Journal. Innovation partners in the Rail & Road industry Rail & Road High-tech expertise

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1 06 07 CTX TC Turn & Mill High-Speed Cutting With ShopTurn 3G multi-channel programming New HSC Center of Excellence in Geretsried, Germany NEW // XXL Machines Turning lengths ECOLINE Series up to 19.7 ft. and a workpiece weight up to 40 tons DMU 50 eco Rail & Road High-tech expertise ULTRASONIC for Rail & Road industry components Integration in all 5-axis Milling Centers from DMG DMG / MORI SEIKI Get complete news online at: Journal dmg / mori seiki a perfect combination 2010 Edition 01 Innovation partners in the Rail & Road industry

2 02 03 DMG / MORI SEIKI 2010 TAKE OFF INTO THE FUTURE ECOLINE Series The right type of stimulus DMG / MORI SEIKI has developed the ECOLINE Series to address the need for flexible, cost-saving options, especially in economically trying times. Outstanding features such as efficiency, innovative technology and unbeatable prices are the key aspects of the ECOLINE Series. XXL Machines A ne of large part complete Additional information is available on Page 28 / 29 The new XXL Machining Centers from DMG / MORI SEIKI open up new dimensions in large part machining for our customers. The NT6600 DCG, from our partner MORI SEIKI, sets new standards in Turn & Mill complete machining with up to 19.7 ft. in turning lengths. dmg / mori seiki a perfect combination Take off into the future Since early 2009, DMG and MORI SEIKI have been closely collaborating. The strategic partnership includes production, purchasing, research and development, as well as customer financing and sales & service in selected markets. In 2010, GILDEMEISTER and MORI SEIKI are concentrating on their activities in the traditional US market, the growth market of India, as well as Australia. Both companies have agreed to join all their sales and service activities into one company. DMG / MORI SEIKI India since April 1 st, 2010 DMG / MORI SEIKI India in Bangalore will be responsible for the complete service and support for the entire product portfolios of both manufacturers. The employee know-how and the technologies of both companies strongly complement each other. DMG / MORI SEIKI USA since April 1 st, 2010 The corporate headquarters of DMG / MORI SEIKI USA, northwest of Chicago, features a showroom stocked with up to 25 of the latest CNC machines available for demonstrations and test cuts. NEW // DMU 50 eco Entry into 5-axis machining

3 w level machining suncarrier highlights Up to a 35% higher energy yield with vertical tracking to the position of the sun Module surface up to approx. 3,229.2 ft. 2, power up to 53 kwp per SunCarrier Long life cycle, statistical calculation outlook over 50 years Maintenance-free and storm protected Turn-key project solutions SunCarrier Intelligent and environmentally friendly with up to a 35% increased yield With the development of the SunCarrier tracking system from a+f GmbH, a subsidiary of the GILDEMEISTER Corporation, great strides have been made in the construction of industrial solar power plants. Get on board now. We will offer you a market-leading solution with the highest return. Solar park of Bürener Maschinenfabrik GmbH 21% of energy consumption in production is covered by SunCarrier Six installed systems each generate 33,000 kwh per year Construction time of only four weeks State-guaranteed purchase prices See the new XXL Machines LIVE in the Experience Center Turn & Mill in Bielefeld (Germany), where we will develop a customized technology package especially tailored to your needs. Additional information is available on Page 10 / 11 XXL Machines: NT6600 DCG cooperation market machine from DMG / MORI SEIKI DMG / MORI SEIKI Australia since March 1 st, 2010 The new service and technology center in Clayton, Melbourne (VIC) has combined the competencies of both organizations to offer customers innovative technology, the best service and unlimited solutions for any customer challenge. Dr. Eng. Masahiko Mori, CEO MORI SEIKI Co. LTD. // Dr. Rüdiger Kapitza, CEO GILDEMEISTER AG

4 04 05 TURNING TECHNOLOGY CTX // CNC UNIVERSAL TURNING MACHINES ctx alpha / beta / gamma 25% more power with Direct Drive Technology, a Y-axis and a linear motor With a unique configuration and a multitude of high-tech components the CTX alpha / beta / gamma is unmatched in this machine class. Such characteristics of this innovative and variable machine design include integrated spindle motors for a highly-dynamic acceleration and delay control, a 12 or 16 pocket servo turret with driven tools in the standard version, an optional Direct Drive as well as the cost-efficient Y-axis. dmg s loader For bar diameters up to 4.1 in. and bar lengths up to 63.0 in. Powerful up to 6,000 rpm. All CTX machines can be retrofitted inexpensively Attractive complete packages for bar machining on the CTX Series

5 01 01 Complete machining with a Y-axis 02 Linear motor on the Z-axis The Y-axis now up to 50% more cost efficient CTX alpha / beta is also available immediately with a Y-axis ctx alpha / beta / gamma highlights Driven tools in the standard version, optional turret with Direct Drive Technology for more power and precision Highest stability and durability more rigid Y-axis, highest cutting performance Complete machining in all sizes Tail stock in the standard version Large application range enlarged axis hub, the largest turning diameter and the highest torque CTX expansion options A solution for every challenge technical data CTX beta 800 linear: Swing diameter over bed: 27.6 in., Chuck diameter: 9.8 / 12.4 in., Cross travel X: 11.8 in., Vertical travel Y: ± 2.4 in., Longitudinal travel Z: 33.5 in., Drive power (40 / 100% DC): 45.6 / 33.5 hp., Max. rotational speed: 5,000 rpm., Number of tools: 12 (16)*, DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline with ShopTurn, Heidenhain Plus it with DINPlus (TurnPlus)* * Optional 02 Linear Drive Advantages of linear motor technology ctx beta linear / ctx gamma linear highlights Linear motor as an option in the X-axis, active cooling, glass scale in the X-axis Higher precision with higher productivity and dynamics Long lasting availability wear-free drive, no maintenance 36 month guarantee on linear motor components The CTX line can be customized as an intelligent building block system. It is available as a standard single-spindle feed machine with a fast turret and driven tools, the optional Y-axis and counter spindle, upgrading to the turning / milling spindle and tool magazine (CTX TC). Most expansion options are also available with linear drive for the highest precision. driven tools y-axis counter spindle

6 06 07 TURNING TECHNOLOGY CTX TC // TURN & MILL TURNING / MILLING CENTERS ctx beta tc / ctx gamma tc Turn & Mill complete machining ShopTurn 3G for the highest performance Turning and Milling on the CTX TC With the highest level in complete machining, you will reach your finished part considerably faster. The CTX gamma 2000 TC with a turret and the revolutionary ShopTurn 3G control offers the maximum productivity with up to a 60% time savings during programming. ctx beta tc / ctx gamma tc highlights Easy and fast Turn & Mill programming with ShopTurn 3G Easy-to-operate ShopTurn cycles 12-station turret for additional flexibility and productivity (for the CTX gamma 2000 TC) Powerful turning / milling spindle with an NC-controlled B-axis and torque motor Maximum stability and precision with the thermo symmetric design and active cooling Diverse tool magazines are available for the CTX beta 1250 TC and the CTX gamma 1250 / 2000 TC ENERGY SAVING technical data CTX gamma 2000 TC linear: Max. machining diameter 24.8 (27.6)* in., Max. machining length: 78.7 in., Max. output main spindle (40 / 100% DC): 60.3 / 46.9 hp., Max. output milling spindle: 29.5 hp. (30.8 / 42.9)*, Max. rotational speed: 12,000 (8,000, 18,000)* rpm., Y-axis: ± 7.9 in., B-axis: 240 degrees, Only: Number of tools: 36 (120)*, DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline with ShopTurn or Heidenhain Plus it with DINPlus (TurnPlus)* * Optional

