CTX production turning machines

Transcription

1 CTX beta 800 4A CTX beta A CTX production turning machines

2 Machine and technology Applications and parts Control technology Energy efficiency Technical data CTX beta 4A with the highest stability and long-term accuracy. 02 CTX 4A + + Maximum flexibility thanks to the patented and proven TWIN concept with two independent working areas* + + Cutting diameter of up to 340 mm and turning length of up to 800 or 1,250 mm station VDI 40 (Direct Drive turret and optional Y2 axis) on both turrets + + Tool set-up time of less than 30 seconds with VDI 40 with TRIFIX precision interface + + CELOS from DMG MORI with SIEMENS and ShopTurn 3G: ERGOline Control with 21.5" multi-touch monitor * optional

3 Turret-type turning machines for maximum flexibility and productivity. Turret for all requirements and optimal cutting performance + + VDI 40 interface, 12 tools, 28 Nm, 11.3 kw and 4,000 rpm + + VDI 30 interface, 16 tools, 28 Nm, 11.3 kw and 4,000 rpm + + Direct Drive turret with VDI 40 interface, 12 tools, 34 Nm, 14.2 kw and 10,000 rpm Tool set-up time of < 30 seconds thanks to VDI with TRIFIX + + Maximum stability and repeatability of less than 6 µm As standard for all star turrets + + Play-free and flexible double centring + + Increased rigidity thanks to enlarged contact face with hole pattern 4A: Patented and proven TWIN concept* + + Two independent working areas thanks to the unique working area concept with two turrets and the cross traverse of the counter spindle-tailstock combination driven VDI 40 tools (TRIFIX ) and Direct Drive turret* + + Up to two Y axes for machining complex components (optional lower turret) * optional 3D control system with exclusive DMG MORI technology cycles + + Operate 4.5 on SIEMENS 840D solutionline for user-friendly multi-channel programming with animated icons + + Exclusive DMG MORI technology cycles for simple conversational programming with parameterised input screens

4 Machine and technology Applications and parts Control technology Energy efficiency Technical data CTX beta 4A with the patented TWIN concept Machine with two turrets and a main and counter spindle as standard + + Optimal use of the working area thanks to the unique working area concept with two turrets and cross traverse* of the counter spindle-tailstock combination* + + Y axis on both turrets (upper ±60 mm, lower* ±40 mm) for efficient complete machining of bar, shaft and chuck components + + Two VDI 40 star turrets with a total of 24 driven tool stations and the VDI 40 TRIFIX precision quick-change system + + Tool set-up time of less than 30 seconds thanks to the TRIFIX precision quick-change system + + Direct Drive* turret rated at 10,000 rpm, 14.2 kw and 34 Nm maximises material removal rate + + The highest long-term accuracy thanks to glass scales on both X axes + + Maximum thermal stability thanks to water-cooled spindle motors + + CELOS from DMG MORI with SIEMENS and ShopTurn 3G for up to 60 % less programming time thanks to innovative multi-channel programming * optional

5 : TWIN concept: 4-axis machining at the counter spindle with upper and lower turrets 2: TWIN concept: 4-axis machining at the main spindle and workpiece support by the tailstock 3: TWIN concept: Simultaneous machining at the main and counter spindles Turning length CTX beta 800 4A // ø max. 340 mm CTX beta A // ø max. 340 mm 800 mm 1,200 mm

6 Machine and technology êêtwin concept Applications and parts Control technology Energy efficiency Technical data X1 = 300 mm Z1 = 800 mm (CTX beta 800 4A) 1,170 mm (CTX beta A) Y1 = 120 mm (± 60) Z3 = 780 mm (CTX beta 800 4A) 1,200 mm (CTX beta A) 06 Tailstock travel* = 300 mm 300 mm Cross traverse* = X2 = 195 mm Z2 = 780 mm (CTX beta 800 4A) 1,200 mm (CTX beta A) Y2* = 80 mm (± 40) * optional

