journal World première: DMC 850 V and a new design nº rd generation DMC V range for high performance vertical machining

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1 Magazine for DMG MORI customers and interested parties CELOS from DMG MORI from the idea to the finished product. 24 world premières in 2014, 8 of which featured at the open house exhibition at DECKEL MAHO in Pfronten. DMG MORI Systems Automation solutions for maximised productivity. journal nº World première: DMC 850 V and dmc 1150 v with celos and a new design 3 rd generation DMC V range for high performance vertical machining

2 2 intro world premières technologies ecoline systems lifecycle services 24 world premières in 2014, 9 of which are in the first six months. 24 world premières in 2014 attest to the status of DMG MORI as the global leader in machine tool innovation. We will present nine of those world premières in the first half of We will present 15 additional world premières, 9 of which are from MORI SEIKI, at the grand opening in Tokyo in July and at the trade fairs IMTS, AMB and JIMTOF in autumn. CELOS from DMG MORI and the new DMG MORI design are raising the bar for our customers. Take advantage of innovative technological solutions and the top class quality of our machines and services. See page 4 for more about first quality 9 world premières in the first half of 2014 from dmg mori _ CTX beta 800 TC Turn-mill complete machining _ SPRINT 20 5 linear Automated turning on a set up area of just 1.92 m 2 _ DMC 850 V and DMC 1150 V 3 rd generation for high performance vertical machining _ DMC 80 H duoblock 4 th generation Horizontal machining with 30 % more precision, efficiency and performance _ DMC 80 FD duoblock 4 th generation 5-axis milling and turning _ DMU 270 P 5-axis machining up to 12 tonnes _ DMU 70 ecoline 5-sided machining with 3D control technology _ LASERTEC 65 additive manufacturing Laser additive manufacturing with integrated final milling machining See page 5 onwards for more on the world premières Journal All trend setting developments and highlights from DMG MORI in 6 topic sections: NLX2500SY (white version) pages 2 4 Intro Innovation offensive First quality for our machines and services. pages 5 18 World premières and innovations CELOS From the idea to the finished product. An overview of 9 world premières. pages Technologies and success stories New technologies, ranging from universal turning to 5-axis simultaneous machining of advanced materials.

3 Journal n CELOS From the idea to the finished product. One Brand for the World. A globally leading partnership. One name since October On 01 October 2013, GILDEMEISTER AKtien- GESELLSCHAFT became DMG MORI SEIKI AKtien- GESELLSCHAFT. MORI SEIKI CO., LTD. became DMG MORI SEIKI CO., LTD. The new common branding for all sales and service companies worldwide DMG MORI. from dmg mori Order the new journal collection box now by journal@dmgmori.com The new DMG MORI design Multi functional, user friendly and value retaining available in either black or white at no extra cost. DMC 850 V (black version) All trends and innovations in If your mobile phone has a QR code reader, you can go straight to the homepage. pages ecoline pages dmg mori systems pages LifeCycle Services World première of the DMU 70 ecoline. The full ECOLINE range with integrated 3D control technology. Perfect automation of processes. Four automated segments. References: ZF, Willi Elbe Group, Tsuzuki Manufacturing Co., Ltd. Focusing on maximising productivity.

4 4 intro world premières technologies ecoline systems lifecycle services DMC V range: Ball screw nut and linear guide cooling for maximum workpiece precision. New design: Long life surfaces with fine structure paint for higher scratch resistance and protection against damage. First quality for our machines and services. Our machines and services are synonymous with innovative technological solutions and top-class quality. Our quality is a major factor in the market success of DMG MORI. Our high quality requirements are enforced everywhere by means of a trendsetting quality management system: First quality. First quality is a process determining factor, from the creation of the product to the use of the machine. First quality forms the basis of a continuous company-wide improvement process. By transparently documenting the processes and procedures, results can be qualitatively collected, expertly assessed and compared in detail in order to continually optimise the process. The principles of attaining the highest possible quality are brought to life during the development process as part of first quality and they cover all parts of the company, including our comprehensive DMG MORI Life Cycle Services. Last but not least, we implement our high quality requirements in the form of a 5-year guarantee for linear motors. Clear first quality standards are also defined in supplier management before being coordinated with all suppliers and implemented in their companies. Quality standards far exceeding the requirements of ISO 9001 are also in effect in our international production plants. For example, every machine from DMG MORI is quality-tested for over 100 hours before being approved for delivery. Besides our strategic and organisational quality measures, training employees involved in the product creation process chain is a decisive factor for our success. Continuous advanced training and qualification measures are therefore a fixed part of the first quality strategy of DMG MORI. stable value, robust and precise New design with maximised value retention thanks to factory tested long-life surfaces High robustness through the use of bearings with higher load ratings in the milling spindles Integrated machine protection measures, e. g. Machine Protection Control (MPC), designed to automatically switch off the machine in the event of collisions or overloading Higher precision thanks to innovative cooling concepts in all new machines, e. g. NLX, duoblock, DMC V, HSC, etc. OPERATE 4.5 as the new system platform from DMG MORI for all machines with SIEMENS control systems: _ Standard interface with the latest controls for all technologies _ Standardized and field tested automation technologies, from the drives to the CNC control system 9 SINUMERIK Operate The intuitive and standardized operator user interface for all technologies siemens.com / sinumerik Straight forward and featuring numerous new powerful technological functions, the SINUMERIK Operate user interface makes CNC machine operation as simple as never before. By combining machining step and high-language programming under one system interface, NC programming and production planning are quickly and efficiently achieved. Whether turning or milling, operation always has the same look-and-feel. And you are supported in your day-today work using intelligent functions such as animated simulation and screenshots. Answers for industry.

5 Journal n nº CELOS From the idea to the finished product The new DMG MORI machine design A guide to 9 of 24 world premières in 2014, 8 of which are already at the open house exhibition in Pfronten World premières and innovations celos at the grand opening in Bergamo ctx beta 800 tc sprint 20 5 dmc 850 v dmc 1150 v dmc 80 fd duoblock 4 th generation dmc 80 h duoblock 4 th generation Concept study at the open house exhibition in Pfronten and world premières at IMTS / AMB 2014 dmu 270 p lasertec 65 additive manufacturing dmu 70 ecoline

6 6 intro world premières technologies ecoline systems lifecycle services From the idea to the finished product. CELOS is as easy and intuitive to use as a smartphone. CELOS from DMG MORI simplifies and speeds up the process from the idea to the finished product. CELOS APPS facilitate consistent management, documentation and visualisation of order, process and machine data for the user. CELOS is a combination of production plant and higher level corporate structures, and thus it forms the basis for a fully digitised, paper free production process. CELOS is compatible with PPS and ERP systems, it can be networked with CAD / CAM applications and it is compatible with innovative CELOS APP expansions. app menu Central access to all available applications. 21.5" multi-touch screen for quick and easy operation. multi-touchcontrol panel with CELOS and MITSUBISHI, for groundbreaking user comfort with a unique range of functions. smartkey Personalised user authorisation: Individually adapted access privileges to the control system and the machine. With integrated USB storage. standard Uniform user interfaces for all new high tech machines from DMG and MORI. consistent Consistent management, documentation and visualisation of order, process and machine data. compatible Compatible with PPS and ERP systems. Can be networked with CAD / CAM products. Open to trendsetting CELOS APP extensions. CELOS APPs 4 examples» Detailed information and demo versions of all available APPs can be found online: 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. Filter function for sorting orders by date, client, status etc. job assistant Define and process orders. Menu guided set-up of the machine and processing of production orders in the dialogue. Reliable error prevention thanks to work instructions with binding acceptance function. Completed, new and unfinished orders are marked in different colours.

7 Journal n ,5" multi-touchscreen for quick and easy operation e. g. rotating and magnifying the workpiece in JOB MANAGER DOCUMENTS Digital library with full text search. Clear library structure for easy and quick orientation. Digitised storage of all machine related manuals, documentation and customer data. Full text search and bookmark function for repetitive reference areas. CAD-CAM-VIEW Visualise workpieces and optimise program 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. Display as a window in the CELOS user interface or in full screen mode.

8 8 intro world premières technologies ecoline systems lifecycle services The new dmg mori design multifunctional, user friendly and value retaining. from dmg mori multi-touch control panel NLX2500SY (white version) with CELOS and MITSUBISHI, for innovative comfort of use with a unique range of functions. NLX2500SY available from the 2 nd quarter 2014 with CELOS from DMG MORI, 21.5" ERGOline and MITSUBISHI.

9 Journal n The holistic high quality standard of DMG MORI is illustrated by the new joint design. The new design features more functions, increased user friendliness and high value retention. Besides all of the technical features, you can choose between two machine designs. The new DMG MORI design is available in either black or white at no extra cost. improved functionality Maximal view into the working space for better monitoring of the production process. Improved functionality: e. g. the safety glass is removed from the outside. from dmg mori DMC 850 V (black version) retention of value / long life surfaces Premium range in fine structure for higher scratch resistance and protection against damage. user-friendliness CELOS with SIEMENS: ERGOline Control with 21.5" multi-touch monitor. DMC 850 V available now: 19" ERGOline with HEIDENHAIN TNC 640 or Operate 4.5 on SIEMENS 840D solutionline, from the 2 nd quarter 2014: CELOS from DMG MORI with 21.5" ERGOline and SIEMENS.

10 10 intro world premières technologies ecoline systems lifecycle services The stage of innovations an overview of 9 world premières. turning technology CTX beta 800 TC Turn-mill complete machining with the new, ultra-compact turn-mill spindle. The new CTX beta 800 TC from DMG MORI adds to the successful CTX TC range and represents a lower cost entry to turn-mill complete machining for workpieces up to 500 mm in diameter and with a turning length of up to 800 mm. On the one hand, the automatic tool change system with up to 80 tools provides the customer with maximum flexibility during classic turning machining. On the other, the B axis and the new turn-mill spindle allow for turn-mill complete machining and even 5-axis simultaneous machining. To do so, users can take advantage of the 200 mm Y hub. The core element is the Direct Drive B axis with a continuous swivel range of ±110 and the new ultracompact turn-mill spindle. The compact design of the spindle, with an integrated extraction cylinder for the tool clamper, allows for torque of up to 120 Nm from a spindle just 350 mm in length. Compared to a conventional spindle, this represents 170 mm more working area and 20 % more torque. Additionally, you can save considerable tool costs as standard tools can be used to machine bevelled surfaces and holes. Workpieces measuring up to ø 500 mm and with a turning length of 800 mm can be machined on just 8.5 m² thanks to the ultra-compact turn-mill spindle. Exclusive DMG MORI technology cycles to save up to 60 % of your time. CTX beta 800 TC Turning and milling for the price of a universal turning machine highlights of the ctx beta 800 tc _ Ultra-compact turn-mill spindle for minimal space requirements in the working area and 20 % higher torque _ 170 mm more space with the new B axis: Bore through or hollow turn 150 mm long workpieces horizontally Display of approach and retract traverses, switching the transformations on / off. ctx tc: 5-axis simultaneous machining _ Free form surfaces can be machined thanks to 5-axis interpolation on the main and counter spindles _ Turning and milling with interpolating B axis _ The machine features higher precision and electronic and mechanical compensation _ Includes the intelligent movement guidance system Advanced Surface for perfect surfaces, dynamics and precision _ The 5-axis movements can be programmed by the client's CAD / CAM system available from May 2014: CELOS from DMG MORI, Operate 4.5 on SIEMENS 840D solutionline. Maximum turning length: 800 mm, max. workpiece diameter: 500 mm; Y hub: ±100 mm; main spindle ISM 76 rated at 5,000 rpm, 380 Nm, 34 kw; HSK-A63 turn-mill spindle rated at 12,000 rpm, 120 Nm, 22 kw; disc-type tool magazine with 24 slots, optional chain magazine with up to 80 slots

11 Journal n turning technology SPRINT 20 5 from June 2014: Short and plain turning of workpieces measuring up to ø mm with 5 linear axes on a set-up area of under 2 m². Steadies* with a diameter of up to 200 mm and chucks* measuring up to 400 mm can be used (*optional). The new SPRINT 20 5 is built at the fully modernised plant of GILDEMEISTER Italiana in Brembate di Sopra and represents the addition of an entry level machine for machining bars with a diameter of up to 20 mm to the SPRINT range. The SPRINT 20 5, presented at the grand opening in Bergamo ( ) in June, comes with 5 linear axes and a C axis on the main spindle as standard. Overall, the working area can accommodate 23 tools, where 4 slots are equipped for driven tools, arranged on 2 tool carriages. Optionally, 2 of the 4 slots can be equipped for back facing with driven tool stations, including a C axis for the counter spindle. The space requirements of just 1.92 m² are unique in this class of automated turning machine, especially in combination with the large working area for workpieces up to 600 mm in length and up to 23 tools. Z1 Z2 X2 Working area with space for 23 tools on 2 independent linear carriages, including 4 driven tool slots for the main spindle and 2 optional driven tool slots for the counter spindle. Y1 X1 _ Turn-mill spindle rated at 12,000 rpm, 22 kw and 120 Nm, optional high-speed version rated at 20,000 rpm _ Workpieces measuring uo to ø 500 mm and with a turning length of 800 mm on 8.5 m² _ 6-side complete machining with a main spindle rated at up to 770 Nm* and a counter spindle* rated at 6,000 rpm _ Large, transparent working area with good accessibility and a 350 mm working depth to the centre of the spindle _ Eccentric machining thanks to the 200 mm Y hub * Optional SPRINT 20 5 For machining workpieces measuring up to ø mm on a set-up area of under 2 m² An outstanding ratio of working area to space requirements highlights of the sprint 20 5 _ SWISSTYPEkit* for short and plain turning on one machine, < 30 min tooling time _ 23 tool slots on 2 independent linear carriages _ Up to 6 driven tools, 4 slots as standard _ 20 % shorter tooling times with the quick tool-change system* _ Long workpieces measuring up to 600 mm are discharged through the counter spindle* _ High pressure coolant supply* of up to 120 bar _ CNC control system M70 from MITSUBISHI with 10.4" colour display * Optional at the grand opening in Bergamo set-up area of just 1.92 m 2 Bar machining up to ø 20 mm; maximum headstock hub of 60 mm, and optionally with SWISSTYPEkit up to 180 mm, workpiece length of up to 600 mm if equipped with the optional spindle unload extension; 23 tool slots of which 4, or optionally 6, are for driven tools (6,000 rpm, 1.45 Nm and 0.9 kw); main spindle rated at 10,000 rpm, 14 Nm and 2.2 kw and the counter spindle is rated at 10,000 rpm, 4.8 Nm and 1.5 kw (S1 100 % DC)