7 dmg automation CTX TC tool handling with a 90, 120, 150 tool storage area th 90 tool handling highlights 90 storage pockets for tools with up to 13.2 lbs. handling weight, optional 120 (TH 120) and 150 (TH 150) tools are possible A 6-axis robot works continually from the tool rack and equips the tool changer Optimal accessibility to the tool changer through the swivel device Control through the tool management of the machine tool control CTX beta 1250 TC with TH 90: With the TH 90, TH 120, TH 150 tool handling systems automation solutions are immediately available for increased tool storage capacity. Channel 2 Tool holder 2 Channel 1 Tool holder 1 ShopTurn 3G multi-channel programming: Up to a 30% productivity increase through the DIN / ISO user interface that combines ShopTurn cycles with DIN functions. live Demonstration of your workpiece Experience high technology exclusively in our new DMG Experience Centers Turn & Mill in Bielefeld, Tortona or Shanghai. We will demonstrate the whole world of complete machining on your workpiece, LIVE in operation. For an appointment please contact us: DMG / MORI SEIKI USA, Tel: (847) , info@dmgmoriseikiusa.com The DMG Virtual Machine delivers a real illustration of your DMG machine 1:1 on your PC, and it shortens setup times by 80% with the highest process safety. dmg microset The process optimizer in tool presetting vio highlights Amortization < 1 year possible Flexibility through a modular design Unique design allows optimal access to the spindle Unmatched user comfort through servo-manual operation High quality components (e.g. precision spindle)

8 08 09 PERFORMANCE PARTNERSHIP CTX beta 1250 TC with Sinumerik 840D sl ShopTurn 02 HSC 55 linear with Sinumerik 840D sl and SINUMERIK MDynamics technology package SINUMERIK // More flexibility more functionality more productivity From turning via turn/milling all the way to High-Speed Cutting (HSC), all machining process steps can now be programmed and operated from within a uniform user interface. SINUMERIK Operate The new user interface for efficient machine operation ProgramSYNC Higher productivity for multi-channel machines. Multi-channel user interface for easy editing, synchronization, simulation and run-in of even the most complex workpieces ShopTurn/ ShopMill The 3rd generation of production process programming, complete turning and milling operation including a B-axis with ShopTurn Easy milling and mold machining with ShopMill ProgramGUIDE Graphic programming with animated elements Easy user guide with free contours and complex cycles SINUMERIK MDynamics New technology packages for 3 and 5-axis milling Optimal movement guide through Advanced Surface for the best surfaces SINUMERIK 840D sl Open, flexible, powerful powerful innovations The new Sinumerik MDynamics technology package with "Advanced Surface" offers an optimized movement guide through the harmonization of the velocity profile also during HSC milling. This leads to higher surface quality all the way to an ultra smooth workpiece surface. Siemens Industry, Inc., Drive Technologies Motion Control, 390 Kent Avenue, Elk Grove Village, IL T: (800) , SiemensMTBUMarCom.industry@siemens.com, Phoenix Contact stands for intelligent Ethernet in automation technology. Aside from standard components, we develop customized network solutions with our customers that are tailored to their needs. The DMG NAT-Switch for the latest machine tools is a result of this successful cooperation. It combines the NAT-Router and 7-Port Switch in one device. This combination illustrates the most efficient way to couple two networks with each other. Our sales representatives are always available to you for consultation. We make Ethernet easy. PHOENIX CONTACT 586 Fulling Mill Road, Middletown, PA 1705 T: (717) , F: (717) , info@phoenixcon.com UNRIVALED PRECISION! RENISHAW // Optimize your machine tool performance with measurement technology High accuracy on-machine inspection with strain gauge technology (RMP600 + OMP400) Non-contact broken tool detection system (TRS2) Compact laser system for tool setting and tool monitoring (NC4) Measurement software for fast creation of probing cycles for workpiece and tool measurement (Productivity+ Active Editor Pro) Renishaw apply innovation! DMG Innovation Prize Winner 2009 DMG / MORI SEIKI PowerProbe Series Preliminary caliper design Renishaw, Inc., 5277 Trillium Blvd, Hoffman Estates, IL T: (847) , F: (847) , usa@renishaw.com,

9 Jason Cox, Chief Technical Officer and Chad Tharp, Division Manager 02 Colin McGuire, Production Manager and Jeremy Wampler, Cell Operator 03 An aircraft structural component in production on Cox's 5-axis cell 04 New aircraft designs often use complex single-piece machinings cox machine inc. turning technology CTV Vertical Lathes Vertical machining for serial and universal production ctv series highlights Large Y-axis stroke (up to ± 3.9 in. for eccentric drilling and milling operations) Large Z-axis hub part heights from in., diameter up to 8.7 in. (CTV 160 / 250) Automation with up to 48 pockets in the standard version simple height adjustment for diverse workpiece lengths with automatic workpiece alignment (CTV 160 / 250) Chip-to-chip time < 5 seconds (CTV 160) High stability, for challenging daily production (CTV 160 / 250) Small footprint dmg automation Up to a 20% productivity increase a critical competitive advantage wh 3 workpiece handling with 6-axis robots Amortization < 1 year possible Reduction of unit costs High process safety and quality High level of autonomy with the 15-pocket workpiece carrier loop Additional operations can be integrated: measuring, cleaning, burring, labeling Optimal machine accessibility through side clearance Easy to operate WH 10 / WH 25 workpiece handling for loading of a CTV 160 linear 6-axis robot with a workpiece magazine for workpieces up to 22.0 / 55.1 lbs. DMU 70 Boosting milling production in cellular manufacturing with a 5-axis machine With its fortunes tied directly to the aerospace industry, Cox Machine s management thinks out of the box to get full productivity from their equipment. The company also purchases new, more productive equipment and develops better ways to utilize it mentions Jason Cox, Chief Technical Officer. Cox Machine of Wichita, Kansas, was founded in 1954 by Ernest Cox after he gained years of experience as a machinist at Cessna Aircraft Company and Kansas Tool. Wichita is the heart of the aerospace community with Cessna Aircraft, Spirit AeroSystems Inc., Boeing, Hawker Beechcraft, and Bombardier Learjet all having divisions there. Cox Machine produces parts for general aviation; business, commercial and military jets that mainly fit within a 2 square feet envelope and are primarily made from aircraft aluminum. Cox noted that not having a five-axis machine was causing perception problems with clients. To address this, they purchased six VMC three-axis DMG machines and a DMU 70 five-axis machining center. They then developed a manufacturing cell with two DMG 835v machines and the DMU 70. The reason I purchased the DMU 70 machine was because of its rigidity, says Chad Tharp, Division Manager for Machining. I also like that the table rotates and supports a part within it. The machine s footprint is very small making it work well in a cell. We can also get easy part movement between machines. After purchasing the DMU 70, Cox found that their customers were so impressed with their manufacturing abilities that they won enough new work to develop another cell, and thus now plan to purchase more DMG machines. Cox Machine, Inc., 5338 W. 21st Street, Suite 100, Wichita, KS T: (316) , F: (316) , info@coxmachine.com, Amortization in 11.2 months: In unmanned, 2-shift operations with a 20% productivity increase

10 10 11 XXL MACHINES TAKE OFF INTO ANOTHER DIMENSION Production at the highest level: With the continuous development of the NT6600 DCG, turning lengths of up to in. are now possible. Workpiece: Crankshaft Material: C 45 Machine: NT6600 DCG nt6600 dcg / dmu 600 p XXL Machines A new level of large part complete machining The new XXL Machining Centers from DMG and MORI SEIKI open up a new dimension in large part machining. DMG sets standards both in Turn & Mill complete machining up to 19.7 ft. in turning length, as well as in 5-axis machining up to 40 tons. Experience the NT6600 DCG Machine LIVE for large part machining in the Experience Center Turn & Mill in Bielefeld, where we will develop a customized technology package together with you for your special requirements. mori seiki nt6600 dcg Turn & Mill complete machining up to 19.7 in. in turning length Turning diameter: 42.1 in. nt6600 dcg highlights technical data NT6600 / 4000 DCG: Max. swing diameter: 42.1 in., Max. turning diameter: 42.1 in., Cross travel X: 40.9 in., Vertical travel Y: ± 13.0 in., Longitudinal Z: / 239.2* in., Main spindle: Spindle drilling: 7.2 / 10.8* in., Main / Max. counter spindle: (25% DC / 30 min. / cont): 40.0 / 34.7 / 30.0 hp., 60.0 / 50.0 hp.**, Max. torque: (40% DC): 2,400 / 5,003.6* ft. / lbs., Speed range: 1,500 / 1,000* rpm., Turning / milling spindle: Tool holder: BT50 / CAT50 / HSK-100A / Capto C8, Max. spindle speed: 8,000 rpm., Tool spindle drive motor (30 min. / cont): 40.2 / 29.5 hp., Max torque (15% DC / 15 min. / cont): ft. / lbs., Number of tools: 50 (100, 140, 180)**, Tool length: 23.6 in., MAPPS IV High-Performance Operating System for Integrated Mill Turn Centers * Specifications for the NT6600 DCG / 6000 DCG ** Optional Turning length: in. Milling performance of the highest class Box-in-Box design for extreme rigidity and vibration-free operation Large Y-traverse path ± 13.0 in. Two drive motors allow the highest acceleration values Stable flatbed construction no deformation during machining Direct Drive motors for fast and precise indexing of the tool spindle Y-traverse path: ± 13.0 in. XXL - Cooperation market machine NT6600 DCG from MORI SEIKI.

