). The turret is also optionally available in VDI design with the TRIFIX® high-speed clamping system. The NLX2500 SY/700 has been designed with generous traverse distances in order to cover a wide spectrum of parts. The turning length is 705 mm (27.8 in), and the maximum turning diameter is 366 mm (14.4 in). A turning diameter of 460 mm (18.1 in) is possible if the Y-axis is omitted. In addition, a clearance of 80 mm (3.1 in) allows larger diameter bars to be machined.

Finally, an important feature for machining accuracy is the excellent temperature management. For this purpose, the coolant floods through the machine body and the machine bed in a circuit, ensuring a constant temperature of the whole machine.

MAX 3000 – High-speed 30-tape vertical machining center revolutionizes the shop floor
Made for the demands of the automotive industry, the MAX 3000 30-taper vertical machining center comes standard with a high-speed, 2-station automatic pallet changer (APC) and offers both superior rigidity and agility. The machine was developed aiming at high-precision, high-speed machining of small workpieces, with the first priority on enhancement of customers’ productivity and efficiency. The compact MAX 3000 features a footprint of only 4.6 m2 (49.5 sq.ft.) despite employing a two-station APC. The table working surface of 600 mm x 300 mm (23.6 in x 11.8 in), which is suitable for machining small automotive parts, allows a round table to be installed, enabling the machine to offer a broad range of machining from small part machining using high-speed feed to complex machining requiring simultaneous 4-axis control.

The MAX 3000 achieves the fastest rapid traverse rate of 62 m/min (2,440.9 ipm) in its class on all axes. In order to suppress pitching, the MAX 3000 has reduced the weights of the column and other moving parts without losing its rigidity, and minimized the distance between the center of gravity of the moving parts and the guideways. Roller guides are used for the guideways to offer even better repeatability. The MAX3000 comes with the MAPPS IV high-performance operating system.

Additive Manufacturing – Additive and subtractive machining in one setup
Additive manufacturing offers new possibilities for high complexity and individuality and the market for additive technologies is growing quickly.

DMG MORI’s unique hybrid solutions combine subtractive machining (SM) and laser metal deposition processes for additive manufacturing. The LASERTEC 65 3D is based on a DMU 65 monoBLOCK® machine and has been developed by SAUER LASERTEC in Pfronten, Germany, in collaboration with DMG MORI USA. The LASERTEC 4300 3D is based on the turn-mill center NT4300SZ from Iga, Japan. Both machines are equipped with powerful diode lasers for deposition of the metal, while the 5-axis and turn-mill machine platforms enable highly accurate SM operations to be carried out. The metal deposition process via powder nozzle is up to 20 times faster than laser sintering in a powder bed. All common metal powders can be processed, including steel, nickel and cobalt alloys, brass or titanium. Wear protection layers can also be applied on the base material.

One strength of this process is the option to successively build up layers of different materials. Wall thicknesses of 0.5 mm to 5 mm (0.02 in to 0.2 in) are possible depending on the laser and the nozzle geometry. Complex 3D contours can also be generated in layers without supports. The individual layers can then be accurately machined before the areas become inaccessible to a cutter or other tools due to interference with subsequently deposited component geometry. The combination of the two processes is a sensible choice for repair work and the production of mold tools. Additionally, it offers many interesting options for lightweight components, prototypes or small batch production.

For integral parts which are traditionally milled with a material waste rate of 95 percent and more, significant cost savings can be achieved and the rate of waste can be reduced to about 5 percent. Series production is planned for fall 2014.

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