7 Over 1,700 machines installed with the TWIN concept. Example Collision-free machining with two turrets axis machining of long, thin shafts with the support of the independently moveable tailstock* + + Y axes for demanding complete machining (optional lower Y axis) Example Two independent working areas with cross traverse + + Collision-free machining with two turrets and tailstock axis machining Example Diagonally moving counter spindle for face machining long components at the main and counter spindles + + Collision-free machining with two turrets and tools measuring up to 300 mm axis machining Example 4 3-tool strategy* + + Tool 1 working at the main spindle and tool 2 at the counter spindle (coupled operation on turret 1) + + Tool 3 at the main spindle (turret 2) axis machining * optional

8 Machine and technology êêdirect Drive Applications and parts Control technology Energy efficiency Technical data Direct Drive turret rated at up to 10,000 rpm for more productivity thanks to the maximised material removal rate. + + TRIFIX precision quick-change system for all machines with counter spindles, turret configured as a star turret + + Optional Direct Drive turret rated at up to 10,000 rpm (star turret) + + Maximum milling performance thanks to driven tools with a gear reduction of up to 4 : 1 and block tool screw fastening 08 Type // speed // output (40 / 100% ED) // torque (40 / 100% ED) CTX beta 800 / A Turret VDI 30, 16-station star turret // 16 4,000 rpm 11.3 / 5.6 kw // 28 / 18 Nm VDI 40, 12-station star turret // 12 4,000 rpm 11.3 / 5.6 kw // 28 / 18 Nm VDI 40, 12-station star turret // Direct Drive TRIFIX // 12 10,000 rpm 14.2 / 10.9 kw // 34 / 26 Nm standard, optional CTX beta 800 / A Standard: VDI 40 4,000 rpm, 11.3 kw, 28 Nm Optional: VDI 40 Direct Drive 10,000 rpm, 14.2 kw, 34 Nm CK45 high-performance milling 1 : 1 tool drive 1 : 1 tool drive 4 : 1 tool drive Material removal rate cm 3 /min Spindle speed rpm 1,401 4,775 5,602 : 4 Output kw Torque Nm Feed mm / tooth Cutting depth / width mm 1.5 / / / 50 Cutting speed m/min Number of teeth Mill diameter mm Specific cutting force N/mm 2 1,910 1,910 1,910 CK45 tapping Thread size mm M M M Spindle speed rpm

9 09 CTX beta 800 / A CTX beta 800 / A Tool drive Tool drive, turret with Direct Drive Power (kw) P (S3) Torque (Nm) Power (kw) 14.2 Torque (Nm) P (S3) P (S1) Md (S3) Md (S1) P (S1) Md (S3) Md (S1) Speed (rpm) 20 3,000 3,150 4,000 8,000 Speed (rpm) ,000 5,000 6,300 8,000 10,000

10 Machine and technology Applications and parts Control technology Energy efficiency Technical data Integrated spindle drives rated up to 680 Nm for the highest machining performance. + + Maximum dynamics thanks to integrated spindle drives rated at up to 5,000 rpm or 680 Nm and integrated C axis (0.001 ) + + Maximum precision and temperature stability thanks to the water-cooled drives of the main and counter spindle sided complete machining thanks to the counter spindle supplied as standard + + Bar machining up to Ø 102 mm 10 Type // speed // output (40 / 100 % ED) // torque (40 / 100 % ED) // bar capacity // spindle head (flat flange) CTX beta 800 / A CTX beta 800 / A Motor spindle Main spindle Counter spindle ISM 76 synchro // 5,000 rpm // 32 / 25 kw // 360 / 280 Nm 65 (76) mm // 170h5 ISM 102 synchro // 4,000 rpm // 48 / 40 kw // 680 / 570 Nm 102 mm // 220h5 standard, optional CTX beta 800 / A ISM 76 synchro // Main spindle and counter spindle, 32 kw, 360 Nm, 5,000 rpm ISM 102 synchro // Optional main spindle, 48 kw, 680 Nm, 4,000 rpm High-performance roughing CK45 // 150 mm component diameter CK45 // 200 mm component diameter Material removal rate cm 3 /min Clamping depth mm Cutting speed m/min Feed mm/u High-performance drilling CK45 CK45 Tool diameter mm Spindle speed U/min 462 (391) 462 Cutting speed m/min Feed mm/u ISM 76 synchro ISM 102 synchro 5,000 rpm / 32 kw / 360 Nm 4,000 rpm / 48 kw / 680 Nm Power (kw) Torque (Nm) Power (kw) Torque (Nm) 32 P (S6) P (S1) Md (S6) Md (S1) P (S3) P (S1) Md (S1) Md (S3) Speed (rpm) 850 5,000 10,000 Speed (rpm) ,000 6,300