11 Large parts weighing up to 40 tons, traverse path up to 19.7 ft., slide with a 59.1 in. path, exchangeable milling heads dmg xxl machines in bielefeld turn & mill up to 19.7 ft. in length 5-axis milling up to 40 tons XXL Machines live In the DMG Experience Center Turn & Mill in Bielefeld: NT 6600 DCG from MORI SEIKI, technology presentations and customized technology packages for your individual requirements. // recently opened on march 10, 2010 in bielefeld 39.9 in. Y = in. dmu 600 p world premiere starting november 2010 The perfection of the gantry series Z = 49.2 in. (59.1 in.*) W = 63.0 in. dmu 600 p highlights (78.7 in.*) Modular design on the proven gantry structure Exchangeable heads up to 1,843.9 ft. / lbs.* for flexible adaptation to the machining task Powerful milling / turning table* Highest stability and maximum rigidity with the use of GGG60 The highest dynamics with up to 9.8 ft. / s² of acceleration and a rapid traverse up to 98.4 ft. / min. Tool exchange magazine for up to 313 tools Complete machine cover* Optimized base design with less complexity > 800 gantry machines installed Exchangeable milling heads technical data DMU 600 P: X / Y / Z: / / 49.2 (59.1)* in., Cross beam W-axis: 63.0 (78.7)* in., Main drive: 49.6 (67.1)* hp. / (1,843.9)* ft. / lbs. / 6,000 rpm., Rapid traverse / Feed X / Y / Z: 82.0 / 98.4 / 98.4 ft. /min., Tool holder / Magazine pockets: CAT50 / 60 Pockets**, DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline or Heidenhain itnc 530 * Optional ** Optional: Chain magazine with up to 180 pockets X = in.

12 12 13 TURNING TECHNOLOGY SPRINT // CNC AUTOMATIC TURNING X1 linear Y2 Y1 Z1 C2 X2 02 Machining time: 45 seconds C1 Z Machining time: 60 seconds 01 The work area design of the SPRINT 20 linear allows simultaneous machining with two tools, whereby the job times are significantly reduced 02 Connector housing / Automotive industry 03 Distributor / Hydraulics industry sprint 20 linear cnc automatic lathe The new automatic lathes for challenging materials and complex workpieces up to 1.0 in. sprint 20 linear highlights Linear drives for maximum precision, performance and efficiency, axes, two Y-axes in the standard version Integrated spindle drives with 10,000 rpm. for the main and counter spindles Up to two tools in simultaneous operation No unloading time with the unloading system on the counter spindle (in the standard version) Energy efficiency: Automatic machine shut-off Numerous software options for optimal efficiency swisstypekit: Conversion kit for the retrofitting of a long automatic lathe with a 9.4 in. spindle hub. This allows you to easily integrate the electronic guide bushing and to change the machine configuration. technical data SPRINT 20 linear: Axes: 6 + 2, Max. bar diameter 0.8 (1.0)* in., Max. rotational speed: 10,000 rpm., Main drive power (40 / 100% DC): 7.4 / 5.0 hp., Axis rapid traverse: ft. / min., Axis acceleration: 32.8 ft. / s 2, Stroke Z1-axis: 3.2 in., DMG SLIMline Panel with 15" screen and Fanuc 310is * Optional THK Leading Manufacturer of Linear Motion Guides "High Accuracy", "High Rigidity" Contributing to Further Improving Performances of Machines and Systems. As the pioneer of linear motion systems, THK has made constant efforts to develop new products by pursuing high accuracy and high rigidity, which are required for manufacturing equipment including machine tools. The ball/roller cage technology, which has been developed through THK s comprehensive technologies and know-how, not only improves machine performances, but also provides optimization, such as lowered particle generation and reduced maintenance, for customers using our products. Equipped with the ball/roller cage technology in addition to the energy-saving effect of linear motion systems, our products are consistently evolving into products friendly to the global environment. THK intends to continuously make contribution for our customers as a company focused on creative development that makes use of its ingenious ideas and unique technologies. THK America, Inc., 200 East Commerce Drive, Schaumburg, IL T: (847) , F: (847) ,

13 TURNING TECHNOLOGY GMC // CNC MULTI-SPINDLE TURNING CENTERS X4 Z4 W5 01 Machining time: 9 seconds 03 Machining time: 8 seconds W4 Z3 X3 X2 02 Machining time: 12 seconds 04 Machining time: 12 seconds 05 W3 Z2 01 Housing 02 Ball pin 03 Piston 04 Coupling 05 Work area of the GMC 20 gmc 20 cnc multi-spindle turning center The revolutionary GM Series Up to 65% reduced set-up times gmc 20 highlights 65% reduced changeover times (in comparison to GM machines) Highest productivity in the CNC Multi-Spindle Series Reduction of machine life costs mechanical devices rather than curves or special tools Machine setup is suited for the production of complex workpieces with medium batch sizes for a reduced investment value Highest capacity (Cpk: 1.67 in h6) Now at a reduced price with a CPU, 10 CNC channels, a maximum of 31 CNC axes and integrated safety functions Drum indexing with Hirth serration Five cross-slides, plus slides for rear-sided machining and frontal slides Optional: Independently-controlled frontal spindle, a U-axis, frontal milling device, radial drilling device, and a multi-sided and thread milling device technical data GMC 20: Max. bar diameter: 0.8 in. (1.0 in.), Spindle pitch diameter: 7.1 in., Number of spindles: 6, Main drive power (100% DC): 20.1 hp., Max. rotational speed 6,500 rpm., Drum indexing time: 0.7 sec., DMG SLIMline Panel with 15" screen: Siemens 840D powerline (1x) NSK // Partnership based on trust and trust based on partnership The GILDEMEISTER Group, as one of the major manufacturers in the highly specialised Global Machine Tool Industry, demands critical components with the latest technology and innovation as they determine the ultimate quality of the machine tool. NSK therefore provides: Super Precision Spindle Bearings Super Precision Ball Screw Support Bearings Linear Guides for High Accuracy & High Rigidity Ball Screws for High Speed Machine Tools Recent developments in high speed 5-axis machining have created demand for long life sealed angular contact ball bearings, prepacked with grease. To meet this need NSK provides ROBUST sealed precision bearings with high grade SHX steel and specific NSK grease this extends grease life, allows easier handling during assembly and significantly improves spindle performance. A solution from NSK adopted by the GILDEMEISTER Group. NSK Corporation, 4200 Goss Road, Ann Arbor, MI T: (734) , F: (734) , info@nsk-corp.com,

14 steering / drive technology steering / motor technology Crankshaft Machined on the GMX Series Steering element Machined on the GMX Series Control housing Machined on the DMC H Series 16 cylinder crankshaft housing Machined on the DMU 210 P Railway axle bearing Machined on the DMC 80 H duoblock RAIL & ROAD HIGH-TECH EXPERTISE FOR THE RAIL & ROAD INDUSTRY Rail&Road Mobility is an essential part of modern societies. Besides intelligentlynetworked traffic systems, there is now a requirement for a new way of thinking in the area of drive technologies. Longevity, energy efficiency and safety are prominent requirements in vehicle manufacturing. DMG and MORI SEIKI machine tools fulfill these requirements on a daily basis in tough routine production, with stand-alone machines, or in process chains for the production of the most complex workpieces. control 14 15