12 12 intro world premières technologies ecoline systems lifecycle services milling technology DMC 650 V, DMC 850 V, DMC 1150 V High performance vertical machining of up to 1,500 kg, 700 mm Y axis and SK50 spindle rated at 303 Nm. As the 3 rd generation vertical machining centre, the new DMC V range with CELOS from DMG MORI and in the new design brings together experience from over 10,000 successful installations of this range. Both world premières, the DMC 850 V and the DMC 1150 V, are raising the bar even higher in the range, featuring a 14,000 rpm base spindle rated at 121 Nm and rapid traverses of up to 36 m/min as standard, and are designed to machine workpieces weighing up to 1,500 kg. Optionally the DMC 650 V can be expanded for power milling with a 303 Nm torque spindle (SK50). Tool magazines with up to 120 slots are also available. The cooled drives and guideways guarantee the highest precision. The large working area allows for the high-performance machining of workpieces weighing up to 1,500 kg with the optional SK50 spindle and 303 Nm. highlights of the new dmc v range DMC 650 V The new vertical machining centre with a unique machine concept for more performance and flexibility _ High performance equipment as standard base spindle rated at 14,000 rpm / 121 Nm, 36 m/min rapid traverse _ SK50 spindle rated at 303 Nm (optional) _ Tool magazine with up to 120 slots _ Workpiece weight of up to 1,500 kg _ 30 % higher precision with cooled drives and guideways _ With the experience from over 10,000 vertical machining centres sold _ SANDVIK COROMANT tool kits for milling, drilling and tapping DMC 850 V Stable design with rigid table and overhead cutting unit, optionally with a rapid traverse of up to 42 m/min white version The new DMG MORI design is available in either BLACK or WHITE at no extra cost. Travel X / Y / Z: 650 / 520 / 475 mm; rapid traverse: 36 (42) m/min; spindle speed: 14,000 rpm; output: 14.5 kw; torque: 121 Nm; table size: mm; workpiece weight: 800 kg; tool magazine: 20 (30 / 60 / 120) slots Travel X / Y / Z: 850 / 520 / 475 mm; rapid traverse: 36 (42) m/min; spindle speed: 14,000 rpm; output: 14.5 kw; torque: 121 Nm; table size: 1, mm; workpiece weight: 1,000 kg; tool magazine: 20 (30 / 60 / 120) slots

13 Journal n CELOS From the idea to the finished product. 3 rd generation DMC V with a new machine concept _ Stable design with overhead cutting unit _ Rigid table for workpieces weighing up to 1,500 kg _ +28 % larger linear guides _ +25 % larger ball screws _ Innovative cooling concept to guarantee precision Cooled ball screw nuts and guideways on all three axes (X / Y / Z). DMC 1150 V Large working area with 700 mm Y axis for workpieces weighing up to 1,500 kg UNO tool presetting NEW: Auto-focus function for automatically focusing the cutting edge _ FEM-optimised and thermally stable cast iron construction _ Personalised configurations thanks to the modular design _ Snap gauge principle up to diameters of 100 mm (traverse up to X 50 mm) _ 19" colour monitor _ Fine adjustment Innovation 2014 Options: _ NEW manual Balluff system (RFID chip) _ NEW second camera to measure the rotating axis _ 24" touch-screen display _ Convenient system cabinet _ Adapter storage Travel X / Y / Z: 1,150 / 700 / 550 mm; rapid traverse: 36 (42) m/min; spindle speed: 14,000 rpm; output: 14.5 kw; torque: 121 Nm; table size: 1, mm; workpiece weight: 1,500 kg; tool magazine: 20 (30 / 60 / 120) slots Measuring range: X = +200 to 50 mm Z = 400

14 14 intro world premières technologies ecoline systems lifecycle services milling technology duoblock 4 th generation Maximum productivity thanks to the pallet changer and geared spindle rated at up to 1,424 Nm. Fully cooled feed drive and tempered machine bed for up to 30 % higher component precision. Three new palletised versions After the success of the 4 th generation of DMU 80 P duoblock machines, three new versions of this range will be available after the open house exhibition in Pfronten. Their diversity is evidence of the stable basis in the palletised 5-axis version as well as with the horizontal milling head or in the turn-mill configuration. The DMC 80 H duoblock ticks all boxes as a newly developed horizontal machining centre, in high-performance heavy machining and in precise all round machining. The high level of stiffness in the design ensures 30 per cent higher precision values, which are also supported by intelligent temperature management. The new DMC 80 FD duoblock with its redesigned working area also benefits from the optimised overall stiffness and increased precision. The working area is now 8 per cent larger on a smaller set-up area. In addition to the turn-mill and horizontal machining versions, the DMC 80 U duoblock features an automatic pallet changer which facilitates set-up during main time. This reduces non-productive time, thereby optimising the production process. Optionally available pallet storage can also increase the level of automation. Another advantage of the duoblock principle is the universal kit for tailored, complete solutions for a wide range of applications. For example, the range of spindles includes spindles optimised for heavy machining including the powermaster 1000 with 1,000 Nm torque and 9,000 rpm and a geared spindle rated at 1,424 Nm and 8,000 rpm. 30 % more precise, more efficient and more powerful the new benchmark in all sectors. Tool and mould construction Energy technology DMC 80 U duoblock duoblock 4 th generation: Excellent redefined with 30 % more precision, efficiency and performance Tube mould The highest surface finish requirements of up to Ra 0.35 Drill head Machining time reduced by 75 % Aerospace Machine construction Chassis components Up to 50 % higher cutting performance when working with titanium Railway Mould carrier Fully automated series production combined with highly intelligent in-process measurement Automotive Axle bearing 30 % lower energy consumption Cylinder head Highly productive thanks to short non-productive times: 0.5 second tool-changing time Travel X / Y / Z: 800 / 1,050 / 850 mm; rapid traverse: 60 / 60 / 60 m/min.; spindle speed: 12,000 rpm; output: 35 kw; torque: 130 Nm; workpiece size: ø 900 1,450 mm; workpiece weight: 1,400 kg; tool magazine: 63 (123 / 183 / 243 / 273 / 363) slots

15 Journal n Compact, patented, intelligent technology allows quick chip-to-chip times and short set-up times. dmc h Horizontal heavy machining _ Geared spindle rated at up to 1,424 Nm and the improved interfering contour allow for better immersion in the workpiece _ Heavy machining package for up to 50 % higher cutting performance when working with hard to machine materials _ 28 % larger horizontal passage (New: 1,050 mm) dmu p / dmc u / dmc h highlights of the 4 th generation duoblock _ Precision: up to 30 % higher component precision with the fully water-cooled feed drive _ Performance: up to 30 % higher stiffness for maximum cutting performance _ Efficiency: up to 30 % lower energy consumption with intelligent needs based aggregates _ Intelligent wheel magazine with up to 363 tools, 0.5 second tool-changing time and the ability to set up during main and non-productive time powermaster 1000 _ Motor spindle with 77 kw output and 1,000 Nm torque _ Modular design for quick replacement times and easy maintenance _ Spindle Growth Sensor (SGS) to compensate for spindle growth dmu fd / dmc fd Milling and turning in one clamping operation _ Direct Drive table rated at 2,050 Nm and 800 rpm _ Unbeatable know-how: 15 years of experience in turning and milling _ 13 % larger vertical passage (new: 1,070 mm) _ Exclusive software cycles: Multitool, laser measuring sensor packages, electronic balancing, interpolation turning _ Operate 4.5 on SIEMENS 840D solutionline _ Optimised chip disposal suitable for turnings and millings dmu p / dmc u / dmu fd / dmc fd B axis _ Wide range of components, short machining times and higher flexibility thanks to the larger swivel angle of 250 (+180 / 70 ) _ Integrated cable carrier improved interfering contour, higher quality thanks to better sealed housing, longer life span thanks to mechanically guided cables _ 20 % more stiffness thanks to the large YRT bearing

16 16 intro world premières technologies ecoline systems lifecycle services milling technology The innovative, patented wheel magazine allows for set-up during main and non-productive time. DMU 270 P: The new heavyweight in the portal range. Patented technology DMG MORI gearmill complete machining of a spiral bevel gear. _ The most compact magazine on the market (10 % smaller footprint than chain magazines) _ Up to 363 tool slots _ Maximum set-up time of 5.6 seconds _ Extremely short tool-changing time of just 0.5 seconds (0.8 seconds for the HSK-A100) _ Safe holding fixture thanks to the holder MPC Machine Protection Control The DMU 270 P is an optimal addition to the range of portal machines thanks to its considerable advantages in terms of working area compared to the smaller DMU 210 P. The traverses of 2,700 2,700 1,600 mm on X / Y / Z represent an additional 50 % lateral space and approximately 30 % height and length. Therefore, the working area is a remarkable 235 % larger. The interfering contours were also optimised, as DMG MORI redeveloped both the milling head and the inherently protective booth. The maximum workpiece size is now 3,000 mm in diameter and 1,600 mm in height with a maximum load of 12,000 kg. The extremely high inherent stiffness of the machine DMU 270 P: 5-axis machining with 12-tonne workpiece weight and constant temperature control throughout the machine ensure top precision values. The DMG MORI kit also features countless ways to adapt the DMU 270 P to your requirements, be it with expansions to the wheel magazine or intelligent automation options for maximum productivity. One highlight of the operating system is CELOS. With its 21.5" panel, this innovative operating concept provides the best process monitoring and trouble-free machine operations in automatic mode. Additionally, all machine and process data are displayed and documented, allowing the system to be networked with external PPS, CAD and CAM systems. highlights of the dmu 270 p _ Proven portal design _ Large working area X / Y / Z: 2,700 / 2,700 / 1,600 mm _ Large working area for workpieces measuring up to ø 3,000 1,600 mm _ Effortless immersion in deep shapes with the optimised interfering contour of the milling head _ 50 % higher dynamics with the new drive technology in the NC rotary table _ High precision thanks to optimised temperature stability _ Quick set-up at the client with no machine base thanks to the 3-point support _ Quick shut-down in the event of critical vibration conditions _ Increased spindle service life _ Diagnosis and optimisation of the machining process _ Longer service lives for the machine and tools _ Maintenance can be scheduled _ Identification of the cause of spindle failures _ Optimal use of the tool service life _ Increased machine availability _ Available for all DECKEL MAHO machines Travel X / Y / Z: 2,700 / 2,700 / 1,600 mm; rapid traverse: 60 / 30 / 40 m/min.; spindle speed: 12,000 rpm; output: 44 kw; torque: 288 Nm; workpiece size: ø 3,000 1,600 mm; workpiece weight: 12,000 kg; tool magazine: 63 (123 / 183) slots

17 Journal n advanced technology An intelligent combination: Laser cladding with integrated end milling. LASERTEC 65 Additive Manufacturing: Additive manufacturing in finished parts quality. Laser cladding Milling Additive manufacturing unlocks new opportunities for high complexity and individuality in the production of, for example, integral components and similar lightweight components made of high-performance metallic materials. The additive manufacturing market is growing steadily. SAUER LASERTEC, a company of DMG MORI SEIKI AG, has integrated additive manufacturing into a full 5-axis high tech milling machine for the first time. To date, this innovative hybrid solution is unique on the global market. The process uses an application process featuring a metal powder feed which is up to 20 times faster than generation in a powder bed. Until now, additive processes were limited to the production of prototypes and small parts which would otherwise be impossible to manufacture with other conventional technologies. By combining additive and cutting processes in one machine, additive technology can complement and enhance traditional machining methods. Process direction Powder Laser beam Inert / carrier gas Melting point Applied material Application zone Workpiece Metal powder is applied to a base material and fused to it in layers. This causes the metal powder to form a strong weld with the surface. After cooling, a metal layer is formed which can be machined. highlights of lasertec 65 am 1 Additive manufacturing A 3D component is created: 2 Repairing An intelligent combination: Laser cladding with integrated end milling _ The unique combination of laser application and milling results in the best surfaces and component precision _ Laser cladding with powder feed: 20 times faster than the powder bed method _ It is even possible to produce full components _ Many 3D geometries can be created, including with undercuts _ Repair of turbine components, including in tool and mould construction _ Application of surface courses Laser cladding 1: Basic construction of the cam ring Milling Laser cladding 2: Generation of the flange without supporting geometry Laser cladding Aerospace: Repairing a rotor blade Material: Inconel 3 coating Concept study at the open house exhibition in Pfronten and world premières at IMTS / AMB : Flange drilling Laser cladding 4: Cladding of the cone Milling Tool and mould construction: Roll with wear-resistant coating Material: Stellite 5: Construction of the 12 connectors 6: Milling the entire inner contour 3D contours can also be created with undercuts: e. g. production of a flange without supporting geometry (image 2), production of a cone (image 4). The flexible switching between laser and milling operations allows for the direct machining of component segments that can no longer be reached on the finished part (see image 3). LASERTEC Travel X / Y / Z: 650 / 650 / 560 mm; maximum workpiece dimensions (5-axis): ø mm; maximum loading weight (5-axis): 600 kg (1,000 kg*); minimum set-up area (machine only): approx. 7.9 m²; control system: 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline

18 9 18 intro world premières technologies ecoline systems lifecycle services ecoline DMU 70 ecoline The perfect synthesis of functionality and technology with an NC swivel rotary table for 5-sided machining and the latest 3D control technology as standard! C axis 360 SLIMline with Operate 4.5 on SIEMENS 840D solutionline SLIMline with HEIDENHAIN TNC 620 B axis 10 / +95 Diverse: the latest control technology with 3D simulations Patented NC swivel rotary table with digital drives for 5-sided machining. Robust, servicefriendly spindle with a speed range of up to 12,000 rpm as standard can be upgraded with internal tool cooling. NEW! DMU 70 ecoline 5-sided machining with patented NC swivel rotary table highlights of the dmu 70 ecoline _ Powerful main spindle speed range of up to 12,000 rpm (13 / 9 kw, 83 / 57 Nm, 40 / 100 % DC) _ Large traverses X / Y / Z: 750 / 600 / 520 mm _ Rapid traverse on linear axes: 24 m/min _ SK40 tool magazine with 32 slots chain with holders and double gripper including set-up assistant for tool set-up during main time _ Maximum efficiency NC swivel rotary table with digital drives for 5-sided machining _ 3D quickset *: toolkit designed to monitor and correct kinematic precision * Optional Traverse X / Y / Z: 750 / 600 / 520 mm; rapid traverse on linear axes: 24 m/min; powerful spindle with a speed range of up to 12,000 rpm; 83 / 57 Nm, 13 / 9 kw (40 / 100 % DC); 32-slot chain tool magazine with holders and double grippers

19 Journal n nº NLX, CTX and NEF universal turning now also with CELOS Benchmark in complete turn-mill machining: CTX TC and NTX Automated turning with new technology centre in Italy Infiniti Red Bull Racing: World champion with 5-axis technology from DMG MORI Technologies and success stories