11 1 Systems Intelligent workpiece handling for maximum productivity : Removal of a finished workpiece from the counter spindle and placement on the conveyor belt 11 Complete packages for bar machining + + Automatic NC-controlled workpiece collection device + + Conveyor belt for transporting the workpieces from the machine Integrated workpiece handling: Automatic loading and unloading of chuck components, adapted based on the range of workpieces up to ø mm and 15 kg + + Preparation for bar feed or bar loading magazine + + Up to ø 102 mm 600 mm / 10 kg

12 Machine and technology Applications and parts Control technology Energy efficiency Technical data 1 2 1: Mechanical engineering, steel drive shaft, 280 seconds machining time 2: Automotive industry, stainless steel spiral shaft, 475 seconds machining time CTX beta 4-axis production turning Cast steel steering components // CTX beta A Sector Automotive Highlight Automatic loading and Workpiece dimensions Machining time ø 97 mm 144 mm 150 sec unloading with integrated workpiece handling 12

13 Valve spool // CTX beta 800 4A Sector Hydraulics Workpiece dimensions ø mm Material CK45 Machining time 210 sec Bar diameter 38 mm (h11) Highlight Long thin shaft, very small diameter Valve sleeve // CTX beta 800 4A Sector Hydraulics Workpiece dimensions ø mm Material CK45 Machining time sec Bar diameter 75 mm (h11) Highlight Complete machining, spiral milling 13 Tool holder // CTX beta 800 4A Sector Machine tools Workpiece dimensions ø mm Material 42CrMo4 Machining time 9.2 minutes Bar diameter 65 mm (h11) Highlight Maximum precision h6 Drive spindle // CTX beta A Sector Hydraulics Workpiece dimensions ø mm Material 42CrMo4 Machining time 9.55 minutes Bar diameter 65 mm (h11) Highlight Complete machining, high proportion of milling Control valve // CTX beta A Sector Hydraulics Workpiece dimensions ø mm Material 42CrMo4 Machining time 8.37 minutes Bar diameter 70 mm (h11) Highlight Complete machining Nozzle head // CTX beta A Sector Hydraulics Workpiece dimensions ø mm Material 19MnCr5 Machining time 7.95 minutes Bar diameter 75 mm (h11) Highlight Complete machining, highly precise angular positioning to 0.01

14 Machine and technology Applications and parts Control technology êêcelos Energy efficiency Technical data APP MENU: Central access to all available applications 14 ERGOline Control with 21.5" multitouch monitor and SIEMENS. Uniform Standard user interface for all new high-tech machines from DMG MORI. Continuous Consistent administration, documentation and visualisation of order, process and machine data. Compatible Compatible with PPS and ERP systems. Can be networked with CAD / CAM products. Trendsetting CELOS APP extensions.