15 High-tech expertise for the Rail & Road industry turning technology CTX TC // Turn & Mill Machining Centers: Page Efficient complete machining of crankshafts and camshafts up to 19.7 ft. in turning length CTV // Vertical Turning Machines: Page 9 The highest availability during the production turning of gear parts and steering elements GMC // Multi-Spindle Turning Centers: Page 13 Maximum productivity during the machining of highly-precise mass-production turning parts milling technology DMC H // Horizontal Machining Centers: Page 16 Higher automation level during the precision machining of motor and transmission housings DMU // CNC Universal Milling Machines: Page 25 The highest flexibility in 5-axis machining with a 150 B-axis and an NC rotary table HSC // High-Speed-Cutting Precision Centers: Page 22 Excellent surface qualities and the shortest machining times for die inserts ultrasonic / lasertec ULTRASONIC // 5-axis Precision Centers: Page 34 5-axis hard machining of advanced materials

16 16 17 rail & road ENERGY SAVING DMC 55 H duoblock dmc h duoblock 3rd generation duoblock The complete series up to the DMC 160 H duoblock Production at the highest level From a 15.7 in. to a 49.2 in. pallet size: The highest stability and dynamics with a maximum, easily accessible work area and minimal space requirements. Over 80 application engineers from the Excellence Center will support you from time calculations, to comprehensive planning (Turn Key) of complete production lines. RAIL & ROAD MILLING TECHNOLOGY DMC H // HORIZONTAL MACHINING CENTERS dmc h duoblock series highlights Highest machine dynamics and maximum stability with high static masses and weight-optimized moving parts Optimal chip flow with steep covers and slanted cabins Space-saving design with chip disposal from the rear Vertical chain magazine for the highest process safety and short downtimes with chip-to-chip times of 2.9 seconds (HSK-A63) respectively 3.9 seconds (HSK-A100) High pallet load of up to 6,613.9 lbs. with the new pallet exchange design spindle range DMC 55 / 65 H duoblock CAT40 / HSK-A63 12,000 rpm. Motor spindle, 81.1 ft. / lbs., 26.8 hp. 18,000 rpm. Motor spindle, 81.1 ft. / lbs., 45.6 hp.* 10,000 rpm. Motor spindle, ft. / lbs., 56.3 hp.* DMC 75 H duoblock CAT50 / HSK-A100 10,000 rpm. Motor spindle, ft. / lbs., 59.0 hp. 12,000 rpm. Motor spindle, ft. / lbs., 59.0 hp. 12,000 rpm. Motor spindle, ft. / lbs., 69.7 hp.* DMC 80 H duoblock CAT50 / HSK-A100 8,000 rpm. Gear spindle, ft. / lbs., 49.6 hp.* 12,000 rpm. Motor spindle, ft. / lbs., 69.7 hp. DMC 100 / 125 H duoblock CAT50 / HSK-A100 8,000 rpm. Gear spindle, ft. / lbs., 59.0 hp.* 12,000 rpm. Motor spindle, ft. / lbs., 69.7 hp. * Optional 15.7 x Z=23.6 Y=23.6 X=22.0 1,102.3 lbs. Max. workpiece weight technical data DMC 55 H duoblock : Axis X / Y / Z: 22.0 / 23.6 / 23.6 in., Main drive (40 / 100% DC): 26.8 / 26.8 hp., Torque (40 / 100% DC): 81.1 / 62.0 ft. / lbs., Max. rotational speeds: 12,000 (10,000 / 18,000)* rpm., Rapid traverse X / Y / Z Feed: ft. / min., Tool fitting / Magazine pockets: CAT40 (HSK-A63)* / 45**, Max. pallet size / Max. load 15.7 x 15.7 in. / 1,102.3 lbs., DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline or Heidenhain itnc 530 * Optional ** Optional chain magazine with pockets

17 DMC 75 H duoblock DMC 80 H duoblock DMC 100 H duoblock DMC 125 H duoblock DMC 65 H duoblock 01 Production line: a Loading b DMC 55 H duoblock c Washing and leak test d Installation e DMC 75 H duoblock f honing g unloading The widest spindle range: Chip removal of light metals with 46.9 hp. and 18,000 rpm., or steel and cast iron with up to ft. / lbs x Y=27.6 Z=27.6 X= x Y=31.5 Z=31.5 X= x Y=31.5 Z=31.5 X= x Y= 43.3 Z= 49.2 X= x Y=39.4 Z=41.3 X=49.2 1,322.8 lbs. 2,204.6 lbs. 3,086.5 lbs. 4,409.2 lbs. 4,409.2 lbs x Y=39.4 Z=41.3 X=39.4 production line "crankcase" 18 DMC 55 & 75 H duoblock system machines, with manual workpiece front loading, produce 200,000 crankcases in one production line per year. Workpiece: Crankcase Material: Aluminium Machine: DMC 55 & 75 H duoblock (Minimum space requirement: ft.² incl. maintenance and operator area) 6,613.9 lbs x Y= 43.3 Z= 49.2 X= 63.0 a g b b b b b b b b b b b b b b e e e e c f d c structure of the complete production line DMC 160 H duoblock

18 18 19 MILLING TECHNOLOGY DMU / DMC duoblock // CNC UNIVERSAL MACHINING CENTERS FOR 5-SIDED / 5-AXIS MACHINING 30 / Benefit from industry specific tailored tool packages from our system partner, Walter AG axis simultaneous machining of a housing made of titanium with an NC-controlled B-axis for the highest stability with machining in the axis pivot point 02 NC-controlled A-axis for simultaneous 5-axis milling with negative angles up to 30, NEW // Lower interference contour for better accessibility to the workpiece 03 Spindles with up to ft. / lbs. or up to 30,000 rpm. for use in all industries 04 Complete machining with 5-axis simultaneous milling and turning in one setup 05 Automation with workpiece or pallet handling, e.g. with the RS10 rotary magazine dmu / dmc duoblock Maximum rigidity For use in all industries With the integrated B-axis, the duoblock -series now offers you 5-axis simultaneous machining in the standard version. An optimized large cubic work area for larger table loads, fast tool magazines (with up to 480 pockets), and the shortest chip-to-chip times ensure maximum performance. The patented duoblock design of the 3rd generation excels with the highest rigidity and the longest lasting precision. Energy Rail & Road Automotive technical data DMU 60 P duoblock : Travels X / Y / Z: 23.6 / 27.6 / 23.6 in., Spindle speeds: Standard: 12,000 (18,000 / 24,000)* rpm., Rapid traverse X / Y / Z: / / ft. / min., Number of tool in the magazine: 40 (60 / 120)*, Max. workpiece weight: 1,543.2 lbs., DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline, Heidenhain itnc 530 or Heidenhain MillPlus it Version V600 * Optional 03 5X torquemaster

19 Aerospace Tool / Mold making duoblock the right 5-axis solution for every application DMU 60 P duoblock DMU 80 P duoblock DMU 100 P duoblock DMU 125 P duoblock DMU 160 P duoblock ø 43.3 ø 49.2 ø 60.2 ø 35.4 ø ,543.2 lbs. 3,086.5 lbs. 4,850.2 lbs. 5,511.6 lbs. 8,818.5 lbs Traverse paths (X / Y / Z): 23.6 / 27.6 / 23.6 in. Traverse paths (X / Y / Z): 31.5 / 31.5 / 31.5 in. Traverse paths (X / Y / Z): 39.4 / 49.2 / 39.4 in. Traverse paths (X / Y / Z): 49.2 / 49.2 / 39.4 in. Traverse paths (X / Y / Z): 63.0 / 49.2 / 43.3 in. Industry-specific application packages Together with our system partner, Walter AG, we offer our customers tailored application packages for various industries and uses, such as the aerospace package for titanium machining: dmg aerospace titanium package walter titanium package 5X torquemaster B-axis with a drive High performance tools for titanium machining for up to ft. / lbs. of torque HSK-A100 tool holder When you purchase a DMU P Series machine, you receive a High-pressure cooling unit with a 1,160 psi. Walter tool package of your choice valued at $19,500* internal coolant supply * Currency exchange rate is 1.3 (USD:EURO) Coolant temperature control duoblock series highlights Patented duoblock design Highest rigidity Highest lasting precision with thermo symmetric basic construction Highest dynamics with low moving masses Best accessibility and ergonomics Fast tool magazine with up to 480 pockets The widest spindle range, up to 30,000 rpm., ft. / lbs. or hp. CAT50 / HSK-A100 starting with the DMU 80 P duoblock 3-point support Mechanical engineering Bakery machine (Toast oven) from Werner & Pfleiderer Industrielle Backtechnik GmbH

