journal nº New design The new DMG MORI design with improved functionality, high level of user-friendliness and value retention.

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1 Magazine for DMG MORI customers and interested parties CELOS from DMG MORI simplifies the process from the idea to the finished product. 18 world premieres at EMO Discover DMG MORI to be a global innovation leader in the field of cutting machine tools. New design The new DMG MORI design with improved functionality, high level of user-friendliness and value retention. journal nº

2 2 emo 2013 celos world premieres ecoline systems lifecycle services emo 2013 highlights dmg mori at emo 2013 Innovative technology at the industry's main event in Hanover. In Hall 2 at emo, dmg mori presented its full range of pioneering cutting technologies to approximately 145,000 international visitors. celos from dmg mori, the new joint machine design and 18 world premieres out of a total of 95 high-tech exhibits excited visitors from all sectors. dmg mori will continue to gradually intensify this successful cooperation in order to continue enhancing today's leading technologies and services for its customers. More detailed information regarding the EMO world premieres and innovations from page 11 onwards Technological milestones at emo 2013 in Hanover. celos From the idea to the finished product 15 machines in the new dmg mori design 18 world premieres A total of 95 high-tech exhibits at emo 2013 All trend-setting developments and highlights from dmg mori can be found in the new, clear journal with 6 topic sections. Order the new journal collection box now by journal@dmgmori.com CELOS From the idea to the finished product. page 2 4 emo highlights page 5 10 celos page emo world premieres dmg mori an impressive presentation of its innovative product range at emo From the idea to the finished product. Compatible. Uniform. Continuous. The new dmg mori machine design. Overview of 18 world premieres.

3 Journal n DMG MORI in hall 2 95 high-tech exhibits including 18 world premieres. World premieres of the HSC 30 linear and the HSC 70 linear in the new DMG MORI machine design. Demonstration of technological expertise in the automotive, medical, aerospace and power engineering sectors. page ecoline page dmg mori systems page LifeCycle services World premieres of the CTX 450 ecoline and the CTX 650 ecoline. The complete ECOLINE series. 3D control system technology. Perfect automation of processes. Modular assembly system. Four automated segments. Focusing on maximising productivity.

4 LM Guides Ball Screws Cross Roller Rings Sales Head Offices THK Co., Ltd., Nishi-Gotanda, Shinagawa-ku, Tokyo , Japan, Tel: , THK GmbH, Hubert-Wollenberg-Str , Ratingen, Germany, Tel: , 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: , 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: , 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. Probe TC64-DIGILOG LaserControl NT Revolutionary: High-precision measurement and cyberspeed scans. gy Made in German No. 1 Worldwide. High Performance. Blum. y y Production Metrology Made in Germany Anzeige_DMG_Journal_final.indd :05:47 Precision meets Motion Live demonstration on the machine! Hall 4 Stand F64 Races are won at the pit stop! for CNC-lathes - The new standard for torques up to 200 Nm one-hand operation integrated tool ejection system tool change within a view seconds The quick-change-system also for the heavy duty machining! EWS Weigele GmbH & Co. KG D Uhingen Tel. +49(0) Von der Idee zum perfekten Werkzeug UK From the idea to the perfect tool Ingersoll Werkzeuge GmbH Telefon: +49 (0) Hauptsitz: Telefax: +49 (0) /814 Kalteiche-Ring D Haiger info@ingersoll-imc.de

5 Journal n nº CELOS from the idea to the finished product CELOS APPs simplify operation CELOS job manager job assistant cad-cam view tech calculator celos status monitor documents organizer netservice machine check energy saving settings status monitor control

6 6 emo 2013 celos world premieres ecoline systems lifecycle services 21.5" ERGOline control panel with multi-touch monitor multi-touch operating panel for pioneering operating comfort with unique functionality 30 % faster at the product from the idea CELOS with 21.5" ERGOline and mitsubishi Machine delivery with CELOS from the 2 nd quarter in 2014 onwards. to the finished product. celos from dmg mori simplifies and accelerates the process from the idea to the finished product. celos APPs allow the user consistent management, documentation and visualisation of order, process and machine data. celos eliminates the interface between the workshop and higher level company structures and thereby creates the basis for a consistently digitalised, paperless production. celos is compatible with pps- and erp-systems, can be linked to cad / cam applications and is open for future-oriented celos APP extensions. celos from dmg mori with 21.5" ergoline is available with siemens and mitsubishi. CELOS with 21.5" ERGOline and siemens Machine delivery with CELOS from the 2 nd quarter 2014 onwards.

7 Journal n " ERGOline control panel with multi-touch monitor celos status monitor Here celos visualises the current condition of the machine regarding the process, provides important key figures about the current order and order progress and informs the operator with special icons and text messages about possible NC errors or imminent maintenance work Infinitely variable adjustment of the screen and the keyboard smartkey Customised user authorisation. Individually adapted access privileges to the control system and the machine. new // with internal USB memory Keys for the selection of operating mode Release button for machine functions in operating mode compatible Compatible with PPS and ERP systems. Can be networked with CAD / CAM products. Open to trendsetting CELOS APP extensions. uniform Uniform, intuitive user interface for all high-tech machines from DMG and MORI. consistent Consistent administration, documentation and visualisation of order, process and machine data.