15 From the idea to the finished product. CELOS from DMG MORI enables consistent administration, documentation and visualisation of order, process and machine data. CELOS can be extended with apps and is also compatible with your company s existing infrastructures and programs. CELOS APPs facilitate quick and easy operation: three examples» JOB MANAGER Systematic planning, administration and preparation of orders. +Machine-based + generation and configuration of new orders + + Structured storage of all production-related data and documents + + Easy visualisation of orders, including NC program, equipment, etc. JOB ASSISTANT Defining and processing orders. + + Menu-guided set-up of the machine and conversational processing of production orders + + Reliable error prevention thanks to work instructions with mandatory acceptance function CAD / CAM VIEW Visualise workpieces and optimise programme data. + + Direct remote access to external CAD / CAM workstations + + Central master data as basis for component visualisation + + Immediate change options for machining steps, NC programs and CAM strategies, directly in the control system

16 Operate 4.5 on SIEMENS 840D solutionline with multi-channel programming

17 Up to 50 % higher productivity with exclusive DMG technology cycles : Easy Tool Monitoring: Driven tool load monitoring during the machining process in order to avoid damage to the machine and equipment 3 4 2: Eccentric turning and milling: Machining cylindrical elements of a workpiece whose centres are not colinear with the lathe spindle centreline 3: Alternating speed for vibration-critical clamping applications: The spindle speed changes in order to avoid tool vibration during the machining process 4: Multi-thread cycle: This cycle provides an interface for entering the pitch, number of threads and contour of the thread 5 6 5: Program mode control: Displays the workpiece number and workpiece data; makes it easier to continue machining after a program interruption 6: Turret centre: The pre-position and support position in X and Z are entered directly via the user interface, automatic calculation of the approach traverses 7 8 7: Turret head steady rest: A steady rest mounted on the turret can support the workpiece or retract from it via the cycle 8: Retraction cycle: Emergency function to retract the X and Z axes at the push of a button; operation via Softkey 9: Counter spindle centre: Cycle to automatically transfer a tailstock centre into the chuck of the counter spindle from the turret : Runtime monitor: Graphic display of the program runtime with the cutting and idle times of up to 3 channels in the control system

18 Machine and technology Applications and parts Control technology Energy efficiency Technical data Save up to 30 % energy energy-efficiency measures in DMG MORI machines. MM Design FEM-optimised design with high static and low moving masses. Linear guides Negligible friction thanks to the consistent use of roller bearing technology. Servo technology / frequency control Frequency-controlled coolant and hydraulic pumps instead of fixed displacement pumps with regulator technology.

19 Efficient optimised design + + Optimal drive design + + Drives capable of energy recovery + + Regulated accumulators* + + Minimised friction Efficient intelligent control system + + Process optimisation + + DMG MORI Virtual Machine* + + DMG MORI AUTOshutdown * optional DMG MORI Energy Saving + + Intelligent technology already saves up to 20 % of energy costs as standard over the entire life cycle of your DMG MORI machine tool + + DMG MORI AUTOshutdown: Intelligent standby controls to avoid unnecessary energy consumption when idle DMG MORI Virtual Machine Unique your DMG machine 1 : 1 on the PC + + Efficient production start-up thanks to optimal preparation + + Real part production time calculation thanks to PLC integration + + Full availability of all cycles and NC functions + + The highest process safety thanks to collision detection and working area monitoring + + Accurate machine model with precise working area display + + Set-up and tool setting times are cut by 80 % 19 Higher efficiency EFF 1 EFF 2 IE4 Super Premium Efficiency IE3 Premium Efficiency IE2 High Efficiency IE1 Standard Efficiency IEC-Motors Drives Energy recovery during the braking phases of spindles and feed drives. Motor Use of the latest drive motors with up to 93 % efficiency. Cooling* Inverter-controlled systems for demandbased cooling performance. * optional

20 Machine and technology Applications and parts Control technology Energy efficiency Technical data êêworking areas Working areas CTX beta 800 4A with counter spindle and no X3 slide 796 ø 580 Y1 = 60 Y1 = ,050 Z1 = Y1 565 X1 = ø 580 Y1 460 X2 = ø ø X1 = M M 95 ø * Y2 = X2 = * Y2 = Z2 = 780 Z3 = 780 CTX beta 800 4A with counter spindle with X3 slide and tailstock, optional 796 ø 580 Y1 = 60 Y1 = ,050 Z1 = Y1 565 X1 = ø 580 Y ø 254 = X1 = 300 ø X3 = 180 M M M 340 X2 = X2 = ø 340 ø 210 * Y2 = * Y2 = Z2 = 780 Z3 = 780