20 20 21 MILLING TECHNOLOGY DMU // CNC UNIVERSAL MILLING MACHINES Load weight: Up to lbs Work area with a swivel rotary table and a tool magazine 02 Swivel rotary table dmu 50 / 70 entry into five-axis simultaneous milling Now also with an 18,000 rpm. spindle and a simultaneous swivel rotary table The DMU 50 / 70 Universal Milling Machines opens a new era in shop floor training, labor, as well as tool, fixture and mold making. The advanced high-tech equipment with numerous options ensures ideal and inexpensive entry into the world of 5-axis machining. dmu 50 / 70 highlights New options for more performance: Performance-enhanced NC swivel rotary table for 5-axis simultaneous machining, high rigidity through a large bearing diameter in the B and C-axis, and a load weight up to lbs. Powerful 18,000 rpm. motor spindle with 95.9 ft. / lbs. and 46.9 hp. 60 pocket tool magazine with a double gripper Automation solutions available DMG ERGOline Control with 19" screen and 3D-simulation on the Siemens 840D solutionline, Heidenhain itnc 530 or MillPlus it technical data DMU 50: Axis X / Y / Z: 19.7 / 17.7 / 15.7 in., Main drive (40 / 100% DC): 17.4 / 12.1 (25.5 / 18.8)* hp., Max. rotational speeds: 10,000 (14,000 / 18,000)* rpm., Rapid traverse X / Y / Z: 78.7 ft. / min., Magazine pockets: 16 (30 / 60)*, Fixed table: 27.6 x 19.7 in., Swivel rotaty table: ø 24.8 x 19.7 in., DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline, Heidenhain itnc 530 or Heidenhain MillPlus it V600 * Optional Castrol and the Castrol logo are trademarks of Castrol Ltd, used under licence. Castrol Industrial Solutions to increase productivity and reduce costs Castrol s expertise is in understanding machining and production processes due to close cooperation with machine tool manufacturers, such as DMG and MORI SEIKI customers. In our development centers we design and test products using the latest materials, technology and manufacturing processes. This results in industry leading products setting the standard in metal cutting and lubrication applications. Please contact your local Castrol expert for advice and support in optimizing your metal working process, and work towards improving your business profitability. Castrol Industrial North America Inc., 150 West Warrenville Road; 605-3W, Naperville IL T: (877) , F: (877) ,

21 MILLING TECHNOLOGY DMC V // VERTICAL MACHINING CENTERS Good accessibility to the work area 02 Automation with PH pallet handling dmc 635 / 835 / 1035 v The highest productivity at the best price Pallet changer and automation for the DMC V Series Tested thousands of times, the proven machine design of the DMC V Series will intrigue you with the highest quality at an unbeatable price. It has modern high-tech features in the standard version, such as a 10,000 rpm. motor spindle, a 20-pocket tool magazine with a double gripper, high rapid traverse speeds and high-tech controls. dmc v series highlights Pallet changer for the DMC 635 V (Pallet size in.) 10,000 rpm. motor spindle in the standard version or a 14,000 rpm. / 18,000 rpm. motor spindle (Optional) Magazine for 20 tools with a fast double gripper in the standard version and up to 60 tools in connection with the pallet changer Reduced downtimes with 98.4 ft. / min. rapid traverse and short chip-to-chip times with a 1.6 second tool exchange time DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline, Heidenhain itnc 530 or Fanuc 32i dmg automation PH pallet handling With eight pallet pockets. Also available for the DMU, DMU monoblock and DMU evolution Blechtechnik Schwäbisch Hall GmbH Expertise and know-how from Germany System supplier for every customer request Component and workpiece manufacturing Chip conveyors Coolant devices for machine tools Complete sheet metal manufacturing Steel engineering with mechanical machining Welding, varnishing, powder coating Assembly, electronics, shipping packages Proprietary production facility in the Czech Republic Blechtechnik Schwäbisch Hall GmbH, Im Buchhorn 17, Michelfeld, Germany T: +49 (0) 791 / , F: +49 (0) 791 / , info@blechtechnik-sha.de,

22 22 23 MILLING TECHNOLOGY HSC // HIGH-SPEED CUTTING PRECISION CENTERS hsc 20 / 55 / 75 / 105 linear Highly dynamic 5-axis HSC Precision Machines in a class of their own hsc series highlights Thermo symmetric gantry design for absolute long-term stability 5-axis Precision Centers with an integrated swivel / rotary axis Linear technology in X / Y / Z with > 2 g; water-cooled torque motors in the rotary axes HSC high performance spindles with a max. of 42,000 rpm. Integration of ULTRASONIC Technology* Application-specific automation solutions DMG ERGOline Control available with the Siemens 840D solutionline or Heidenhain itnc 530 * Optional superiority with linear motors Higher precision, productivity and dynamics Longest availability wear-free drive, no maintenance 36 month warranty on linear motor components Aluminium impeller (2618A) ø 1.6 in. 0.7 in., processed on the HSC 20 linear in 79 seconds technical data HSC 55 linear: Travels X / Y / Z: 17.7 / 22.8 (23.6)** / 15.7 in., Main drive (40 / 100% DC): 38.9 / 29.5 hp., Max. spindle speed: 28,000 rpm.***, Rapid traverse X / Y / Z: ft. / min., Number of tools in the magazine: 16 (30 / 60 / 120)* Table dimensions: 18.1 x 23.6 (15.7 x 15.7) in.**, Workpiece wieght: 1,322.8 (440.9) lbs. * Optional ** 5-axis version *** Optional: 18,000 / 42,000 rpm.

23 hsc center of excellence in Geretsried, Germany Opening in November 2010 The sizes of the HSC linear Series at a glance Work area max. X / Y / Z: HSC 20 linear: 7.9 / 7.9 / 11.0 in. HSC 55 linear: 17.7 / 22.0 / 15.7 in. HSC 75 linear: 29.5 / 23.6 / 22.0 in. HSC 105 linear: 41.3 / 31.5 / 22.0 in. Medical Mold making Precision mechanics Electrodes Impeller Automotive Stamping tools Aerospace Tool rotation flexible integration of ultrasonic ULTRASONIC oscillation ULTRASONIC for the hard machining of advanced materials (Hard metal, ceramics, glass, corundum, compounds, GFK / CFK compounds, polymer concrete, expanded materials) Flexible integration of ULTRASONIC in all machines of the HSC product lines allows 5-axis ULTRASONIC & High-Speed Cutting on one machine ULTRASONIC HSK 32 / 63 / 100 Actor system ULTRASONIC secures a reduction of the active process energy, and allows the best possible surface qualities with Ra < in. ø 1.6 / 2.0 in. impeller in 79 seconds Impeller machining on the HSC 20 linear in 79 seconds (Aluminum impeller ø in.) Producibility of ø 1.6 / 2.0 / 2.4 in. Impellers on a machine Compact automation solutions with a linear magazine or with a special robot handling system Tested and qualified clamping system Know-how of the holistic process chain: From the design to the finished impeller

24 24 25 PERFORMANCE PARTNERSHIP NTN Precision Bearings Super precision, ultra high speed and highest load capacity NEW NEW The NTN super precision bearings of the ULTAGE series have been well known in the world of machine tools for many years. Unique solutions like the low-energy consumption technology ( HSL bearings) perform in various machine tool developments throughout the world. For ultra high-speed applications NTN offers innovative solutions. MQCJ for d m x n up to 5.0 x 10 6 with oil-jet lubrication MQGS for d m x n up to 1.9 x 10 6 with grease lubrication The latest member to the ULTAGE family is the ball screw support unit BSTU series, providing a long life with highest load capacity on a low friction level. 01 NTN ULTAGE series 02 MQCJ bearing 03 ULTAGE ball screw support unit BSTU (new) 04 BSTU application model NTN Bearing Corporation of America 1600 E. Bishop Court, P. O. Box 7604, Mount Prospect, IL , U.S.A. T: , F: , mkt@ntnamerica.com, Pragati // A partner for machine tool manufacturers worldwide Pragati is a leading manufacturer of tool turrets and automatic tool changers with a global customer base. Over 28,000 turret heads and 7,500 automatic tool changers currently in operation attest to the quality, reliability and the competitive prices of our products. Turret heads and automatic tool changers are available in various sizes, meeting the demands of every machine tool manufacturer. Tool turret Tool turrets: Fast indexing High repositioning accuracy Electromechanical operation Simple control Available in six sizes Automatic tool changers: Available for vertical machining centers with tapers 30, 40 and 50 Magazine capacities for 20, 24 and 30 tools Short tool-exchange times Modular design for easy maintenance Automatic tool changers Pragati Automation Pvt. Ltd., 19&20, 12 th Cross, 4 th Phase, Peenya Industrial Area, Bangalore , India T: , F: , info@pragati-automation.com, Grundfos The global partner for process and energy-optimized pump systems in cooling lubricant supply Because of their compact design, Grundfos machine tool pumps can easily be integrated into the cooling lubricant holder with various immersion depths, while saving space. The modular design allows over 100,000 individually configurable options. What is important for the optimal application of a pump in the cooling lubricant supply is good adaptability to every machining cycle. Grundfos pumps, with integrated or external frequency converters, are equipped with all important functions for standard applications, and can be flexibly adapted to every requirement. This serves to significantly improve the effectiveness of the pump and the cooling lubricant supply. Grundfos Pumps Corporation, W. 118th Terrace, Olathe, KS T: (913) , F: (913) ,