20 20 intro world premières technologies ecoline systems lifecycle services turning technology NLX 9 models in various configurations. pact design suitable for machining large workpieces with driven tools rated at up to 4,000 rpm (10,000 rpm*) and a Y axis. In configuration type B, 3,225 Nm torque in the main spindle ensure the highest cutting performance (type A = 1,910 Nm). The NLX2500SY/700 is also built for the European market at the premises of GILDE MEISTER Italiana S.p.A. in the Italian commune of Brembate di Sopra in Bergamo. From May onwards built in the new design and with CELOS. All three NLX world premières were presented at EMO with CELOS 21.5" ERGOline and MITSUBISHI and will be available from April The highest precision with a direct distance measurement system from Magnescale with a resolution of 0.01 µm. Efficient complete machining with driven tools, counter spindle and Y axis on the NLX2500SY/700. The successful NLX range with more than 3,000 installed machines already. highlights of the nlx range _ Integrated coolant circulation in the machine bed for improved thermal stability _ Flat slideways on all axes for the highest load capacity _ With BMT technology (turret with integrated drive motor), milling performance comparable to machining centres _ Available in various configurations (e. g. with directly driven tools, Y axis, high-performance counter spindle) BMT built-in motor turret improved milling performance with up to 100 Nm torque and higher milling precision. NLX2500/500 Perfect 2-axis turning on 3.5 m 2 for workpiece lengths of up to 500 mm The success model of the NLX range, the NLX 2500 is now also available from DMG MORI with a 500 mm turning length. A maximum turning diameter of 460 mm and traverses of 260 mm and 500 mm in the X and Z directions make the NLX 2500/500 a versatile turning instrument. The optimised machine design has a small footprint (3.5 m 2 ). The right solution for every application 9 machine models with 29 variations. Turning length (mm) NLX 2500/1250 MC, Y, SMC, SY NLX 3000/1250* MC, Y NLX 4000/1500* Turning MC, Y 700 NLX 2500/700 Turning MC, Y, SMC, SY NLX 3000/700 Turning MC, Y NLX 4000/750 Turning MC, Y 500 NLX 1500/500 MC, Y, SMC, SY NLX 2000/500 MC, Y, SMC, SY NLX 2500/500* Turning Chuck size 6" 8" 10 / 12" 12" 15 / 18" Available immediately with MAPPS IV and 10.4" TFT display.** * Only available in the new design and with CELOS from April 2014 ** 19" for the NLX4000 Turning = fixed tools, MC = driven tools, Y = driven tools and Y axis, SMC = driven tools and counter spindle, SY = driven tools, Y axis and counter spindle Since the market introduction of the NLX series at the end of 2010, more than 3,000 units have been sold successfully. The NLX series offers users maximum performance, flexibility and reliability. Integrated coolant circulation in the machine bed ensures improved thermal stability. The flat tracks in all axes serve as an optimal base for high performance turning. Besides that, the NLX2500/500 convinces with a small footprint and high rigidity. The new NLX3000MC/ 1250 offers users the BMT turret for turning lengths up to 1,250 mm with integrated tool drive for outstanding milling performance. Two characteristic highlights of the NLX4000BY/1500 are the long traverse in the X axis with a maximum of 315 mm (for the MC version 365 mm) and the steady with a maximum diameter of 350 mm as well as the option with the Y axis for a turning diameter of up to 500 mm (or 600 mm in the MC version). The NLX4000BY/1500 also boasts a very comwhite version The new DMG MORI design is available in either black or white at no extra cost. Maximum turning diameter: 460 mm; maximum turning length: 500 mm; bar capacity: 80 mm; speed: rpm as standard; drive output: 18.5 kw; 10-position turret (optional turret with 12 positions)

21 Journal n Optional turret: TRIFIX precision quick-change system. TRIFIX allows the user to change tools in under 30 seconds with a repeat accuracy of under < 6 μm. Integrated coolant circulation in the machine bed for improved thermal stability. 30 % wider, highly stable flat slideways allow for high-performance turning, e. g. width of 80 mm in the NLX2500. NLX2500SY/700 6-sided machining thanks to the main and counter spindles and the turret with a traverse of 100 mm on Y The success model NLX2500SY/700 with counter spindle and Y axis is synonymous with efficient complete machining in one clamping operation or out of the box. The turret comes with the BMT60 interface as standard and can optionally be equipped with VDI-TRIFIX (12 positions). Speed: 10,000 rpm. NLX4000BY/1500 Efficient complete machining of large workpieces up to 500 mm in diameter (600 mm in diameter without the Y axis) BMT technology for outstanding milling performance of driven tools rated at 4,000 rpm (optionally 10,000 rpm), M30 tapping with up to 100 Nm torque, wide slideways on the Z axis, long traverse on the X-axis, steady rest up to ø 350 mm. up to 10 % currency advantage* Maximum turning diameter: 366 mm (460 mm diameter without Y-axis); max. turning length: 705 mm; bar capacity: 80 mm; main spindle: 4,000 rpm, 18.5 kw; counter spindle: 6,000 rpm, 11 kw; 12-position turret (optional turrets with 10, 16 or 20 positions) speed of driven tools 10,000 rpm The best technology at the best price * Benefit from a 10 % currency advantage due to the current development of the YEN Maximum turning diameter: 500 mm (turning & MC version: 600 mm); max. turning length: 1,500 mm; max. bar capacity: 164 mm; speed: 1,500 rpm; drive power rating: 37 kw; 10-position turret (optional 12-position turret); speed of driven tools 4,000 rpm with 100 Nm specification (10,000 rpm optional)

22 22 intro world premières technologies ecoline systems lifecycle services turning technology CTX alpha and CTX beta high tech universal turning with linear drive, Direct Drive and TRIFIX. The universal CTX alpha and beta range gives users maximum flexibility, ergonomics and precision. Thanks to their flexible and modular design, the machines can be built to meet a wide range of customer requirements, from machining simple chuck components to complete machining. For example, spindle motor rated at up to 770 Nm are available for maximum cutting performance. The linear drive on the X axis, optionally available for the CTX beta machines, ensures maximum long-term accuracy. With an acceleration of 1 g, it also guarantees the highest dynamics during machining. As standard, the machines include direct measurement systems on the X axis and liquid cooled spindle motors for maximum thermal stability. The optional Direct Drive turret with a speed of up to 12,000 rpm is a must have for real milling (CTX beta: 10,000 rpm), featuring a torque of up to 34 Nm (CTX alpha: 20 Nm). This turret comes with the TRIFIX precision quick change system as standard, for a tool changing time of under 30 seconds. The most important configurations here include the Y axis with 120 mm hub configuration package for eccentric machining (CTX alpha: 80 mm). Not to mention the 6-sided complete machining package including counter spindle, Y axis and a star turret with TRIFIX. Visit us at the open house exhibition in Bielefeld from May sided complete machining package including main spindle, counter spindle and Y axis with 120 mm hub (CTX alpha 500 with 80 mm) and star turret with TRIFIX. highlights of the ctx alpha 500 highlights of the ctx beta 800 linear CTX alpha 500 Eccentric machining with the Y axis* with 80 mm hub* Available from April 2014: CELOS from DMG MORI with 21.5" ERGOline and SIEMENS, available now with 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline or HEIDENHAIN CNC PILOT 640 _ Direct Drive* turret rated at 12,000 rpm and 20 Nm for maximum cutting performance _ High-performance turning of workpieces measuring up to ø mm with the main spindle rated at 170 Nm * Optional CTX beta 800 linear Linear drive on the X axis with 1 g acceleration and maximum long-term accuracy Available from June 2014: CELOS from DMG MORI with 21.5" ERGOline and SIEMENS, available now with 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline or HEIDENHAIN CNC PILOT 640 _ High-performance turning of workpieces measuring up to ø mm thanks to the main spindle rated at up to 770 Nm* _ Large working area for the use of chucks* measuring up to ø 400 mm and steady rests* up to ø 200 mm * Optional Bar machining up to ø 65 mm; 525 mm max. turning length and 200 mm max. workpiece diameter; main spindle ISM 52 PLUS rated at 6,000 rpm, 170 Nm, 27 kw; 12-position VDI 30 turret, 5,000 rpm, 5.4 kw and 16 Nm Bar machining up to ø 76 mm; 850 mm max. turning length and 410 mm max. workpiece diameter; main spindle ISM 76 rated at 5,000 rpm, 380 Nm, 34 kw; 12-position VDI 40 turret, 4,000 rpm, 11.3 kw and 28 Nm, plus 6 block tool slots

23 Journal n turning technology CELOS from DMG MORI with 21.5" ERGOline and SIEMENS for the simplest workshop programming with 3D control technology. NEF 400 The best performance in its class with integrated spindle motor. The 5 th generation of the NEF range is marking its entry into the world of universal turning machines with the NEF 400 and NEF 600 and provides the best technology at a unique price. Additionally, high-quality German components are used, e. g. control systems, measurement systems, hydraulics, spindles and the turret. As standard, the NEF 400 comes with a liquid-cooled integrated spindle motor. Optionally, the machine can also be equipped with a turret for up to 6 driven tools, including a C axis for the main spindle. Another highlight is the spacious working area which facilitates the machining of workpieces measuring up to ø mm on a set-up area of just 4 m². Star turret with TRIFIX precision quick change system for tool set-up times of under 30 seconds and a repeat accuracy of under 6 µm. Integrated and liquid cooled spindle motor rated at 340 Nm for maximum cutting performance and temperature stability. Linear drive minimal maintenance costs, maximum precision and productivity. NEF 400 For machining workpieces measuring up to ø mm on a set-up area of just 4 m² highlights of the nef 400 _ The latest 3D control technology: CELOS from DMG MORI with 21.5" ERGOline and SIEMENS (from Q3 / 2014) _ Alternatively, 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline and ShopTurn 3G or HEIDENHAIN CNC PILOT 640 _ The highest precision thanks to the integrated C axis with resolution (optional) _ Large working area for workpieces measuring up to ø mm on a set-up area of just 4 m² _ Optimal ergonomics and accessibility, working depth of just 289 mm to the main spindle _ Liquid cooled integrated spindle motor for the highest temperature stability _ 5-year guarantee on the linear drive _ 1 g acceleration and 60 m/min rapid traverse _ Maximum long-term accuracy, hardly any wear parts _ High acceleration, no mechanical transmission elements _ Low maintenance, minimal life cycle costs _ Reduced production costs through the highest dynamics and availability _ Available for all CTX beta universal turning machines including Includes HORN tool case Bar machining up to ø 65 mm; 650 mm max. turning length and 340 mm max. workpiece diameter; ISM 65 main spindle rated at 4,500 rpm, 340 Nm, 11.5 kw; 12-position VDI 30 turret

24 24 intro world premières technologies ecoline systems lifecycle services turning technology CTX TC Turn-mill complete machining. CTX TC 5-axis universal turning of workpieces measuring up to ø 700 mm and a turning length of up to 3 m, 6-sided complete machining with the optional counter spindle. CTX TC 4A 5-axis production turning with the main and counter spindle plus additional lower turret; optional turret with Direct Drive for speeds of up to 10,000 rpm. An overview of the CTX TC and CTX 4A range UNIVERSAL: CTX TC PRODUCTION: CTX TC 4A Main and optional counter spindle Main spindle, counter spindle and additional turret beta gamma beta gamma ø 500 mm ø 700 mm ø 500 mm ø 700 mm Turning length 850 mm CTX beta 800 TC Turning length 1,300 mm CTX beta 1250 TC (linear) CTX gamma 1250 TC (linear) CTX beta 1250 TC 4A CTX gamma 1250 TC 4A (linear) ø 550 mm Turning length 2,050 mm CTX beta 2000 TC CTX gamma 2000 TC (linear) CTX gamma 2000 TC 4A (linear) Turning length 3,050 mm CTX gamma 3000 TC CTX gamma 3000 TC 4A 5-year guarantee More power, higher precision. 5 year guarantee on linear motors, highest long-term precision and dynamic performance. CTX gamma 2000 TC linear 6-sided complete machining of workpieces measuring up to ø 700 mm highlights of the ctx gamma 2000 tc linear _ 6-sided complete machining with the main and counter spindle*, counter spindle as standard with the TC 4A _ 5-axis simultaneous machining with the Direct Drive B axis with ±120 swivel range in combination with the technology cycle* _ Y axis with ±200 mm hub for eccentric machining _ Turn-mill spindle rated at 12,000 rpm, optionally up to 18,000 rpm or 8,000 rpm with 160 Nm _ Use of steady rests* for workpieces up to ø 460 mm and chucks* up to ø 630 mm _ CTX gamma 2000 TC 4A linear: Second tool holder in the form of a 12-position VDI 40 turret with TRIFIX precision quick change system, optionally as a Direct Drive turret rated at 10,000 rpm and 34 Nm * Optional including Includes tool case from HORN / LMT / SCHUNK available from the 4 th quarter 2014: CELOS from DMG MORI with 21.5" ERGOline and SIEMENS, available now with 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline. Maximum turning length: 2,050 mm; max. workpiece diameter: 700 mm; Y hub ± 200 mm; ISM 102 main spindle rated at 4,000 rpm, 770 Nm, 45 kw; HSK-A63 turn-mill spindle rated at 12,000 rpm, 100 Nm, 22 kw; disc-type tool magazine with 36 slots, optional chain magazine with up to 180 slots

25 Journal n Success Story turning technology Machining a shank with a milling spindle and swivelled counter spindle. NTX1000/SZM: Complete turning and milling of complex individual and production parts. The machines of the NTX range are compact integrated turn-mill centres and are suitable for machining in the medical technology, aviation and aerospace, medicine, watch and semiconductor industries. Three of our original technologies facilitate outstanding machining with high precision and efficiency. The NTX range is synonymous with high productivity Process-safe production of polygonal connections on a CTX beta 1250 TC 4A in grinder-level quality. Collision free parallel machining with milling spindle and turret thanks to the swivelling counter spindle; swivel range to 195 to allow for workpiece removal. KAMPF Schneid- and Wickeltechnik GmbH & Co. KG Turn-mill complete machining combines five machines into one. KAMPF Schneid- und Wickeltechnik GmbH & Co. KG, based in Wiehl in Cologne, is a technological leader in its field of cutting and packaging technology designed to produce and process items such as plastic film, composite materials, laminates and aluminium foil. Highlights include machines for thin foils with material thicknesses starting at 0.9 μm which are produced at speeds of up to 700 m/min. Besides its innovations, KAMPF also boasts expertise in mechanical production out of its facility in the municipality of Dohr in the Eifel mountains. Recently a CTX beta 1250 TC 4A turnmill machining centre has been causing a furore there. Equipped with a counter spindle, high-performance milling spindle as a B axis and a lower 12-position turret as an additional tool holder with driven tools and a Y axis, the recent investment halved the cost of a drive shaft. Stephan Schleicher, the plant manager in Dohr, describes the initial situation and the effects of the savings: The polygonal connection as a main drive element places extremely high requirements on precision and surface finish, which used to make a grinding process inevitable. DMG MORI was the only manufacturer to guarantee that the workpiece could be produced with the necessary level of process quality on just one machine. On hearing this, KAMPF gave the specialists at DMG MORI the full machining job including a selection of tools and clamping devices and program generation. We then accepted the reference part in Bielefeld and had it measured and verified externally, remembers the plant manager before concluding: All test features were easily within the parameters and, most importantly, they were even achieved through hard everyday work. Whereas in the past we had to produce on five machines including grinding, we can now manufacture fully on the CTX beta 1250 TC 4A! NTX1000/SZM Highly efficient integrated turn-mill centre highlights of the ntx1000/szm _ DDM technology (Direct Drive motor) on the B axis and BMT technology (turret with integrated drive motor for driven tools) _ 40 % smaller set-up area compared to previous models _ ORC technology (octagonal ram construction) on the Y axis for outstanding damping properties and thermally symmetrical construction _ Various configurations are available _ ESPRIT CAM software as standard _ NTX1000 also available with Operate 4.5 on SIEMENS 840D solutionline Contact: KAMPF Schneid- and Wickeltechnik GmbH & Co. KG Mühlener Straße 36 42, Wiehl, Germany info@kampf.de, Swing: ø 370 mm; turning length: 450 mm; Y axis: ±105 mm; main spindle: maximum drive output: 11 kw; maximum speed: 6,000 rpm; spindle: Capto C5 holder, speed: 12,000 rpm (HSC optional: 20,000 rpm); maximum drive output: 7.5 kw