21 CTX beta A with counter spindle and no X3 slide 770 Y1 = 60 Y1 = ,470 ø Z1 = 1, , Y2 460 Y1 535 X1 = X1 = 270 3, ø 580 X2 = ø 254 M 120 M 95 ø M ø 210 * Y2 = X2 = * Y2 = Z20 = 120 Z3 = 1,200 CTX beta A with counter spindle with X3 slide and tailstock, optional Y2 Y1 565 X10 = ø 580 Y1 = 60 Y1 = , Z1 = 1, , X2 = X1 = 300 ø X3 = X25 = ø Pz12 / CH = M ø ø254 M M ø * Y2 = * Y2 = Z2 = 1,200 Z3 = 1,200

22 Machine and technology Applications and parts Control technology Energy efficiency Technical data êêfloor plans Floor plans CTX beta 800 4A Front view Top view 2,372 5,383 4,929 4,183 1,308 2,300 2,424 4, , ,929 5, CTX beta A Front view Top view 2,372 5,990 5,679 6,740 1,308 2,300 2,423 5, ,050 3, ,740

23 Technical data CTX beta 800 4A CTX beta A Working area Maximum swing diameter mm Maximum turning diameter mm Distance from main spindle to tailstock (without chuck) mm Maximum workpiece length with tailstock (machinable) mm Distance from main spindle to counter spindle (without chuck) mm 1,050 1,470 Max. workpiece length with tailstock (machinable) mm 735 1,135 Main spindle (standard) ISM 76 synchro ISM 76 synchro Integrated spindle motor (ISM) with C axis (0.001 ) rpm 5,000 5,000 Drive power (40 / 100 % ED) kw 32 / / 25 Torque (40 / 100 % ED) Nm 360 / / 280 Spindle nose diameter (flat flange) mm 170 h5 170 h5 Spindle diameter at the front bearing mm Draw tube internal Ø mm Maximum chuck diameter mm Counter spindle ISM 76 synchro ISM 76 synchro Integrated spindle motor (ISM) with C axis (0.001 ) rpm 5,000 5,000 Drive power (40 / 100 % ED) kw 32 / / 25 Torque (40 / 100 % ED) Nm 360 / / 280 Spindle nose diameter (flat flange) mm 170 h5 170 h5 Spindle diameter at the front bearing mm Draw tube internal Ø mm Maximum chuck diameter* mm Turret (standard) Tool holder VDI / DIN mm 12 VDI 40 with TRIFIX 12 VDI 40 with TRIFIX Number of driven tools / maximum speed rpm 12 / 4, / 4,000 Drive power / torque (40 % ED) kw 7 Nm 11.3 / / 28 Indexing time 30 seconds Turret slide (upper) X / Y / Z mm 300 / ±60 / (300)* / ±60 / 1,170 Rapid traverse speed X / Y / Z m / min. 30 / 21.2 / / 21.2 / 45 Feed force X / Y / Z kn 5.0 / 4.5 / / 4.5 / 5.0 Turret slide (lower) X / Y* / Z mm 195 / ±40* / / ±40* / 1,200 Rapid traverse speed X / Y* / Z m / min 30 / 30 / / 30 / 45 Feed force X / Y* / Z kn 9.0 / 9.0 / / 9.0 / 9.0 Slide for counter spindle X* / Y mm 180* / * / 1,200 Rapid traverse speed X* / Z m / min 25 / / 45 Feed force X* / Z kn 9.0 / / 9.0 Tailstock mm Force kn Tailstock centre MK 5 5 Machine weight kg 13,500 14,500 Control system ERGOline Control with 19" monitor ** ** CELOS from DMG MORI with SIEMENS and ShopTurn 3G: ERGOline Control with 21.5" multi-touch monitor ** ** * optional, = standard, = not available, ** CELOS as standard from May