25 MILLING TECHNOLOGY DMU monoblock // CNC UNIVERSAL MILLING MACHINES dmu 40 / 60 / 80 / 100 monoblock 5-axis Complete Machine packages for all your needs. Attractive 5-axis complete package with an NC rotary table, NC swivel milling head (B-axis), 3D quickset, caliper, electronic hand wheel, rinsing pistol and three days of startup by DMG / MORI SEIKI. machine type dmu 40 monoblock dmu 60 monoblock dmu 80 monoblock dmu 100 monoblock 5-axis complete Maximum workpiece dimension: Workpiece weight: Footprint / Height: * 3-axial 30 / lbs ,102.3 lbs ,433 lbs ,763.7 lbs lbs. 1,102.3 lbs. / 1,543.2 lbs.* 1,433.0 lbs. / 1,984.2 lbs.* 1,763.7 lbs. / 2,425.1 lbs.* 45.2 ft.² / 85 in ft.² / 89.4 in ft.² / 97.2 in ft.² / in. As a market leader for components in the machine tool sector, Bürener Maschinenfabrik GmbH (bmf) focuses on lasting customer relationships, as well as medium and long-term growth. Highlights of our product range: Chip conveyors: All-round devices for chip disposal Cooling units: Cleaning systems for coolant / lubrication treatment Chip breakers: Power package for chip breakup and disposal Maximal 5-axis performance Machining of a chassis support with 150 B-axis and integrated NC rotary table Bürener Maschinenfabrik GmbH // Technology with new ideas for state-of-the-art machine tools Our products are based on consistent standardization, but they are also available in individualized versions (with a number of variations), in a modular design (in various sizes), and with flexible options (in various designs). Bürener Maschinenfabrik GmbH, Fürstenberger Straße 37, Büren, Germany T: +49 (0) / , F: +49 (0) / , info@bmf.de,

26 26 27 MILLING TECHNOLOGY DMF // TRAVELING COLUMN MACHINES ± axis machining with a swivel milling head and integrated NC rotary table 02 Large work area for multiple clamping (optional twin-table machining with a work area partition wall) top options with more value Swivel milling head as a controlled B-axis for all spindle speeds powerful chip removal with a 8,000, 14,000 or 18,000 rpm. motor spindle (CAT40), 10,000 rpm. motor spindle (CAT50) for large series Integrated NC rotary table Standard tool magazine equipped with 30 pockets but also 60 and 120 pockets available. Effective twin-table machining with work area partition wall Dynamics package with linear drive in the X-axis superiority with linear motor technology Higher precision, higher productivity and dynamics Longest availability wear-free drive, no maintenance 36 month warranty on linear motor components Size of the DMF Series at a glance Max. work area X / Y / Z in.: Z 35.4 in. DMF DMF 360 DMF in. DMF 180 DMF in in in in. X 27.6 in in. Y DMF 180: 70.9 / 27.6 / 27.6 in., DMF 260 7: / 27.6 / 27.6 in., DMF : / 43.3 / 35.4 in., DMF 360: / 43.3 / 35.4, DMF 500: / 43.3 / 35.4 in. dmf 180 / highlights Standard version with ball screws, dynamic options with a linear drive in the X-axis High rigidity and precision with thermo symmetric traveling columns 8,000 rpm. motor spindle in the standard version, 14,000 / 18,000 rpm. (Optional) Short chip-to-chip times with a glide-along tool magazine 5-axis simultaneous machining with a B-axis and integrated NC table additionally with the dmf / 360 / 500 Even larger work area with 43.3 in. in Y and 35.4 in. in Z Powerful motor spindle with 10,000 rpm. and CAT50 / HSK-A100 (Optional)

27 dmg autoshutdown Save up to 60% in energy costs! ENERGY SAVING Configure the shutdown of your machines according to your individual needs with DMG AUTOshutdown, and verifiably save up to 60% on energy consumption during idle times. your benefits DMG AUTOshutdown switches your machines to an energy efficient status. Configure the shutdown of your machines according to your needs! As an add-on to a conventional shut-down process, DMG AUTOshutdown offers fixed wake up and start-up processes. Tests have proven that a savings of $ 3,900 per year are possible (Production: Five days / weeks two shifts / day, one hour for startup). DMG AUTOshutdown: Now standard in DMG machines! dmf series Flexible power milling with an X-traverse path up to in. Depending on your requirement, the DMF Series can be upgraded and retrofitted for the most diverse assignments. This applies to 3-axis milling, all the way to 5-axis simultaneous machining and serial production, with two separated work areas. The dynamic options with a linear drive in the X-axis offer faster rapid traverses and shorter chip-to-chip times. technical data DMF 260: Travels X / Y / Z: / 43.3 / 35.4 in., Main drive (25 / 100% DC): 31.5 / 18.1 hp., Max. spindle speed: 8,000 rpm.**, Rapid traverse X / Y / Z: (262.5 / / 196.9) ft. / min.***, Tools in the magazine: 30 (60 / 120)*, Table dimensions: x 43.3 in., DMG ERGOline Control with 19" screen and 3D-software: Siemens 840D solutionline or Heidenhain itnc 530 * Optional ** Optional: 10,000/14,000/18,000 rpm. *** With linear technology

28 28 29 ECOLINE SERIES NC swivel rotary table with digital drives ShopMill software for the easiest Programming with 3D-simulation NEW // DMU 50 eco Entry into 5-axis machining dmu 50 eco highlights Highest efficiency 5-axis machining of easy to highly-complex workpieces Highest precision NC swivel rotary table with digital drives Milling spindle (8,000 rpm. / 61.2 ft. / lbs. [40% DC] / 17.4 hp. [40% DC]) Tool changer with 16 pockets in the pick-up magazine Direct position measuring system (optional) and a centrally-lubricated roller return guide for high, lasting precision ctx 310 eco ctx 510 eco dmc 55 h eco CNC Universal Lathe Swing diameter over bed: 13.0 in., Max. turning diameter: 7.9 in., Longitudinal travel (Z): 17.7 in., Max. rotational speed: 5,000 rpm., Torque (40 / 100% DC): / 82.6 ft. / lbs., CNC control: SIEMENS 810D powerline with ShopTurn or MORI SEIKI MAPPS IV CNC Universal Lathe Swing diameter over bed: 26.8 in., Max. turning diameter: 18.3 in., Longitudinal travel (Z): 41.3 in., Max. rotational speed: 3,250 rpm., Torque (40 / 100% DC): / ft. / lbs., CNC control: SIEMENS 810D powerline with ShopTurn or MORI SEIKI MAPPS IV Horizontal Machining Center Work area X / Y / Z: 22.0 / 23.6 / 23.6 in., Max. rotational speed: 12,000 rpm., Torque (40 / 100% DC): 81.1 / 62.0 ft. / lbs., Pallet size: 15.7 / 15.7 in., max. table load (assembled weight): 1,102.3 lbs., CNC control: SIEMENS 810D powerline * Available only for Vertical Machining Centers