26 26 intro world premières technologies ecoline systems lifecycle services turning technology TWIN concept: Two independent working areas thanks to the cross traverse of the counter spindle-tailstock combination. turning technology CTX beta 4A 30 % shorter production times thanks to the patented TWIN concept with 2 independent working areas. NZX1500 and NZX2000 Production turning with up to 3 turrets and 3 Y axes. The core of the CTX beta 800 4A and CTX beta A is the patented and proven TWIN concept. This unique working area concept with two turrets and the cross traverse of the counter spindle-tailstock combination allows for parallel, collision-free machining in two independent working areas. Shaft components can also be held up in the main spindle. The working area lets the operator machine workpieces with a diameter of up to 340 mm and a turning length of up to 800 or 1,200 mm. In connection with up to two Y axes (optional lower axis), this allows for the highly efficient machining of complex chuck or bar components. The machine comes with two VDI 40 turrets with a total of 24 driven tool slots and the TRIFIX precision quick change system. The TWIN concept allows for collision-free machining in two independent working areas with two turrets and a tailstock. Turret 1 Z1 C1 Y2 Turret 2 Y1 X1 X2 X3 Y3 C2 NZX2000/800STY3 with main spindle, counter spindle and 3 turrets with 3 Y axes. Z2 Z3 B Turret 3 highlights of the ctx beta 800 4a CTX beta 800 4A Patented and proven TWIN concept with two independent working areas _ Y axis on both turrets (upper ±60 lower* ±40 mm) _ Two VDI 40 star turrets with 24 driven tool slots and VDI 40 TRIFIX precision quick change system _ Direct Drive* turret rated at 10,000 rpm, 14.2 kw and 34 Nm _ 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline with ShopTurn 3G * Optional NZX2000/800STY3 High-efficiency production turning with three turrets for series parts Maximum turning length: 800 mm (CTX beta A: 1,200 mm); maximum workpiece diameter: ø 340 mm; Y hub ± 60 mm; ISM 76 synchro main and counter spindle rated at 5,000 rpm, 360 Nm, 32 kw; two VDI 40 turrets with TRIFIX, 4,000 rpm, 28 Nm, 11.3 kw ctx beta 800 4a with integrated handling: _ NC-controlled loading and unloading with double gripper _ Pallet conveyor for workpiece storage _ Chuck components measuring up to ø mm and weighing up to 15 kg _ 50 % shorter non-productive time than external loading portals thanks to unloading during main time nzx1500 / nzx2000 Cutting diameter: ø 320 mm Turning length: 810 mm Number of turrets: up to 3 Number of Y axes: up to 3

27 Journal n ORC (octagonal ram construction) for maximum stiffness on the Y axis of the lower turret on the NZX1500 or NZX2000. turning technology NZX4000 and NZX6000 High-efficiency shaft machining with 2 turrets. The machines in the NZX range are designed for machining shafts with small diameters (NZX S range) and for machining complex, long and large workpieces with large diameters (NZX4000, NZX6000). The machines in this range guarantee highly efficient and productive machining. The highest precision with a direct distance measurement system from Magnescale with a resolution of 0.01 µm. Magnescale distance measurement system High-resolution magnetic absolute length measurement system Measurement precision class of ± 3 µm Resistant against condensation and oil Impact resistant up to 45 g With the same thermal expansion properties as steel and with a cast iron machine bed Another machine from the NZX range the NZX2500: High-efficiency turning and milling of a crank shaft with 2 turrets and a Y axis in the upper turret: highlights of the nzx2000/800sty3 _ BMT turret for milling at up to 12,000 rpm (6,000 rpm as standard) _ 16 driven stations per turret _ Y axis for all three turrets with 110 mm traverse (optionally available) _ ORC (octagonal ram construction) for maximum stiffness on the Y axis of the lower turret _ Rapid traverses on X / Y / Z: 30 / 20 / 50 m/min NZX4000C/2000Y Large 4-axis turning centre for the efficient and productive machining of large workpieces up to 2 m in length highlights of the nzx4000 and nzx6000 _ BMT turret, turret head with integrated drive motor for milling at up to 3,500 rpm _ Y axis for the upper turret with 200 mm traverse (the NZX4000 comes with a 140 mm traverse) _ Spindle bore for the NZX6000 available with ø 285, ø 375 or ø 560 mm (NZX4000: ø 145, ø 185 or ø 285 mm) nzx4000 Cutting diameter: ø 660 mm Turning length: 1,000 / 2,000 / 3,000 mm Number of turrets: 2 Number of Y axes: up to 1 (upper turret) nzx6000 Cutting diameter: ø 900 mm Turning length 1,000 / 2,000 / 3,000 / 4,000 mm Number of turrets: 2 Number of Y axes: up to 1 (upper turret)

28 28 intro world premières technologies ecoline systems lifecycle services 3 rd 7 th June 2014 We warmly invite you to the grand opening in Bergamo in June rd 7 th June 2014 Grand opening of the fully modernised premises of GILDE - MEISTER Italiana S.p.A. in the Italian commune of Brembate di Sopra in Bergamo. GILDEMEISTER Italiana Opening of the new technology centre and the new production line for mono-spindle and multi-spindle turning machines. GILDEMEISTER Italiana S.p.A. in the Italian commune of Brembate di Sopra in Bergamo is the centre of excellence in the DMG MORI group when it comes to economically machining rotationally symmetric components in larger batch sizes ranging up to mass production. Production turning machines with up to 3 turrets and mono-spindle turning machines for short and plain turning are as much a part of its range of services as the top class of mechanical and CNC-controlled multi-spindle turning machines. Moreover, the NLX2500SY/700 is built for the European market on-site and it will be available in the new design and with CELOS with MITSUBISHI from June Overall, the location has been fully modernised at a cost of over 15 million. For one, a new assembly hall measuring over 1,200 m² was built. Additionally, a new technology centre measuring approximately 1,000 m² was built in order to develop customer specific demonstrations and solutions. For even more quality and precision, the mechanical production area is now air-conditioned to ±1. The production area also now has the following new machines at its disposal: DMC 125 U duoblock and DMC 160 U duoblock, a DMC 100 H duoblock with 33-slot pallet storage and a CTX gamma These machines are used to produce highly precise components such as machine beds for multi-spindle turning machines. Thanks to these comprehensive modernisations, we will be able to build up to 380 machines plus 100 NLX2500s at the location in the future. It will be opened as part of the grand opening from 3 rd 7 th June The new SPRINT 20 5 will also be presented for the first time at the grand opening. Highly modern assembly for machines in the SPRINT range, the multi-spindle turning machines GM and GMC and the NLX2500SY/700. Hydraulics Valve block Material: AISi 430F Dimensions: ø mm Automotive Centrally positioned central block for maximum stiffness when machining workpieces measuring up to ø mm. Handlebar Material: 4SS20 Dimensions: ø mm SWISSTYPEkit (optional) for short turning up to 80 mm and plain turning up to 240 mm; short to plain turning conversion time of less than 15 minutes. GMC 35 ISM Multi-spindle turning machine with 65 % shorter tooling times thanks to CNC technology. highlights of the gmc 35 ism _ Designed to machine highly complex workpiece with up to 56 controlled NC axes for spindles, slides, driven tools* and U and Y axes* _ Centrally positioned central block for maximum stiffness during frontal machining _ Separate drive on each of the six main spindles via an integrated spindle motor with C axis for optimal cutting performance in every operation _ Up to 6 driven tool units* and 5 U axes* for eccentric machining * Optional SPRINT 20 8 linear with SWISSTYPEkit for short and plain turning on one machine. new: sprint 20I5 see page 11

29 Journal n turning technology Machining of long workpieces with two turrets and the TWIN concept for machining in two independent working areas thanks to the cross traverse of the counter spindle-tailstock combination. SPRINT 50 and SPRINT 65: with TWIN concept, 3 turrets or 3 turrets with B axis. Over 45 years of experience in turning machines _ 4,500 multi-spindle turning machines installed around the world _ 4,000 automated turning machines installed around the world _ 50 application technicians for technology and time studies Three tool holders for high efficiency machining of short workpieces, collision free machining with three turrets on the main and counter spindle. Unique 3 turrets with B axis for machining negative angles; swivel range from 23.5 to degrees for angled machining with cost-effective standard tools. Mechanical engineering / short turning Disc Material: CK45 Dimensions: ø mm Medical / plain turning SPRINT 65 with the patented and proven TWIN concept highlights of the sprint 65 with twin concept _ TWIN concept: Cross traverse of the counter spindle-tailstock combination for parallel machining in two independent working areas _ Bar machining up to ø 90* mm, 65 mm as standard _ Large working area, deep hole drilling of over 350 mm on the main and counter spindle possible _ 12-slot VDI 30 turret with TRIFIX precision quick change system _ The highest cutting performance with the Direct Drive turret rated at up to 12,000 rpm _ 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline with ShopTurn 3G Bone screw Material: Titanium Dimensions: ø 6 45 mm (thread) highlights of the sprint 20 8 linear _ Linear drive on the X1 axis for 1 g acceleration and maximum longterm accuracy _ 8 NC axes and two Y axes as standard _ Maximum productivity, 2 tools in use simultaneously _ Automatic workpiece removal for workpieces measuring up to 120 mm as standard _ 0.2-second chip-to-chip time thanks to the linear drive with 1 g acceleration for the shortest non-productive times _ Bar machining up to ø 25 mm, (20 mm as standard) Bar machining up to ø 90 mm*, 65 mm as standard; main spindle rated at 5,000 rpm, 210 Nm and 31 kw; counter spindle rated at 7,000 rpm, 135 Nm and 24 kw; 2 VDI 30 Direct Drive turrets rated at 9,000 rpm and 20 Nm (optionally 12,000 rpm), including TRIFIX precision quick change system

30 30 intro world premières technologies ecoline systems lifecycle services DMG MORI is a very important partnership for us. Without that support none of the results that we see on a Sunday afternoon would be possible. Christian Horner Team Principal Infiniti Red Bull Racing Video of the interview with Christian Horner: Infiniti Red Bull Racing World Champions for the 4 th time with technology from DMG MORI. Sebastian Vettel won the Formula 1 world championship for the first time in 2010 as well as bringing home the Constructors championship trophy for his Infiniti Red Bull Racing team together with his team colleague Mark Webber. Since then the more than 500 employees in the English town of Milton Keynes have gone on to ensure that the double has now been repeated for the fourth time in a row. This incredible success series derives from the many years of racing experience and expertise of the team and their state-of-the-art equipment which includes any number of high tech machines from DMG MORI. If you want to be successful in Formula 1, you have to produce world champion results in all disciplines. Christian Horner, Team Principle at Infiniti Red Bull Racing, is convinced of this and it is why his highest praise goes to the team behind the drivers. But the partner network also has to meet the extremely high demands without which no race can be won. This is true for Renault and Pirelli, the suppliers of the engines and tyres, as well as for Siemens that provides the PLM software and DMG MORI as the supplier of machines for machine shop. For Al Peasland, the person responsible for the technical partnerships, optimum exploitation of the technological equipment in production is a decisive factor. This is true on the one hand due to the limited budget and on the other hand because of the challenge of being faster than the competition when it comes to development. He is convinced: It is thanks to the DMG MORI machines that we are able to produce our complex components so very quickly while at the same time maintaining top quality and precision. Both internal and external communications at Infiniti Red Bull Racing are determined by the high demands placed on production. On the one hand the designers and engineers have to work together closely and on the other hand technological partners such as DMG MORI are also required to contribute their know-how in the respective fields of expertise. With its extensive machining expertise DMG MORI has emerged as an esteemed and valuable innovation partner. The machine park at Infiniti Red Bull Racing currently has 20 CNC-machines from DMG MORI in operation, including no less than eight 5-axis machines from the DMU evo series on which precision parts for wheel suspensions, hydraulics, chassis and gears are produced. The people at Infiniti Red Bull Racing are particularly impressed by the intelligent concept of the NC-controlled swivel / rotary table of the DMU evo centres. The movements of the table are like those of a human hand, so to speak, and this makes understanding and changing over to 5-axis technology far simpler for the operator. DMG MORI also offer ideal 5-axis solutions that include the DMU 200 P and the DMU 125 P duoblock for machining larger components such as carbon gearboxes. The people at Infiniti Red Bull Racing see a parallel between improved lap times on the racing track and the changes that have taken place in the machine shop since they started using 5-axis milling technology. Here, too, a reduction in cycle times is a key criterion for meeting the intense success and deadline pressure. Machine shop at Infiniti Red Bull Racing in Milton Keynes: Production of high tech components on the powerful and dynamic duoblock machining centres Spacious cube-shaped work area for workpieces weighing up to 2,500 kg and maximum long-term precision thanks to the patented duoblock design. 5-axis machining with an NC-swivel / rotary table on a DMU 60 evo.