24 Machine and technology Applications and parts Control technology Energy efficiency Technical data êêoptions Options 24 Machine options Counter spindle Differential pressure clamping for the main spindle Differential pressure clamping for the counter spindle Y axis for turret 1 (upper) Y axis for turret 2 (lower) Glass scale for the Y and / or Z axes TWIN: range of the counter spindle on X and Z, additional tailstock mounted on the slide of the counter spindle with independent hydraulic movement in Z Bar machining / automation Bar machining package with parts catcher, hydraulic hollow clamping device, 4-colour signal light and connection for a bar feed or bar loading magazine Bar loading magazine for a maximum bar length of 1.2 to 3.2 m Preparation for external handling with robot interface, automatic sliding cover and chuck flushing unit Automatic loading hatch for automation with a 6-axis robot // electrical interface for a 6-axis robot Shaft machining Tailstock function for counter spindle Turret-mounted steady rest, clamping range up to 101 mm Chuck for the main spindle Up to 325 mm in diameter including accessories and chuck jaws Chuck for the counter spindle Chuck up to 325 mm in diameter including accessories and chuck jaws Coolant and chip disposal Chip conveyors Chuck flushing unit for the main and counter spindles 8 bar internal coolant supply, 600 l and 40 µm paper belt filter 8 / 20 bar internal coolant supply, 600 l and 40 µm paper belt filter 8 / 20 bar internal coolant supply, 980 l and 40 µm paper belt filter 8 / 20 bar internal coolant supply, 980 l and 40 µm paper belt filter and coolant unit 8 / 20 / 80 bar internal coolant supply, 980 l and 40 µm paper belt filter and coolant unit and additional 80 bar for 4 independent outlets in the turret (upper) Oil mist extraction system standard, optional CTX beta 800 / A

25 25 Control system / software 'Easy Tool Monitoring' technology cycle for tool wear monitoring Technology cycle for eccentric turning and milling Technology cycle for alternating speeds for vibration-critical clamping operations 'Multi-thread' technology cycle with user interface for entering the pitch, number of threads and contour of the thread 'Program mode control' technology cycle for visualisation of the program number, workpiece status and workpiece number 'Turret centre' technology cycle for the use of a rotating centre in the turret 'Turret steady rest' technology cycle for the use of a hydraulic steady rest in the turret Technology cycle for retracting the X axes at the touch of a button (only for eccentric machining) 'Counter spindle centre' technology cycle to automatically transfer a tailstock centre into the chuck of the counter spindle from the turret 'Runtime monitor' technology cycle to provide a graphic display of the program runtime with cutting and idle times of up to 3 channels in the control system Sister tool management system Tool Monitor Programming structure with sub-programs including graphical interface DMG MORI Netservice // DMG MORI Service Agent Miscellaneous Machine adaptation for increased ambient temperatures of up to 40º C (tropical package) CTX beta 800 / A DMG MORI recommends

26 DMG MORI LifeCycle Services Customer First Our service promise! Available for you around the clock: service-hotline.dmgmori.com We have good news for you: Our service and spare parts prices have been completely revised. With our service commitments, we want to meet your high demands with the highest service quality. Please contact us your sales and service team is at your disposal! Top quality at fair prices. It's a promise! Best Price Guarantee for Original Spare Parts. Should you get a spare part offered by us at least 20 % cheaper elsewhere, we will refund the price difference up to 100 %*. Up to 50 % lower service costs. New Flat Call-Out Rate without travel expenses or any additional costs! NEW NEW Spindle service at best prices. The highest level of competence from the manufacturer at new and attractive prices DMG MORI spindle service! Our protective shield for your productivity. Reduced operating costs, highest machine availability and maximum precision DMG MORI ServicePlus! NEW NEW Subject to modification. Technical update rights reserved. The machines depicted here may include some options, equipment and CNC alternatives. *All information and price advantages for Customer First are available at: customer-first.dmgmori.com