29 Fast and easy assembly of the tool-plate magazine (16 pockets) UNO 115 eco Time for a new approach Robust device with low space requirements Single-handed operation with continuous fine tuning in the X and Z-axis Pneumatic axis clamping in both axes Edge-Finder for fast focusing of the tool edge CMOS digital camera with a telecentric lens Easy handling with intelligent image processing the new dmg slimline Panel The latest control technology in an ergonomic design Comprehensive tool management NEW // NEW // MORI SEIKI HEIDENHAIN* MAPPS IV TNC 620 with interactive programming highlights highlights 10.4" screen Shop-floor oriented programmability with visual support and User interfaces for USB and Memory Cards several practice-oriented cycles Efficient programmer system External program creation with dynamic 3D-workpiece and the shortest transfer times, simulation even with large programs via Fast program creation Fast-Ethernet interfaces with high cycle supply and 15" TFT-screen for optimal programming help user comfort Versatile contour path and Measuring cycles for the pattern programming adjustment of workpieces Powerful tool and technology and contact management Visual simulation of the workpiece processing Free contour programming DMG SMARTkey Efficient manufacturing with dmc 635 v eco dmc 1035 v eco dmu 50 eco Vertical Machining Center Vertical Machining Center CNC Universal Milling Machine Travels X / Y / Z: 25.0 / 20.1 / 18.1 in., Max. rotational speed : 8,000 rpm., Torque (40 / 100% DC): 61.2 / 42.0 ft. / lbs., CNC control: SIEMENS 810D powerline with ShopMill, Heidenhain TNC 620 with interactive programming or MORI SEIKI MAPPS IV Travels X / Y / Z: 40.7 / 22.0 / 20.1 in., Max. rotational speed: 8,000 rpm., Torque (40 / 100% DC): 61.2 / 42.0 ft. / lbs., CNC control: SIEMENS 810D powerline with ShopMill, Heidenhain TNC 620 with interactive programming or MORI SEIKI MAPPS IV Travels X / Y / Z: 19.7 / 17.7 / 15.7, Max. rotational speed: 8,000 rpm., Torque (40 / 100% DC): 61.2 / 42.0 ft. / lbs., CNC control: SIEMENS 810D powerline with ShopMill

30 DE M O-M ACHINES DMG SERVICES dmg service 2010 Life Cycle Service for maximum productivity The worldwide DMG / MORI SEIKI service network offers you comprehensive services and service products that are perfectly aligned with your DMG machines and requirements. Increase lasting performance and safety in your production with DMG original products. Whether you need support from a DMG / MORI SEIKI service technician on-site, or want to optimize your production with DMG service products we are always close by. Over 300 machines available immediately! at DMG Spare Parts 95% spare parts availability Available now! Customized for DMG turning and milling machines. DMG Used Machines CERTIFIED PRE-O W NED M ACHINES younger than 5 years DMG Inspection + CERTIFIED PRE-O W NED M ACHINES older than 5 years DEMO-MACHINES dmg spare parts Wear parts in a set You save up to 30%. Only the regular replacement of wear parts secures the performance and precision of your DMG machine. In our modern logistics center, more than 36,000 different DMG and MORI SEIKI spare parts are available for fast and reliable delivery, even for older machine series. Our DMG Maintenance Kits, specially assembled by our experts, contain important wear parts such as scrapers, filters and gear belts, in their original quality and guarantee the safety of your production. your benefits Important wear parts in one set Perfectly-adjusted to each machine type Assembled by DMG experts according to your needs DMG Training DMG EnergySave DMG original high quality spare parts Protection from expensive, consequential damages

31 Information on DMG Service Products are available online at: dmg inspection+ DMG Microset DMG Netservice DMG Automation Additional information is available on page 7 Additional information is available on page 7, 9 and 21 Intelligent foresight for the reduction of downtimes With DMG inspection+ you get the best preventative maintenance for your DMG Machine. Secure an agreement for your safety with our service! Each year, our experts thoroughly test your machines and you immediately receive a checklist from our technicians with a detailed analysis. Based on that, we can jointly arrange a suitable set of actions for the optimization of your machines. The agreement for DMG Inspection+ lasts 3 years. We will test the following for you: Safety functions and equipment, main spindle, scrapers in the work area, hydraulic devices, lubrication, cooling lubricant devices, cooling units, control cabinet ventilation and cooling, functional components and software version dmg training plus Fit for recovery Utilize current excess capacities for the lasting qualification of your employees, and utilize the full potential of your machines while increasing employee motivation at the same time. We will develop a customized training program based on an extensive needs assessment on-site at your location. With the implementation of our program, the costs for the needs assessment and training program will be reduced! Our complete training program is available online at: dmg netservice Now standard in DMG machines! A green light for your machine! With DMG Netservice, you have direct access to DMG Service know-how. At the press of a button, DMG specialists analyze your problems as if they were on-site at your facility! This is how you reduce your service costs and simultaneously increase machine availability. your benefits Prompt analysis and technical support VPN access with the highest data protection Considerable increase of machine availability Faster and more bidirectional data exchange Reduced service, personnel and travel costs Optional connection via broadband connection Applies to new orders starting April 1, 2010; technical specification guarantee dmg energysave Up to 75% energy savings. A small device with a great impact. With DMG EnergySave the new retrofit package for your machine ENERGY SAVING tool you will benefit from energy savings of up to 75%. The innovative hardware module switches the machine to an automatic neutral position during idle times, and brings it to the familiar emergency shut-off position, thereby considerably reducing power consumption. Easiest handling, minimal investment, a maximum impact on savings dmg energysave highlights Reduction of power consumption by up to 75% Up to 10 different closed-current switching periods By keeping the familiar emergency shut-off mechanism, easy restart is guaranteed Short amortization time Fast installation in the machine control cabinet Can be used with machines from other manufacturers

32 32 33 DMG SERVICES // DMG VIRTUAL MACHINE // SIEMENS NX CAD / CAM DMG Virtual Machine The real 1:1 illustration of your DMG machine on a PC highlights // efficiency Efficient production start-up through optimal preparation Increase your efficiency with maximum production safety and a reduction of setup times Real job-time calculation with the integration of the PLC by up to 80%! Total availability of all cycles and NC functions highlights // safety Highest process safety through collision and work area inspection The DMG Virtual Machine integrates geometry, kinematics and dynamics of real DMG machines, such as all functionalities of the Authentic machine model with the accurate work area representation NC and PLC. With DMG Virtual Machine you can plan and verify Comprehensive control of all program all procedures and processes within your production. Whether and production processes in advance your NC program is available from a CAM program or is created highlights // speed directly on the CNC control, you will know in advance how your Up to an 80% reduction of setup and assembly time processes will later run on the shop floor. Fast knowledge-acquisition of DMG machines and controls 1:1 Shop floor programming igus E-Tube RX A new milestone in chip protection for machine tools 4 x tighter: New plastic E-Tube design, completely free of edges, gaps and awkward contours. Oval shape repels chips. Covered connecting elements and tight tube links keep chips out. Easy opening... large usable cross section... cable friendly interior separation... special solutions available (i.e. high temperature up to +850 C). 03 Alround chip protection for your machine tool. 01 four times tighter than other time-proven E-Tubes 02 snap-open on outer radius 03 comes as fully harnessed ReadyChain in 2-10 days igus 50 N. Broadway P.O. Box East Providence, RI T: , F: , webmaster@igus.com,

33 dmg virtual machine and siemens nx cad / cam Highest process safety With cad / cam programming and DMG Virtual Machine Build, program, simulate and manufacture everything from one source. In order to meet market demands for processing complex workpieces on time and in time frames that are always becoming shorter, an efficient and smooth-functioning process chain is necessary. DMG and Siemens have met these challenges and, with their DMG Virtual Machine and NX CAD / CAM software products, deliver a globally-unique solution. A complete process chain! The NC program is exported through defined interfaces via the post processor, just like all operating resources. The import into the DMG Virtual Machine provides insight into possible adaptations after that, it goes directly and safely to production on the DMG machine siemens nx cam / dmg virtual machine highlights Highest process safety thanks to DMG and Siemens CAM system with the latest technology in turning and milling Perfectly-synchronized post processor Export of all production-relevant data from NX CAM into the DMG Virtual Machine Exact machine simulation through the integration of the original PLC and NC Maximum efficiency of your DMG machine through the reduction of setup and assembly time Elektroanlagen GmbH Klaus Weiss Complex solutions for individual needs With a spirit of innovation and dedication, Elektroanlagen GmbH Klaus Weiss has emerged as a leading supplier of cable assembly and control cabinet construction over the past 18 years and has, to this date, produced industry controls for the most diverse applications on over 64,583.4 square ft. at three locations in Ruhla and Seebach. From development to on-time delivery Comprehensive planning, highly qualified technicians and engineers lay the foundation for the efficient production of installations. With efficient quality management and zerodefect tolerance, at Elektroanlagen GmbH Klaus Weiss everything is linked correctly. Multiple-time winner of the GILDEMEISTER Award. Elektroanlagen GmbH Klaus Weiss in high demand! 01 Headquarters in Ruhla 02 DMG CTV Series 03 DMG DMU Series & 2006 Award for Supplier Performance 2007 Award for Innovation Elektroanlagen GmbH Klaus Weiss, Ruhla, Germany T: +49 (0) / , info@elektroanlagen-weiss.de, from the concept to the finished workpiece Concept cad / cam programming Simulation Production 1 From the concept to the drawing 2 With Siemens NX CAM 3 With DMG Virtual Machine 4 With DMG Machine