31 Journal n Success Story milling technology monoblock Next generation: 1,000 machines sold. A range a success story. Racing Technology Advantages for this workpiece: High dynamics = short processing times Large swivel range 5 / +110 Spindle speeds of up to 42,000 rpm Axel journal for the F1 racing cars from Infiniti Red Bull Racing produced on a DMU evo Material: aluminium Be it 5-axis simultaneous machining, highly dynamic and high-speed milling, integrated turn-milling, high-torque machining or in the highly connected field of productive parts manufacturing with 3 5 axes the machine tools of the monoblock are top class bases of competitive machining in almost all sectors. Even after over 1,000 models having been sold, monoblock machines are the best route from raw materials to a masterpiece. ±120 ±120 5-axis simultaneous machining with a swivel rotary table. highlights of the dmu 105 monoblock DMU 60 evo linear Dynamic 5-axis machining with swivel rotary table and linear drive on the X and Y axes. Optimised gantry design for the best stability and a large working area in spite of low space requirements. Dynamic swivel rotary table with a large swivel range of 5 / Linear drives with the best dynamics for reduced processing times and the highest precision. Comprehensive basic equipment with a 14,000 rpm spindle, NC swivel rotary table, tool magazine with 30 slots and direct distance measurement systems. DMU 105 monoblock Maximum stability from one casting. _ Large working area for workpieces measuring up to ø 1,240 mm, 690 mm height and weighing up to 2,000 kg with the swivel rotary table, and for workpieces measuring up to 1,400 1, mm and weighing up to 2,500 kg with the rigid table _ Crane loading from above to over the table centre as standard _ Accessibility and ergonomics: Door opening of 1,700 mm, tool loading from the front during main time and fully accessible from the front, even in automatic mode _ The lowest space requirements on a set-up area of 15 m 2 SK50 / HSK-A100 available for the DMU 105 monoblock monoblock range not palletised DMU 65 / 75 / 85 / 105 / 125 monoblock DMU 65 / 85 / 105 / 125 FD monoblock Pallet version DMC 65 / 85 monoblock DMC 65 / 85 FD monoblock Traverse X / Y / Z: 600 / 500 / 500 mm Rapid traverse: 80 m/min. Table dimensions: mm Load weight: 400 kg Spindle: 14,000 rpm, 18.9 kw, 100 Nm Traverse X / Y / Z: 1,135 / 1,050 / 750 mm; rapid traverse: 40 m/min.; spindle speed 10,000 rpm, output: 13 kw, torque: 83 Nm; workpiece size: ø 1, mm; workpiece weight: 1,500 kg; tool magazine: 30 (60 / 90 / 120 / 180) slots

32 32 intro world premières technologies ecoline systems lifecycle services milling technology DMF range column milling machines with traverse of up to 6 m and workpiece weight of up to 10 t. With traverses of up to 6 m, the DMF range provides maximum flexibility in manufacturing. Be it for the heavy machining of workpieces weighing up to 10,000 kg with spindles rated at up to 413 Nm, 5-axis machining with integrated NC table and B axis, complete machining with turn-mill technology or series production with two separate working areas. An optional linear drive on the X axis guarantees the highest precision and dynamics with a rapid traverse of up to 80 m/min. The DMF range at a glance: Large working area for the greatest flexibility in a range of applications. Z 900 mm 700 mm DMF 180 DMF 260 DMF 260 DMF 360 DMF 600 highlights of the dmf range Y 700 mm 1,100 mm 1,800 mm DMF 180 Maximum flexibility, from the vertical machining of long parts to 5-axis machining and turn-mill technology 2,600 mm 3,600 mm 6,000 mm DMF 600 linear 6 m traverse on the X axis and 10,000 kg workpiece weight X _ For machining long, heavy components of up to 6 m and 10,000 kg _ Heavy machining at up to 413 Nm and SK50 / HSK-A100 _ Production in two working areas with optional working area divider _ 5-axis machining with B axis and integrated C axis _ Turn-mill machining at up to 1,200 rpm _ Thermosymmetrical travelling column for maximum stability across the entire traverse _ Standard version with ball screws, dynamic version with a linear drive on the X axis _ Motor spindle rated at 8,000 rpm (SK40), 14,000 / 18,000 / 10,000 rpm* _ Short chip-to-chip times with the moving tool magazine _ INGERSOLL tool package for milling and drilling * Optional Traverse X / Y / Z: 1,800 / 700 / 700 mm; rapid traverse: 40 (80) m/min; spindle speed: 8,000 rpm; workpiece weight: 1,500 kg; tool magazine: 30 (60 / 120) slots Traverse X / Y / Z: 6,000 / 1,100 / 900 mm; rapid traverse: 80 / 60 / 60 m/min.; spindle speed: 8,000 rpm; workpiece weight: 10,000 kg; tool magazine: 30 (60 / 120) slots

33 Journal n axis machining with integrated NC table and B axis. milling technology 5-axis simultaneous machining on an NVX5080II with the optional 5AX-DDRT200X rotary table. NVX-range Vertical machining centres with outstanding stiffness and durability. The NVX5000II range was developed from the NVX5000 range of premium machines. These vertical machining centres allow for higher productivity and operability thanks to their stiff machine structures. They are equipped with flat slideways with outstanding vibration damping properties. Linear drive on the X axis high precision and rapid traverses of up to 80 m/min. Coolant circulation paths technology integration ULTRASONIC 260: High-efficiency composite machining: 50 % faster manufacturing times with reduced process forces thanks to ULTRASONIC NVX5080II 800 mm traverse on the X axis and 1,000 kg workpiece weight highlights of the nvx range _ Outstanding stability and damping through the use of flat slideways on all axes _ High-torque spindle rated at 8,000 rpm as standard optional 15,000 rpm with the ISO50 holder, with the ISO40 configuration: 13,000 rpm as standard, 12,000 rpm with reinforced spindle and 20,000 rpm with the HSC configuration _ Integrated coolant system in the machine bed and column for improved thermal stability* _ Efficient 4 or 5-axis machining with the optional Direct Drive (DDRT) rotary table * Optional ULTRASONIC complete machining of a CFK central console ( mm); lateral cutting, boring, recesses in under 4 minutes. Traverse X / Y / Z: 800 / 530 / 510 mm; table size: 1, mm; maximum load: 1,000 kg; milling spindle: 8,000 rpm (15,000 / 20,000 rpm optional)

34 34 intro world premières technologies ecoline systems lifecycle services milling technology Linear drive with up to 80 m/min. rapid traverse in all axes as standard. HSC spindle with shaft, flange and jacket cooling. New HSC range: The highest long term accuracy of < 5 µm and surface finishes of under Ra 0.15 The HSC 30 linear and the HSC 70 linear set new standards for precision and surface quality in tool and mould construction. DMG MORI is taking its 20-year HSC history into a new dimension at high speed: Outstanding features include the unique long term precision of under 5 μm thanks to the innovative cooling concept and thermosymmetrical design, as well as perfect surface finishes of under Ra 0.15 thanks to HSC spindles with shaft, flange and jacket cooling. On top of that come the known advantages of linear motors on all axes for the highest dynamics and a 5-year guarantee. The performance capacity is rounded off by numerous specific control system cycles for the HSC technology. The new HSC linear machines are available with CELOS with 21.5" ERGOline and SIEMENS from the 2 nd quarter of 2014 onwards. In addition, both machines can be supplied with Operate 4.5 on SIEMENS 840D solutionline or HEIDENHAIN TNC 640. The new image in the new DMG MORI machine design provides the perfect visual framework for the innovative highlights that are helping to produce perfect components. Still available in 2014: HSC 20 linear, HSC 55 linear, HSC 75 linear, HSC 105 linear HSC centre, Geretsried in Munich Annually, over 2,500 visitors rely on our know-how and find out about the latest technologies and strategies in the tool and mould construction process chain in the HSC centre. The service offered comprises a comprehensive series of seminars and workshops, user training and customer-specific test machining. We also offer our customers support with HSC machining issues. HSC 30 linear The highest precision on 4.5 m² Thermosymmetrical design for the highest component precision: < mm: Linear drives on X, Y and Z with a rapid traverse of 50 m/min and 1.2 g acceleration, and the 40,000 rpm HSC spindle with shaft, flange and jacket cooling as standard. 5-axis version with swivel rotary table. HSC 70 linear A new dimension of precision Thermosymmetrical design for the highest component precision: < mm: Linear drives rated at 80 m/min and 10 m/s² on all axes as standard. Precision spindles rated at up to 40,000 rpm with shaft, flange and jacket cooling. Innovative cooling concept temperature control of the machine bed, drives and guideways. Traverse X / Y / Z: 320 / 300 / 280 mm; rapid traverse: 50 m/min; spindle speed: 40,000 rpm; workpiece weight: 200 kg; tool magazine: 30 (60) slots Traverse X / Y / Z: 650 / 600 / 380 mm; rapid traverse: 80 m/min; spindle speed: 18,000 rpm (28,000 / 40,000); workpiece weight: 700 kg; tool magazine: 30 (60 / 120) slots

35 Journal n Thermo-symmetrical portal construction and innovative cooling concept. ultrasonic 5-axis precision machining of advanced materials (e. g.: sapphire glass, Zerodur, zirconium oxide, silicon carbide / nitride). ULTRASONIC 30 linear: Maximum contour precision and surface finishes of Ra < 0.1 μm when working with advanced materials. ±120 Innovative cooling concept: Thermosymmetrical portal design, HSC spindle with shaft, flange and jacket cooling. With the ULTRASONIC 30 linear, DMG MORI is presenting a new 5-axis precision machine for advanced materials in the highly stable gantry design and holistic temperature management for the highest precision and perfect surface finishes. Thanks to ultrasound supported grinding with minimal process forces, the ULTRASONIC 30 linear makes it possible to attain surface qualities of Ra < 0.1 μm. Linear drives on X, Y and Z with accelerations of over 1.2 g and a rapid traverse of 50 m/min ensure the highest dynamics and contour precision. The ULTRASONIC technology of SAUER is based on a standardised HSK interface which can be flexibly integrated into almost all 5-axis milling machines from DMG MORI. ULTRASONIC ultrasonicoscillation khz ULTRASONIC operation principle: Overlaying the standard tool rotation with an additional oscillation on the Z axis. highlights of the hsc 30 / 70 linear highlights of the ultrasonic 30 linear _ The highest long term precision of under 5 µm thanks to the innovative cooling concept and thermosymmetrical design _ The best surface qualities of under Ra 0.15 thanks to HSC spindles with shaft, flange and jacket cooling _ Linear motors on all axes as standard for the highest dynamics and precision with a rapid traverse of up to 80 rpm and a 60-month warranty _ HAIMER tool holder package for the highest tool clamping precision Tool and mould construction Tool and mould construction Optical industry ULTRASONIC 30 linear 5-axis precision machining of advanced materials with up to a 40 % reduction in process forces _ Complex geometries in precision parts for the optical / watch / medical industries as well as precision mould construction, e. g. made from Zerodur, ceramics and sapphire _ Up to 40 % reduced process forces with ULTRASONIC _ < 5 µm long term stability thanks to the high precision gantry design and holistic temperature management _ Highly dynamic, actively cooled linear drives on X, Y and Z with over 1.2 g _ Flexible 5-axis simultaneous machining with optimal swivel range of ±120 on the B axis Available from June 2014: CELOS from DMG MORI with 21.5" ERGOline and SIEMENS, available now with 19" ERGOline with Operate 4.5 on SIEMENS 840D solutionline Casting mould for the automotive industry Material: Dimensions: mm Ra < 0.2 µm Mould for engine cover Material: Dimensions: mm Ra 0,25 µm Gyroscope Material: Zerodur (glass ceramics) Machining time: 12 hours Tool and mould construction Tool and mould construction Watch industry Stamping tool Material: Dimensions: ø 48 mm Ra 0,15 µm Hip pin die Material: Dimensions: mm Ra 0,22 µm Watch case Material: Sapphire glass Machining time: 18 hours Traverse X / Y / Z: 320 / 300 / 280 mm; rapid traverse: 50 m/min.; acceleration: 12 m/s 2 ; spindle speed: 40,000 rpm; table load: max. 80 kg (5-axis version)

36 36 intro world premières technologies ecoline systems lifecycle services milling technology Milling spindle with SK / BT50 and large spindle bearing for the highest machining speeds (from the NHX5500). NHX range Horizontal machining centres with outstanding stiffness, flexibility and precision. With the NHX, DMG MORI is presenting a compact, rapid horizontal machining centre for highefficiency series production up to mass production in various fields such as the automotive industry and general mechanical engineering. The NHX machines come with DDM technology and direct distance measurement systems on axes as standard. The use of shorter tools close to the centre of the pallet is also factored into the structure of the machines this allows for higher stability in various machining operations. highlights of the nhx5000 highlights of the nhx6300 NHX5000 Horizontal machining centre with the highest precision and dynamics. _ 500-slot pallet machine with up to 700 kg maximum load (500 kg as standard) _ ISO40 tools measuring up to 550 mm in length and 12 kg in weight _ The highest dynamics thanks to the 60 m/min rapid traverse on X, Y and Z _ Milling spindle rated at 12,000 rpm, optional torque increase or HSC spindle rated at 20,000 rpm _ Direct distance measurement systems from Magnescale as standard NHX6300 Highly precise and rapid machining centre with outstanding performance in the machining of large workpieces _ 630-slot pallet machine with up to 1,500 kg maximum load _ ISO50 tools measuring up to 630 mm in length and 30 kg in weight _ The highest dynamics thanks to the 60 m/min rapid traverse on X, Y and Z _ Milling spindle rated at 8,000 rpm, optional torque increase or increased speed rated at 15,000 rpm _ Direct distance measurement systems from Magnescale as standard Maximum workpieces dimensions: ø 800 1,100 mm; maximum table load: 500 kg (700 kg)*; pallet size: mm; tool holder: ISO40 * Optional Maximum workpieces dimensions: ø 1,050 1,300 mm; maximum table load: 1,500 kg; pallet size: mm; tool holder: ISO50

37 Journal n milling technology DMC 60 / 80 H linear: Universal 5-axis machining, resulting in up to 25 % more productivity and precision with linear drives. highlights of the dmc 60 h linear _ Linear drives: Maximum long term accuracy, minimum maintenance costs and 5-year guarantee for the linear drives _ Dynamics: 100 m/min rapid traverse and 1 g acceleration _ Precision: < 4 μm circular accuracy and < 6 μm roundness _ 5-axis compatibility: Integrated swivel rotary table _ Powertrain variants: Direct loading from above _ Set up entirely during main and nonproductive time: chip-to-chip time of just 2.5 seconds _ Machine width of just 2.5 m Ideal for positioning in production lines; space requirements of just 15.6 m² with pallet changer Model with ball screws, rapid traverses of 60 m/min on X, Y and Z At a great entry level price _ Operate 4.5 on SIEMENS 840D solutionline or HEIDENHAIN itnc 530 HSCi _ 5-axis configuration for machining negative angles down to 25 CPP Carrier Pallet Pool: Can be expanded for up to 8 machines and 2 setup stations. User friendly software based MCC-LPS III system controller. 3-layer production of vehicle gearboxes on five highly dynamic precision centres of the DMC 60 H linear. Success Story SITEC GmbH High-precision 24 / 7 production of gearboxes on five DMC 60 H linear machines. SITEC GmbH has been the top German location for over 20 years in terms of high standard machining of a range of materials. High precision machining of series parts, for example for the lorry and commercial vehicle industry, is part of its range of services as well as the 5-axis milling of highly complex individual components. For the 3-layered production of lorry gearboxes, the company recently installed five highly dynamic precision centres of the DMC 60 H linear and in doing so, has attained maximum efficiency and precision since the first workpiece. The strengths of the direct drives are brought fully to bear here, especially with regard to the extremely narrow shape and position tolerances. Besides the excellence of the horizontal centres, the installation offers another special feature. In order to set up all new machines next to one another in spite of the lack of space, the coolant units were installed on a pedestal in cooperation with DMG MORI. This meant that the compact horizontal centres, at just 2.5 metres wide, could be brought even closer together without impairing the accessibility of the control system and tool magazine. The close manufacturing network includes a large streamlining effect together with the integrated clamping hydraulics, as Managing Director Ulrich Sigloch explains: The automatic clamping saves us 2 minutes of set up time with every clamping operation. Together with the short routes and the optimised logistics, 2 employees per shift are enough to optimally manage the 5 centres, where we would otherwise have had to include another operator. Contact: Sitec GmbH Lingwiesenstraße 6, Korntal-Münchingen, Germany info@sitec-praezision.de

38 38 intro world premières technologies ecoline systems lifecycle services dmg process chain DMG process chain Quick and easy to the finished workpiece thanks to CAD / CAM and 1 : 1 simulation. Create with SIEMENS NX CAD, programming with SIEMENS NX CAM and then 1 : 1 simulation of the NC program in the DMG Virtual Machine. Thanks to the perfect combination of the latest CAD / CAM turning and milling technology and exact machine simulation, the productivity of all DMG MORI turning and milling machines can be maximised. dmg mori software solutions Job preparation MORI MfgSuite Simple programming MORI MfgSuite post processor Hassle-free program output MORI MfgSuite NC simulation Powerful machine simulation highlights _ Accurate machine models are provided by MORI SEIKI and facilitate trouble free machine configuration _ Complete integration of the MAPPS parameters _ Virtual machine environment, just like the real machine _ Full compatibility with MAPPS / MORI-AP tool data highlights _ Universal MORI-APT-CL format which can be transferred to the various MORI SEIKI machines _ Integration of the tested standard template for every MORI SEIKI machine _ Adjustable post template that can be tailored to the specific NC program X of the client highlights _ MORI MfgSuite is Windows software which carries out process simulations with powerful and highly precise collision monitoring _ Precise models of MORI SEIKI machine tools are supplied as standard for a simple configuration _ Trouble-free use of the MAPPS parameters

39 Journal n programming siemens nx cad / cam Thanks to the latest NX CAD technology, you can take advantage of extremely fast model preparation based on your type of production. NX CAM supports all the machining strategies of your DMG MORI machine, both in turning and milling. The output of programs by certified post processors guarantees the feasibility of the NC paths. New: Optimised thread machining when turning and perfect radius offset support when milling 1 : 1 simulation dmg virtual machine After automatically loading the NC programs and all relevant resources from NX into DMG Virtual Machine, a unique 1 : 1 machine simulation can be carried out thanks to the full integration of the control system and the exact depiction of the machine geometry and kinematics. Collisions and programming errors are identified before they occur in the machine. New: 30 % higher simulation speed and 30 % higher simulation stability production dmg mori machine tools Now nothing can prevent you from realising your idea on a DMG MORI machine. Manufacture your workpieces on your DMG MORI machine 100 % free from collisions. Even more economical, safe and fast thanks to SIEMENS and DMG MORI! New: Integration of the CTX beta 4A universal turning machine, Integration of the NTX1000 turning and milling machine Job Monitoring DMG Service Agent High availability thanks to punctual maintenance! DMG MORI Messenger Keeping you informed of what is happening in your production! The DMG Service Agent is the intelligent maintenance system aimed at increasing the availability of your DMG machines. The DMG Service Agent informs you about necessary repair work in due time and supports you with the work. The actual machine running time is automatically read from the PLC and is recorded. You plan the execution of your maintenance work, based on this data. Your advantages: Automatic activation of due service and maintenance work Advance notice of maintenance work for worn parts Reduced idle times increased productivity: The new DMG MORI Messenger allows you to access detailed machine status information live wherever and whenever you want. Thanks to permanent on-line monitoring you can always keep an eye on your production and thereby reduce down-times significantly. Your advantages: Clear machine live status Evaluation of machine running time, idle state and disruptions

40 40 intro world premières technologies ecoline systems lifecycle services DMG Programmer 3D Turning 50 % shorter set-up times for multichannel machines. Highlights Advance program testing in the 3D working area simulation Automatic generation of proven structured programming Part production time calculation at the push of a button Can be connected to available CAM systems and Virtual Machine (optional) With DMG Programmer 3D Turning you have a programming and simulation tool that allows you to program quickly and efficiently while minimising programming error related collisions and lost production on your DMG machines. LM Guides Ball Screws Cross Roller Rings Sales Head Offices THK Co., Ltd., Nishi-Gotanda, Shinagawa-ku, Tokyo , Japan, Tel: , thk@thk.co.jp THK GmbH, Hubert-Wollenberg-Str , Ratingen, Germany, Tel: , info.ehq@thk.eu THK (Shanghai) Co., Ltd., 1002 Kirin Plaza, 666 Gubei Road, Shanghai , China, Tel: , THK India Privated Limited, 2nd Floor, 4/4, 1st Main Road, Industrial Town West of Chord Road, Service Road, Rajajinagar, Bangalore , India, Tel: , thkindia@thkind.com THK LM SYSTEM Pte. Ltd., 38 Kaki Bukit Place LM Techno Building, Singapore , Tel: , THK America, Inc., 200 East Commerce Drive, Schaumburg, IL , USA., Tel: , chicago@thk.com Leading Supplier of Linear Technology As the pioneer of the Linear Motion Guide, THK is constantly developing new products in its pursuit of the highest standards in terms of product precision and product rigidity. Both of which are paramount and vital to machine tool manufacturers. THK products along with Caged Ball/Roller technology maximise machine performance, provide a longer service life and are locally available throughout the world. The benefits of using this technology include: a reduction in the frequency and cost of maintenance works and environment conservation with reduced energy consumption and lower dust emissions. THK will continue to support machine tool manufacturers to further their success, by not only offering original and established technologies. But also by developing unique and new technologies, all over the world. Make Anything With ESPRIT That s right. Anything. From simple to complex, use the CAM software that can handle it all. Five-Axis? Multi-tasking? Swiss machining? ESPRIT is created to handle the industry s most advanced CNC machines. And our customer service is icing on the cake. Our applications engineers are always ready to help you overcome whatever challenge you re facing. WE RE READY WHEN YOU ARE GET MOVING 9

41 Journal n nº World première of the DMU 70 ecoline: 5-sided machining with NC swivel rotary table for the highest levels of precision CTX 450 ecoline / CTX 650 ecoline: The new compacts for chuck sizes 250 mm and 400 mm with 3D control technology 3D control technology: The largest entry level selection, Operate 4.5 also supplied as standard with ECOLINE Energy efficiency ECOLINE DMU 50 ecoline NEW // DMU 70 ecoline 5-sided machining with patented NC swivel rotary table.

42 42 intro world premières technologies ecoline systems lifecycle services dmu 70 ecoline DMU 70 ecoline The perfect synthesis of functionality and technology with an NC swivel rotary table for 5-sided machining with the latest 3D control technology as standard! 5-sided machining with patented NC swivel rotary table with digital drives _ Maximum load of 350 kg _ Workpiece mounting surface of ø mm _ Swivel range from 10 to +95 _ Table clamp hydraulic / automatic including electronic angle display and plane transfer After the success of the DMU 50 ecoline, DMG MORI is offering another high-precision 5-sided machining centre in its entry level segment in the form of the DMU 70 ecoline. This will now give operators conscious of price and quality the opportunity to machine larger components from 5 sides: The DMU 70 ecoline comes with traverses of mm on X / Y / Z. The patented NC swivel rotary table its swivel range is from 10 to +95 has a workpiece mounting surface of ø mm and it can be loaded with up to 350 kg. Additionally, it features digital drives and a hydraulic table clamp. The 12,000 rpm spindle and rapid traverses of 24 m/min on the linear axes guarantee impressive power characteristics, while the tool chain magazine with 32 SK40 slots and a rapid double gripper provides the necessary flexibility. Additionally, the DMU 70 ecoline is equipped with a 3D quickset to monitor and correct the machine kinematics and it can be automated. In terms of control technology, Operate 4.5 on SIEMENS 840D and HEIDENHAIN TNC 620 are available, both with the ergonomic SLIMline panel for optimal operating comfort. Powerful main spindle with a speed range of up to 12,000 rpm (13 / 9 kw, 83 / 57 Nm, 40 / 100 % DC) Large traverses X / Y / Z: 750 / 600 / 520 mm Rapid traverse on linear axes: 24 m/min 32-slot SK40 tool magazine Chain with holders and double gripper including set up assistant for tool loading during main time Maximum efficiency NC swivel rotary table with digital drives for 5-sided machining 3D quickset * Tool kit for checking and correcting kinematic precision SLIMline with Operate 4.5 on SIEMENS 840D solutionline or SLIMline with HEIDENHAIN TNC 620 * Optional

43 Journal n ctx 450 ecoline and ctx 650 ecoline The new compacts for chuck sizes 250 mm and 400 mm with 3D control technology. The CTX 450 ecoline and CTX 650 ecoline are the first two turning machines to be developed jointly by DMG and MORI. The new CTX ecoline models combine numerous competences. Their stable design guarantees the highest precision, the comprehensive equipment promises maximum efficiency, the 3D control system technology from SIEMENS, HEIDENHAIN and MITSUBISHI ensures flexibility and the processspecific configurations allow the operator to upgrade the machine to complete turning and milling machining. Large cutting diameters (ø 400 mm / ø 600 mm) and unique bar capacities of ø 65 mm / ø 102 mm (optionally ø 75 mm / ø 110 mm) for this class guarantee flexibility when machining chucks and bars. CTX 450 ecoline The new compact for chuck size 250 mm 3D control technology: _ 15" SLIMline with Operate 4.5 on SIEMENS 840D solutionline _ 15" SLIMline with HEIDENHAIN CNC PILOT 640 _ 10.4" TFT display with MAPPS IV with MITSUBISHI* VDI 40 servo turret* with 12 driven tool stations*. Large bar capacity of ø 65 mm / ø 75 mm*. Space saving installation thanks to optional rear chip conveyor. NEW! CTX 650 ecoline 2,000 Nm torque and chuck size of 400 mm 3D control technology: _ 15" SLIMline with Operate 4.5 on SIEMENS 840D solutionline _ 15" SLIMline with HEIDENHAIN CNC PILOT 640 VDI 50 servo turret* with 12 driven tool stations*. Large bar capacity of ø 102 mm / ø 110 mm*. Water cooled motor spindle rated at 2,000 Nm torque and 230 rpm without gearbox support. 1,905 mm 2,690 mm 1,833 mm Compact set up area of 4.9 m² Swing over bed: 650 mm; turning diameter over slide: 400 mm; longitudinal path (Z): 600 mm; bar capacity: ø 65 mm (optionally ø 75 mm); torque: 370 / 280 Nm (40 / 100 % DC); drive output: 17.5 / 12.5 kw (40 / 100 % DC) Compact set up area 9,8 m² Swing over bed: 860 mm; turning diameter over slide: 600 mm; longitudinal path (Z): 1,150 mm; bar capacity: ø 102 mm (optionally ø 110 mm); torque: 2,000 / 1,700 Nm (40 / 100 % DC); drive output: 48 / 41 kw (40 / 100 % DC) Best performance _ VDI 40 / 50** turret with 12 tool stations as standard _ Optional rapid servo turret with 12 driven tool stations and 6 block tools _ Tool changing time of 0.15 seconds (CTX 450 ecoline) and 0.4 seconds (CTX 650 ecoline) for 1 station at 30 Compact set up area _ Rear chip transporter _ The front of the machine is 30 % slimmer _ Efficient use of the production area (available for the CTX 450 ecoline) Maximum stability _ Optimised cast iron machine beds for the best stiffness and vibration characteristics _ Ball screws of the highest quality and roller guide linear roller guideways _ High rotational precision and durability with the main spindles in 4 bearings * Optional * * Data for the CTX 650 ecoline

44 44 intro world premières technologies ecoline systems lifecycle services ecoline range User-friendly 3D control technology with ergonomic SLIMline panel this is what modern and responsible work stations look like now. ECOLINE 9 machines perfect for any application. ECOLINE from DMG MORI has always endeavoured to continue the unique entry level success story with turning and milling machines. The success of the ECOLINE range is based on four pillars: Proven best in class technologies for optimal performance data The exclusive use of proven components from leading manufacturers for the highest performance Unique 3D control technology and diversity for simple programming and rapid processes Innovative design for more productivity and better ergonomics International production network for maximum customer proximity and minimal additional investment costs Integration into the global network of DMG MORI LifeCycle Services for optimal support ECOLINE Managing Director Ralph Christnacht summarises as follows: Our ECOLINE machines are successful around the world because our customers are able to attain efficient and reliable machining results with a low investment and we are able to respond to the requirements of the markets with our products. This is also reflected in the latest innovative development of the DMU 70 ecoline the expansion to the successful DMU 50 ecoline. Both machines score highly in terms of 5-sided machining thanks to their patented NC swivel rotary tables. Moreover, the ECOLINE family was already expanded recently with the new CTX 450 ecoline and CTX 650 ecoline. Whereas the CTX 650 ecoline focuses primarily on high performance machining with its high-torque drives, the CTX 450 ecoline is a faster all rounder in a range of fields of application with its maximum efficiency and minimal space requirements. The MILLTAP 700 compact machining centre also boasts top values in all types of application and diverse configurations such as the optionally integrated 4 th and 5 th axis and its compatibility with automation solutions. This portfolio means that ECOLINE is universal and is therefore able to provide a suitable response to international demand with its machines. This is underlined by the numerous locations around the world and the high quality service of DMG MORI: ECOLINE is there, where the customer is. CTX ecoline range CNC universal turning machines Sandvik Coromant tool kit for CTX ecoline with six tools for turning, drilling, punching and threading cutting, as well as six suitable VDI 30 / 40 / 50 tool holders and 70 replacement inserts. No compromises during turning VDI 30 / 40 / 50 turret now optionally with up to 12 driven tool stations Large chuck diameter of 210 mm / 210 mm / 250 mm / 315 mm Y axis* on the CTX 510 ecoline for more efficient production when milling and turning in one clamping operation DMC V ecoline range Vertical machining centres Powerful spindle rated at 8,000 rpm, 83 / 57 Nm and 13 / 9 kw (40 % / 100 % DC) and optional motor spindle rated at 12,000 rpm, 83 / 57 Nm and 13 / 9 kw (40 % / 100 % DC) Tool magazine for 20 tool stations (30 stations)* and a rapid double gripper Shorter non-productive times: 30 m/min rapid traverse, tool changing time of 1.6 seconds Impressive natural talents for flexibility and maximum precision Servo turret* with synchronous motor with 50 % shorter tool changing time and hydraulic clamp The highest stiffness and precision and low space requirements thanks to the C-frame design CTX 310 ecoline CTX 450 ecoline NEW! CTX 510 ecoline CTX 650 ecoline NEW! DMC 635 V ecoline DMC 1035 V ecoline * Optional