34 34 35 ULTRASONIC / LASERTEC Maximum tool rotation rpm. ULTRASONIC produces a significant reduction of process power and, with that, allows excellent surface qualities of Ra < in., longer tool durability and minimized micro fissures in the material. ultrasonic premium applications ULTRASONIC oscillation khz ULTRASONIC // Advanced Materials ultrasonic Flexible ULTRASONIC integration in all 5-axis Milling Centers* from DMG Through the overlapping of the tool rotation and the additional oscillating movement kinematics that are based on the special HSK 25 / 32 / 40 / 63 / 100 actor system, hard-brittle and hard-to-cut materials such as ceramics, glass, hard metal, corundum, compounds or expanded materials can be machined problem-free with reduced process power. Component: Mirror mount made from zerodur Industry: Optics industry, Aerospace technology Machines: ULTRASONIC P / U / FD duoblock Receiver: HSK 63 / 100 Component: Paddle wheels made from polymer concrete Industry: Pump industry, equipment manufacturing Machines: ULTRASONIC P / U / FD duoblock Receiver: HSK 63 / 100 Component: Dental prosthesis made from hipped zirconium oxide Industry: Dental industry Machines: ULTRASONIC 10 / 20 linear Receiver: HSK 25 / 32 Component: Compressor mold made from hard metal Industry: Tool and mold making, tool manufacturer Machines: ULTRASONIC 20 linear Receiver: HSK 32 / 40 Component: Wear parts made from ceramics Industry: Textile, pump industry Machines: ULTRASONIC 20 linear Receiver: HSK 32 / 40 * All ULTRASONIC Machines come exclusively with the Siemens 840D solutionline; the following actor options are available according to machine type: ULTRASONIC HSK 25 / 32 / 40 / 63 / 100 actor system lasertec PrecisionTool 50% time savings with the machining of cutting edges and clearance angles in pkd / cvd / cbn lasertec 20 PrecisionTool highlights 5-axis machining of ø 0.1 in. Complete radius CVD cutter in 6.5 min in. Cutting edge honing (no disruption) 50% time savings compared to eroding methods Finish machining of cutting edges and end mills on one machine Size and shape accuracy in the µm range Easy programming with parameterized entry Siemens 840D solutionline with special software features axis machining of a ø 0.1 in. Complete-radius CVD cutter in 6.5 minutes 02 Parameterized programming for inserts and end mills 02

35 range of applications lasertec 20 PrecisionTool lasertec 40 PrecisionTool lasertec 50 PrecisionTool Clearance angle and cutting-edge machining for PCD / CVD inserts Clearance angle and cutting-edge machining for PCD / CVD end mills / Reamers Step chip guides in PCD / CBN inserts Prototype machining of cutting inserts made from hard metal Cutting-out of inserts made from PCD / CBN (3-axis) Cutting-out of inserts made of PCD / CBN (5-axis) axis laser structuring of a PET bottle mold lasertec 50 Shape Easy and intuitive Surface texturing for tool and mold making lasertec 50 Shape highlights 5-axis laser texturing of surfaces in molding tools Special 3D-software for the automatic generation of the surface structure from the stl data record or Bitmap Linear drives in X, Y with > 1 g; Torque motors in the rotary axes High size accuracy better than in., laser source: fiber (50 / 100 W) Automatic "Patch" function for seamless, large-surface structures technical data LASERTEC 50 Shape: X / Y / Z: 19.7 / 19.7 / 27.6 in., Number of axes: 5, Laser power: 50 / 100 W (Fiber); DMG ERGOline Control; LASERSOFT 3D LASERSOFT axis machining on the LASERTEC 50 Shape 03 LASERSOFT 3D for surface structuring

36 MONTFORT ADVERTISING D Touch Probes from HEIDENHAIN stand for fast, time-saving workpiece alignment and tool measurement 02 TNC 620 on DMG SlimLinePanel 03 itnc 530 this HEIDENHAIN control increases the productivity of milling machines and machining centers 04 Linear and Angle Encoders from HEIDENHAIN make it possible: accuracy from the first part Manufacturing More Efficiently with HEIDENHAIN HEIDENHAIN controls are universal and yet simple to operate. Their rapid and accurate path control ensures high-quality surfaces and very short machining times, even for complex workpieces. Optimize safety with CollisionMonitoring The itnc 530 with CollisionMonitoring can detect crash situations. A new feature: now the fixtures can be entered and graphically displayed. For milling machines and machining centers: itnc 530 TNC 620 MillPlus it Optimize the machining time with AFC Adaptive feed control (AFC) automatically regulates the feed rate of the itnc 530, taking into consideration the respective spindle power and further process data. For lathes and lathe centers: HEIDENHAIN Plus it Optimize non-productive times HEIDENHAIN 3-D touch probes can do more than enable you to align and measure your workpieces quickly and exactly. You can also measure between working steps. And you can measure tools. Functional readiness is indicated on the new 3-D touch probes by a blinking LED. HEIDENHAIN CORPORATION 333 East State Parkway, Schaumburg, IL T: (847) , F: (847) , info@heidenhain.com, Gondrand Atege GmbH m-solutions. The logistics solution for the engineering sector. With the m-solutions product, we offer our customers in the machine construction industry customized, innovative supply chain management concepts. As a delivery partner, we ensure that your production parts are delivered just in time and that your completed machines are professionally packaged, globally-transported and installed at the end customer site. ATEGE GmbH, Carl-Benz-Straße 11, Frankfurt, Germany T: +49 (0) , m-solutions@atege.de, DMG / MORI SEIKI BOSTON: 753 Forest St., Ste. 200, Marlborough, MA 01752, USA, Phone: (508) , Fax: (508) DMG / MORI SEIKI CHARLOTTE: 4345 Morris Park Dr., Charlotte, NC 28227, USA, Phone: (704) , Fax: (704) DMG / MORI SEIKI CHICAGO: 2400 Huntington Blvd., Hoffman Estates, IL 60192, USA, Phone: (847) , Fax: (847) DMG / MORI SEIKI CINCINNATI: 9466 Meridian Way, West Chester, OH 45069, USA, Phone: (513) , Fax: (513) DMG / MORI SEIKI DALLAS: 9001 Currency St., Irving, TX 75063, USA, Phone: (972) , Fax: (972) DMG / MORI SEIKI DETROIT: Cabot Dr., Novi, MI 48377, USA, Phone: (248) , Fax: (248) DMG / MORI SEIKI HOUSTON: 1251 Lumpkin Rd., Houston, TX 77043, USA, Phone: (713) , Fax: (713) DMG / MORI SEIKI LOS ANGELES: 5740 Warland Dr., Cypress, CA 90630, USA, Phone: (562) , Fax: (562) DMG / MORI SEIKI SAN FRANCISCO: th St. Ste. C, Berkeley, CA 94710, USA, Phone: (866) , Fax: (510) DMG / MORI SEIKI SEATTLE: nd Ave. South, Ste. A109, Kent, WA 98032, USA, Phone: (253) , Fax: (253) info@dmgmoriseiki.com, Imprint: Journal DECKEL MAHO: Journal for customers and interested parties. Responsible for the content: DMG Vertriebs and Service GmbH. Design, layout, organization, and photos by: Montfort Advertising America Inc., Chicago, Illinois. Circulation: 600,000 pcs. Products subject to discontinuation without notice. Products subject to availability. The machines depicted here may include some options, equipment and CNC alternatives available at an additional charge. 32