45 Journal n ecoline range ECOLINE Ready for automation. Opening the door for automated processes in entry level machines: Automated systems have long been an everyday occurrence in mass production. But now, component manufacturers are beginning to recognise the benefits of flexible automation for the productivity of material removal processes. In this context, the ECOLINE range is now raising the bar in the entry level as ECOLINE machines, with their clearly defined interfaces and powerful control technology, are compatible with a range of automated systems right out of the box. The equally flexible and powerful combination of a DMU 50 ecoline or DMC 635 V ecoline with a WH 10 workpiece handling system from DMG MORI Systems, as well as a combination of the MILLTAP 700 with WH 3, are just two examples of numerous possibilities. DMU 50 ecoline and DMC V ecoline MILLTAP 700 Automated door on the right measuring mm and with a distance to the floor of 780 mm for the DMU 50 ecoline and measuring mm for the DMC 635 V ecoline and with a distance to the floor of 760 mm Profibus automated interface from DMG MORI with defined functions Integration into a safety circuit Hydraulic and pneumatic feeds to the work table designed for up to 200 bar of hydraulic and 10 bar of pneumatic pressure WH 10 WH 2 WH 3 Complete machining thanks to integrated accessory options Finished system with high storage capacity and intuitive controls 6-axis industrial robot, loading capacity optionally up to 25 kg 2 or 4-drawer models with a maximum loading capacity of 300 kg per drawer for loading during main time Automated door on the right measuring mm and with a distance to the floor of 770 mm Profibus automated interface from DMG MORI with defined functions Integration into a safety circuit Hydraulic and pneumatic feeds to the work table designed for up to 240 bar of hydraulic and 6 bar of pneumatic pressure High degree of autonomy (up to 2 hours of automatic operation) An automation solution flexibly adapted to the MILLTAP 6-axis industrial robot, loading capacity optionally up to 7 kg 15-slot circulating tool holder system for particularly high storage capacities See page 49 for more on systems DMU ecoline range CNC universal milling machines Sandvik Coromant tool kit for DMC V ecoline / DMU ecoline with four high quality milling tools of the CoroMill series and tool holder optionally ISO 40, BT 40, CAT 40 as well as 30 high performance milling inserts. 5-sided machining with patented NC swivel rotary table The highest efficiency NC swivel rotary table with digital drives for 5-sided machining of simple to highly complex workpieces Powerful spindle rated at 8,000 rpm, 83 / 57 Nm and 13 / 9 kw (40 % / 100 % DC) or 12,000 rpm for the DMU 70 ecoline; optionally increased speed of 10,000 rpm, 83 / 57 Nm and 13 / 9 kw (40 % / 100 % DC) for the DMU 50 ecoline The tool change system of the DMU 50 ecoline features 16 slots in the pick-up magazine and an optional chain tool magazine with holders and double grippers and 30 slots; it features 32 slots as standard for the DMU 70 ecoline MILLTAP High efficiency compact machining centre Sandvik Coromant tools: More productivity! Sandvik Coromant tools suitable for the MILLTAP 700 from DMG and MORI. Sensationally fast with long term precision Patented tool change system with a tool changing time of 0.9 seconds and a chip-to-chip time of under 1.5 seconds Highly dynamic spindle with a maximum torque of 45 Nm and a speed of 10,000 rpm (10,000 rpm high torque*, max. 78 Nm / 18,000 rpm*, max. 40 Nm / 24,000 rpm*) High axis acceleration of 18 m/s², 60 m/min. rapid traverse and linear guides, size 35 Direct distance measurement system on X / Y / Z* for the best repeat and long term precision Direct distance measurement system* and centrally lubricated recirculating roller guides for high long term precision Even more efficient and flexible thanks to the optionally integrated 4 th and 5 th axis a DMG MORI model (DDR) or WH 2 WH 3 workpiece handling. DMU 50 ecoline DMU 70 ecoline NEW! MILLTAP 700 * Optional * Optional

46 46 intro world premières technologies ecoline systems lifecycle services slimline with operate 4.5 on siemens 840d solutionline DMG MORI Messenger: Permanent online monitoring of your DMG MORI machines for more productivity through reduced downtime. Operate 4.5 covers all fields of cutting technology with its drive and control technology. OPERATE 4.5 is the new system platform from DMG MORI for all machines with SIEMENS control systems including for ECOLINE Operate 4.5 covers all fields of cutting technology with its drive and control technology OPERATE 4.5 provides users with a standard operating interface with the latest controls for all technologies OPERATE 4.5 is simply a holistic service package for maximum productivity in machining OPERATE 4.5 on SIEMENS 840D solutionline is included as standard in all ECOLINE machines with SIEMENS control systems 15" SLIMline with Operate 4.5 on SIEMENS 840D solutionline 15" TFT display with a clear screen design The latest generation of software and intuitive user guidance from the drawing to the finished workpiece 3D workpiece simulation Workshop orientated programming with ShopMill or ShopTurn Numerous cycles such as rigid tapping, pocketing and falling contours as standard The program memory consists of 5 MB NC storage and an additional 4 GB on the system CF card 1.5 faster block processing time more performance and less consumption Energy efficiency 30 % 30 % lower energy requirements for machine tools 1) Numerous individual measures are making the ECOLINE the efficiency class. DMG MORI has always strived to develop, design and build innovative and high quality, stateof-the-art machine tools. A machine s energy consumption is increasingly becoming the focus. The ECOLINE machines stand out due to their significant reductions of energy consumption and their prevention of energy loss. 1) The actual energy saving essentially depends on the application and utilisation of the machine tool. The above statements merely identify potentials which can be reached by using latest generation machines instead of previous machine concepts for the same application.

47 Journal n ecoline control systems The right 3D control technology for every user. 15" SLIMline with HEIDENHAIN CNC PILOT 640 / TNC " TFT display with a clear screen design Comfortable programming with the new full ASCII keyboard 1.5 ms block processing time as standard 250 MB program memory on a CF card Workshop orientated programming with graphic support Rapid data interface for externally generated programs Includes workpiece and tool measurement cycles with a single touch system 10,4" TFT Display with MAPPS IV with MITSUBISHI MAPPS IV user system with control console and front end Windows PC 3D machining simulation for easy contour verification Automatic programming function with process menu DNC operation through use of the external and user storage area Import and release of programs over MORI SEIKI servers using external PCs File display and note function for accessing operating instructions, drawings and texts SLIMline with Operate 4.5 on SIEMENS 840D solutionline SLIMline with HEIDENHAIN CNC PILOT 640 / TNC 620 MAPPS IV with MITSUBISHI CTX 310 ecoline CTX 450 ecoline CTX 510 ecoline CTX 650 ecoline DMC 635 V ecoline DMC 1035 V ecoline DMU 50 ecoline DMU 70 ecoline MILLTAP 700 * Standard * without SLIMline 1. Energy recovery! 3. Linear guidance technology 4. DMG AUTOshutdown 5. Innovative 400 V technology Recovery of the braking energy of drive axes and the main spindle for the supply network, energy savings of approx. 10 %. efficient dynamics kwh + 2. Auxiliary equipment with IE2 Energy saving of 5 % compared to IE1.4 thanks to the use of auxiliary equipment like the pump and chip conveyor with energy efficiency class IE2. 50 Hz efficiency: IE % 60 Hz efficiency: IE % IE2 Linear guidance technology ensures lower friction coefficients, therefore: reduced energy consumption thanks to smaller motors reduced impact on the environment thanks to the less frequent use of lubricants Maximal energy efficiency thanks to the configurable machine. Automated and unmanned Systems using energy can be switched off (pumps, pneumatics, screens, light etc.) Wake-up switch-on based on a schedule Starting a warm-up program ENERGY SAVING Reduced heat and reactive power losses of 19 % in the field of control system and drive components thanks to the introduction of the innovative 400 V technology Heat dissipation in W 711 w 200 v 598 w 400 v

48 48 intro world premières technologies ecoline systems lifecycle services ecoline production plants. Wherever you are. Whatever you are producing. ECOLINE is nearby. FAMOT Pleszew Sp. z o.o., Pleszew, Poland DMG Shanghai MT Co., Ltd., Shanghai, China Ulyanovsk MT OOO, Ulyanovsk, Russia NEW! in 2014 Machines: CTX 310 ecoline CTX 450 ecoline CTX 510 ecoline DMC 635 V ecoline DMC 1035 V ecoline DMU 50 ecoline DMU 70 ecoline Machines: CTX 310 ecoline CTX 450 ecoline CTX 510 ecoline DMU 50 ecoline DMC 635 V ecoline DMC 1035 V ecoline MILLTAP 700 Machines: CTX 310 ecoline DMC 635 V ecoline DMC 1035 V ecoline Plants with ECOLINE production: GILDEMEISTER Drehmaschinen GmbH, Bielefeld, Germany Machine: CTX 650 ecoline NEW! in 2014 DECKEL MAHO Seebach GmbH, Seebach, Germany Machine: MILLTAP 700 DMG MORI SEIKI Co., Ltd. Chiba, Japan Machines: CTX 450 ecoline MILLTAP 700 DMG MORI Manufacturing and Digital Technology Laboratory, Davis, USA Machine: CTX 450 ecoline from eni research lubricants and solutions for high tech metalworking. a world moving with you eni refining & marketing cutting fluids and industrial lubricants The research laboratories of eni, leader in the Italian industrial lubricants market, has developed new metalworking products Aquamet coolants Aster mineral based neat cutting oils Metalcut vegetable and biodegradable cutting oils The partnership with DMG/MORI SEIKI calls for the use of eni lubricants, greases and cutting oils on all group s machine tools and encourages the development of new technological solutions for improving the customer s production and manufacturing processes. eni refining & marketing s commercial structure is available to identify the most suitable solutions for all lubrication needs in all European countries. eni refining&marketing via Laurentina, Rome ph eni.com 9 Inveio Uni-directional crystal orientation New GC4325 for steel turning Performance beyond what the eye can see The first insert grade featuring Inveio An innovation at the atomic level has changed the face of metal cutting. The finely controlled structure of its coating guarantees that GC4325 shows longer tool life and more reliable wear in the widest range of steel turning applications. It red efines the performance possibilities of ISO P25 and is everything you ever needed in one single insert. See the whole story at:

49 Journal n nº DMG MORI Systems processes perfectly automated Expertise in all automation sectors: Machine integrated automation, standard automation, flexible production cells and production lines Systems feed belt Connection of an additional feed belt to a cleaning machine increased productivity with 2 3 machines 6-axis robot Feeding and workpiece handling by a 6-axis industrial robot modular expansion The system can be flexibly expanded dmc 55 h duoblock Workpiece machining on 6-axis robot Feed by Fanuc robot 6 DMC 55 H duoblock feed and unloading belt with a custom conveyor belt Flexible production cell + 6 DMC 55 H duoblock machines, workpiece handling up to 40 kg + Prioritised processing by the next available machine + Simultaneous machining of 3 different components More on page 52

50 50 intro world premières technologies ecoline systems lifecycle services Automation solutions for Industry 4.0 DMG MORI Systems Your full solution from a single source. The topic of Industry 4.0 is on everyone s lips around the world. It focuses on systematically increasing the flexibility of products and production by integrating all the stages of a process and supply chain into one smart factory. Therefore, the machine tools industry is also facing a revolutionary period primarily in terms of the inevitably increasing degrees of automation. As your expert partner, DMG MORI Systems can provide you with all fields of flexible automation from a single source. As a universal service provider, we can support you through all phases of project implementation: From detailed situation and job analysis and engineering, installation, set up and training to rapid service support from the largest and most integrated network in the world. Machine Technology The unique automation expertise of DMG MORI Systems is reflected in over 3,000 successful projects around the world. Thanks to our comprehensive portfolio of machine tools and a full range of various automation solutions, we can generate optimal solutions to meet any requirements: From automated stand alone machines to flexible production systems consisting of several production units with sub-processes (e. g. burring, cleaning and marking). Rely on our system expertise and make your company a driver of Industry 4.0. Range of machines for all applications Comprehensive machine expertise for almost all technology Technology planning Machine design Cycle calculation Simulation Analysis, advice and implementation for all automation segments. segment 1 segment 2 Machine integrated automation Standard automation Uwe Kling Managing Director Contact: DMG Automation GmbH Seemühle 5, Hüfingen Tel.: +49 (0) 771 / automation@dmgmori.com Rotary and linear storage As machine accessories, DMG MORI factories have a selection of automation systems which have already been integrated into the machine. Workpiece or pallet handling Efficient robot or portal solutions with additional modules (cleaning, measuring, brushing, etc.) as plug and play solutions or available as customised versions. Our on-line amortisation computer immediately shows you the cost advantages of our standard automation systems. You can find everything to do with automation and the services of DMG MORI Systems online at Optimisation of machining steps within the machine Optimisation of loading and unloading segment 1 segment 2

51 Journal n Over 3,000 successful projects segment 1 Machine integrated automation. dmc 60 h linear with rs 12 highlights _ Maximum productivity with 12 pallets in the system _ Linear drives on X, Y and Z with a 60-month warranty _ High dynamics with 100 m/min rapid traverse and 1 g acceleration _ Intelligent tool magazine with 303 tools for set-up during main and non-productive time _ Chip-to-chip time of only 2.5 seconds Automation Periphery Projection of the entire material flow Layout planning Integration and implementation of all automation solutions Integration of additional operations such as burring, inscribing and cleaning Improved value creation Reduction in manual activities segment 3 segment 4 We even automate third-party products! segment 2 Standard automation. WH 3 U on a CTV 160 Flexible manufacturing cells Production lines highlights _ Automated operation duration of over 1 hour _ Material flow via movable re-stackable baskets _ Almost no workpiece damage _ No manual workpiece transportation _ Maximum basket load of 40 kg _ Travel speed of 2 m per second Linking of multiple process sequences Portal solutions, fixed or mobile robots and additional modules for multi-machine loading with integration of additional operations. Overall solutions in serial production Planning and implementation of pallet, portal and robot handling into the production line, including host computer system. Automation of sequential machining steps segment 3 segment 4 Serial production

52 52 intro world premières technologies ecoline systems lifecycle services segment 3 Flexible manufacturing cells From the blank to the finished workpiece complete machining to meet your requirements. In this segment we project the entire material flow for your workpiece. Together, we create the automation solutions for various machine tools. Of course we will incorporate the necessary additional tasks, for instance deburring, cleaning or assembling, into the optimal workflow. As a result you get an automation cell with maximum productivity. Reference: ZF- Saarbrücken Loading and unloading of measuring machines. Customer advantages: Avoid errors, costs covered in under one year, process optimisation with the customer, high degree of autonomy Cycle time: 12 seconds per workpiece Customer advantages: Tailored to individual requirements Most efficient use of space Large workpiece weights possible Unmanned production Just in time production Turnkey projects Medium and large batch sizes Large number of workpiece variants Success Story Willi Elbe Group A production system thanks to plug & play. The Willi Elbe Group, based in Tamm in Baden-Wuerttemberg and with production plants in Germany, Norway, Switzerland and China, produces full steering modules and steering components for the international car and commercial vehicle industry with approximately 600 employees. The bases of its global success are comprehensive development expertise, modern operational management and the use of the latest manufacturing technology. In this context, one highlight is a flexible manufacturing system from DMG MORI Systems which was initiated and configured three years ago in order to be gradually expanded over time. In the final stage of configuration, the entire system will feature six DMC 55 H horizontal machining centres from DMG MORI. Five of these machines are currently integrated and are loaded and unloaded by robots and connected to a parts cleaning system by a custom feed belt. From there, the workpieces are automatically integrated into the later process stages. Customer advantages: High batch sizes made possible High degree of machine capacity utilisation through machine prioritisation Varied expansion options Custom concept development A complete solution from a single source You can find a detailed description of the system on page 49

53 Journal n segment 4 i range New revolutionary concept for flexible and space saving series production. i50 A production line for crankcases Six i50 machines with loading portals and 2-arm portal loader, buffer for rough parts and robot to transport the finished parts Space saving integration of measuring units, cleaning or deburring stations etc. between the machines Robot to transport the finished parts 2-arm portal loader Buffer for rough parts i concept // i50 Up to 50 % lower space requirements with 100 % more flexibility thanks to the linking of two machines. i80l Compact horizontal machining centre for the serial production of engine components in the automotive sector. Use as double spindle cell A set up area of just 11.3 m² for a combination of two machines as a double spindle cell Control of two machines via a joint mutual system 100 % more flexibility thanks to independent traverse of the axes in every machine Use as production line Minimal space requirement of only 1.5 m machine width or 2.1 m distance form machine centre to machine centre, including 600 mm maintenance space Highlights of the i80l Horizontal machining centre without pallet changer for the serial machining of cylinder heads and cylinder blocks Improved stiffness thanks to the Z axis in the table Double arm tool changer Highly dynamic A axis thanks to the use of Direct Drive motors 1,700 mm 2,700 mm 3,100 mm 3,650 mm 1,490 mm A set up area of just 11.3 m² for a combination of two i50 machines, operation of both machines from one control system. A set up area of just 5.4 m² and low construction height of the working area for short loading and unloading times. 2,550 mm Traverse X / Y / Z: 800 / 550 / 850 mm; workpiece mounting surface on table: 1, mm; spindle speed max.: 8,000 rpm; rapid traverse: 60 m/min; tool magazine: 20 slots; set-up area: m 2

54 54 intro world premières technologies ecoline systems lifecycle services segment 4 Tsuzuki Manufacturing Co., Ltd. Process optimisation through the partial automation of material handling. Success Story Partially automated production line with two linked NHX5000 machines and one NVX7000. Every millisecond counts, especially in mass production. Efficiency is the top priority here. But maximum efficiency cannot always be achieved with a fully automated solution. In the case of the Japanese vehicle supplier Tsuzuki Manufacturing Co., Ltd., DMG MORI Systems had to face a special challenge. The component manufacturer based in the Japanese prefecture of Nagano proudly bears the seal of quality Made in Japan. Tsuzuki enjoys the full confidence of the automotive industry and manufactures parts including key components for chassis, gears and engines. Tsuzuki wanted a production line for its plant in Thailand on which three different gearboxes could be produced simultaneously and in various sizes. With years of experience in optimising machining processes and implementing tailored solutions, DMG MORI Systems and Tsuzuki Manufacturing Co., Ltd. developed a partially automated production line with two linked NHX5000 machines and one NVX7000. Workpiece changing continues to be a manual task it is carried out between the individual machining steps in order to save as much time as possible. Thanks to the automation solution from DMG MORI Systems, Tsuzuki was able to optimise both its productivity and its machining times a complete success. Customer advantages: Simple workpiece changing The manual conveyor facilitates the transportation of heavy workpieces Partially automated production line for highly flexible production Scope of delivery: NHX NVX clamping device bearing + conveyor + clamping device conveyor + clamping device lift + clamping device transfer unit Customer: Tsuzuki Manufacturing Co., Ltd. SAVE GENERATE STORE USE A guide to the energy costs. Reduce your energy consumption with the GILDEMEISTER energy monitor. Sustainable reductions in and the ongoing you identify potential energy savings and define optimisation of energy consumption require and implement measures with its intelligent a continuous energy management process. analytical functions. This saves energy costs and The GILDEMEISTER energy monitor records helps your company remain competitive. all relevant energy consumption and helps Our experts can draw up your optimised energy efficiency solution designed to reduce your energy costs. Contact us and request our introductory offer today. Functions Detailed usage analyses Energy reports at the click of a mouse Cost centre allocation Efficiency assessments based on energy indexes Now Request an introductory offer! Your advantages Easy to integrate Easy to access via your internet browser Intuitive to operate Transparent energy costs across your whole company Ready for ISO GILDEMEISTER energy solutions Tel.: +49 (0) Fax: +49 (0) energysolutions@gildemeister.com a+f GmbH: Carl-Zeiss-Straße Würzburg Germany

55 Journal n nº Service fact check Spare parts around the globe Training straight from the manufacturer around the world Join in the celebrations: 20 years of DMG MORI used machines LifeCycle Services LifeCycle Services more than just a machine

56 56 intro world premières technologies ecoline systems lifecycle services service & spare parts LifeCycle Services available round the clock on a 24 / 7 hotline. Service fact check at dmg mori. DMG MORI customers are right to expect a lot from our service. Anyone who builds machine tools as a premium manufacturer must also provide top service. Therefore, DMG MORI LifeCycle Services is synonymous with highly qualified employees, short response times, availability round the clock and maximum replacement parts availability. The DMG MORI service fact check shows what we offer our customers. Dr. Maurice Eschweiler Board of Industrial Services DMG MORI SEIKI AKTIENGESELLSCHAFT To always be available to our customers is a real bonus. In doing so, we can ensure maximum performance and machine availability. Thomas Wolf Managing Director DMG MORI SEIKI Services GmbH Every day we work on providing the best service. Because our focus is on the customer, no ifs or buts. Speed LifeCycle At DMG MORI LifeCycle Services, our top priority is to be there for our customers round the clock. That s why we have set up a free 24 / 7 service hotline. Our employees answer every call immediately and forward the query to our experienced service technicians on the hotline. At DMG MORI, long waiting times are a thing of the past. We call every customer back quickly and are able to resolve over half of all issues on the phone free of charge. This way, we can guarantee our customers rapid support with problems and maximum machine availability every time. DMG MORI LifeCycle Services expertise, safety, reliability. Our expertise for your productivity. Top service _ Free 24 / 7 service hotline for availability round the clock _ Over 2,500 certified service staff around the world _ 143 sales and service centres for maximum customer proximity _ Our technicians have on average over 10 years of professional experience Top service Customer s Speed & availability Exclusive training know-how from the manufacturer Hungary: Romania: Denmark: Norway: Sweden: +46 (0) Africa: Middle East: +971 (4) South East: _ Prioritised processing of customer phone queries _ Quick call back (normally within one hour) _ 60 % of all queries are resolved over the phone _ Around 270 experienced hotline staff worldwide _ On site with the customer in 24 hours _ Over 200 highly qualified training experts to train machine operators and service technicians _ 11 training centres worldwide _ Customized training courses on site with our customers

57 Journal n DMG MORI Maintenance kits. Manufacturer know-how Services Replacement parts available immediately around the world _ 7 spare parts centres around the world _ Replacement parts availability rate of 95 % _ 170 million in replacement parts worldwide _ More than 100,000 different replacement parts in stock in Geretsried alone _ 5 million investment in our Global Parts Centre in Geretsried _ Available for machines dating back to 1970 Original replacement parts in a full package! up to 30 % compared to ordering a single replacement part highlights _ All important wear parts in one kit _ Perfectly matched to the relevant machine type _ Contents compiled by our experts _ Original spare parts of the highest quality _ Save up to 30 % with an attractive package price _ Ensure machine availability and productivity _ Protection against expensive subsequent damage atisfaction Original replacement parts Our result*: satisfied customers _ Satisfaction with the overall service: 2.0 _ Quality and expertise of field service: 1.7 _ Replacement parts availability: 1.9 _ Hotline satisfaction: 2.1 Example: Service kit for the milling machine DMC 105 V Example: Service kit for the turning machine CTX 600 linear * On a scale from 1 to 6 Spindle maintenance box. highlights We have significantly improved the performance and productivity of our DMG MORI machines with the upgrades and accessories from DMG MORI. _ Professional motor spindle maintenance support _ All components in one system _ Perfectly coordinated based on the tool clamping system _ Ensures machine availability and productivity christian scheid managing director of zsm zertz + scheid maschinenbau- und handelsgesellschaft mbh Availability For the clamping systems SK40, SK50, HSK-63 and HSK-100.

58 58 intro world premières technologies ecoline systems lifecycle services spare parts Tailored training concepts are at the heart of the DMG MORI Academy. DMG MORI Spare Parts Spare parts availability around the globe. germany 1 4 russia 3 usa china 7 2 japan india 5 6 thailand Global spare parts supply 1 germany 5 india Global Parts Centre, Geretsried Indian Parts Centre, Chennai 2 japan 6 thailand Global Parts Centre, Nara Thailand Parts Centre, Ayutthaya uno usa American Parts Centre, Dallas 4 russia Russian Parts Centre, Moscow 7 china China Parts Centre, Shanghai Only original replacement parts from DMG MORI can guarantee maximum production reliability. UNO Unique high tech features for the entry level of tool set up devices highlights _ Global logistics network with 7 Spare Parts Centres on 3 continents (with a storage area of over 60,000 m 2 ) _ Replacement parts availability > 95 % _ Original replacement parts straight from the manufacturer _ Over 100,000 different items in stock Geretsried alone processes over 20,000 orders per month _ Quick delivery to 86 countries _ Over 600 tonnes of air freight per year _ Cost optimised returns process _ New and replacement parts are available _ Many replacement parts also for older ranges dating back to 1970 _ Order via our 24 / 7 service hotline for even faster shipment _ Certified processes under ISO 9001 BF 155 TFT monitor with keypad Long-term discount! Highlights: DIY replacements possible Chassis with stainless steel front plate, integrated keypad and AR-coated protection glass Accessories: Mounting material, ribbon cable, power plug, key caps Availability: For all HEIDENHAIN control systems itnc 530 / MillPlus / MillPlus IT (ID ) Measuring range: X = +200 to 50 mm Z = 400

59 Journal n training DMG MORI Academy: Training expertise built up around the world from a single source. Teachware The DMG MORI Academy is the top choice when it comes to training at a worldclass level. Our customers around the world rely on training skills straight from the manufacturer. As the largest CNC academy in the world, the DMG MORI Academy trains not only our own service technicians in operating, programming and preventative maintenance, but also our customers. We can pass on our knowledge to you book your course today! 11 training centres worldwide, NEW Wernau (DE) and Uljanovsk (RU) under construction Over 200 highly qualified training experts around the world to train machine operators and service technicians 50 training machines worth over 14 million 50 classrooms with over 300 PCs and programming stations Service training for maximum production reliability Train in a future orientated way and produce more productively: Whether it is industrial production or training with software identical to that of the DMG Programming / Training Software, you can programme and train independently of the machine tool. Increase your machine availability and reduce errors by means of test runs on the PC. Contact: Christian Ortmeyer teachware@dmgmori.com Contact: training@dmgmori.com Measuring and testing Innovation Auto-focus + Manual Balluff system + Second camera UNO Tool presetting for maximum productivity. highlights _ FEM optimised and thermally stable cast iron construction _ Personal configuration with the modular design _ Snap gauge principle up to diameters of 100 mm (traverse up to X 50 mm) _ 19" colour monitor _ Fine adjustment Options: NEW Auto-focus to automatically focus on the cutting edge NEW manual Balluff system (RFID chip) NEW second camera to measure the rotating axis 24" touch screen display Convenient system cabinet Adapter shelf The segment illumination of the UNO 20 / 40 makes it easier for us to visually check the cutting edge. The 45 magnification is also impressive. martin knödlseder, manager toolshop global technology eu, sumida ag

60 60 intro world premières technologies ecoline systems lifecycle services used machines dmg mori used machines: Your partner for immediately available dmg mori machines. We are celebrating 20 years of DMG MORI used machines! highlights _ The world s largest seller of used DMG MORI machines for 20 years _ Immediately available offers _ Unique selection _ Certified quality _ Attractive financing solutions SHOWROOM MACHINE USED MACHINE Functional testing tests / geometry control / corrections Original replacement parts replacement of wear and defective parts USED MACHINE Before you bring a used or showroom machine online, it is subjected to a strict and comprehensive battery of tests. All components are painstakingly inspected. If any components are not in their optimal condition, our experts will restore the machine tools to the top level. Wear parts and any parts that are not 100 % in working order are replaced by new, original replacement parts. cleaning Component inspections receiving inspection Pre-delivery inspection 100-hour endurance test customer acceptance We are celebrating 20 years of DMG MORI used machines join in! Our current anniversary offers: CTX beta axis universal turning machine with C axis and tool drive no machine technology type year of manufacture CTX beta A Universal turning machine NZ 1500T3Y3 Universal turning machine MSL 42-7 Automated turning machine NT 4300DCG/1500SZ Turn-mill complete machining centre DMC 635 V ecoline Vertical machining centre DMC 55 H ecoline Horizontal machining centre DMU 80 FD duoblock Universal milling machine for 5-sided machining NVX 5080/40 Vertical machining centre NHX 5000 Horizontal machining centre HSC 55 linear High speed cutting precision centre 2011 Used machine: Year of manufacture: 2013 Machine no: Equipment ISM102 main spindle with semi-hollow clamping device ø 95 mm, ISM 52 counter spindle, C axis and Y axis in place of tailstock, bar machining package for the CTX beta with ø 95 mm, more powerful coolant pump rated at 12 bar and 23 l/min, slat band chip conveyor CTX beta, DMG Netservice on board CNC-SCOUT Find your dream machine in the right configuration online at: cnc-scout.dmgmori.com 9 DMG MORI SEIKI Europe AG Lagerstrasse 14, CH-8600 Dübendorf Tel.: +41 (0) 44 / , Fax: +41 (0) 44 / info@dmgmori.com, Impressum: Journal dmg mori Journal for customers and interested parties. Publisher and responsible for the contents: DMG Europe Holding (Dübendorf, Switzerland). Concept, design, organisation and photos: Montfort Werbung, A-6833 Klaus. Circulation: 600,000 copies. All prices stated in this Journal are based on local list prices (EUR plus packaging, transport and VAT) and may therefore deviate in other countries or be subject to local exchange rate fluctuations. Prices as well as technical changes, availability and prior sale subject to changes. Our relevant General Terms and Conditions apply.