8 8 emo 2013 celos world premieres ecoline systems lifecycle services uniform user interface with touch operation compatible, uniform, consistent. celos app selector: Central access to all available applications. celos supports the user in daily practice with a process-oriented menu structure. Thanks to the touch functionality of celos the user gets to the app selector with one single touch. Similar to a smart phone or tablet PC, the user has got direct access to all available APPs, which are differentiated according to their application field and can be selected with a single touch via the app selector. At emo 12 celos APPs will be available. For instance, celos APPs like the job manager or job assistant support machine operators with the network-integrated preparation, optimisation and systematic processing of production orders (with work pieces, equipment and NC programmes).

9 Journal n CELOS APPs simplify fast and easy operation: 3 Examples» job manager Systematic planning, administration and preparation of orders. Machine-related creation and configuration of new orders Structured saving of all productionrelated data and documents Easy visualisation of orders, including NC programme, equipment, etc. job assistant Defining and processing 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 cad-cam view Visualise work pieces and optimise programme data. Direct remote access to external CAD / CAM workstations Central master data as basis for component visualisation Immediate change options for machining steps, NC programmes and CAM strategies, directly in the control system visionary workshop of the future With its open structure and integration ability, celos offers unique opportunities for the expansion of functionality with targeted applications.

10 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 Perfect spindle, perfect chips If you are looking for a reliable partner to have your machines running 24/7, look no further! KESSLER has been working with the machine tool industry for more than 90 years: As a system partner, we offer our customers complete solutions along the entire product development process and build exactly the components you need to build your high-end products - from spindles, spindle systems and main drives to complete rotary swivel tables. Visit our booth D12 in Hall 25 at the EMO in Hannover from September 2013 or give us a call: High-tech Spindles Motor Technology System Engineering Service Solutions Grooving, part-off, perfection. Performance at its peak UK Hall 5 Stand B49 Whichever alloys you have to machine, Horn offers innovative solutions. Efficient, economical, precise; individually customized when required to create the perfect process. Ours is the most complete grooving and part-off program worldwide, supported by expert process planning and augmented by first class special tool design and build capability. As a technology leader, we define the standards in the sector. With more than 18,000 standard precision tools and experience of more than 100,000 application solutions, we are your advantage. CTX/TC technological package HORN LEADERS IN GROOVING TECHNOLOGY GROOVING PARTING SLOT MILLING BROACHING COPY MILLING DRILLING REAMING

11 Journal n nº The new DMG MORI machine design Overview of 18 EMO world premieres 18 world premieres nlx 2500/500 nlx 3000mc/1250 nlx 4000by/1500 ctx beta 2000 tc ctx 450 ecoline ctx 650 ecoline ctv 315 linear dmc 85 fd monoblock dmu 80 p duoblock sprint 65 dmc 650 v dmf 600 linear ultrasonic 30 linear hsc 70 linear hsc 30 linear i80l uno dixi 270

12 12 emo 2013 celos world premieres ecoline systems lifecycle services emo machines of the new DMG MORI design live at emo The combined strength will in future be underlined by the uniform machine design. The new design of dmg mori is available at no extra cost, either in black or in white. from dmg mori NLX 2500SY (white version) NLX 2500SY available from the 2 nd quarter 2014 onwards with CELOS from DMG MORI with 21.5" ERGOline and MITSUBISHI.

13 Journal n The holistic high quality standard of DMG MORI is illustrated by the new joint design at EMO. Visitors can convince themselves of the advantages of the new design thanks to more functionality, added user-friendliness and retention of value on 15 high tech machines. Besides all of the technical features, the customer can choose between two machine designs. The new design of DMG MORI is available at no extra cost, either in black or in white. improved functionality Maximum view into the working area for better monitoring of the production process. Improved functionality: e. g. assembly the safety glass from the outside. user-friendliness CELOS from DMG MORI: ERGOline Control with 21.5" multi-touch-screen and common user interface. retention of value / long-life surfaces Premium range in fine structure for higher scratch resistance and protection against damage. from dmg mori DMU 80 P duoblock (black version) DMU 80 P duoblock available from the 1 st quarter 2014 onwards: 19" ERGOline with HEIDENHAIN TNC 640 or with Operate 4.5 on SIEMENS 840D solutionline, from the 2 nd quarter 2014 onwards: CELOS from DMG MORI with 21.5" ERGOline and SIEMENS.

14 14 emo 2013 celos world premieres ecoline systems lifecycle services Overview of the scene of 18 EMO world premieres. turning technology NLX three world premieres complement the series. A A Coolant system Integrated coolant circulation in the machine bed for improved thermal stability. B Flat tracks 30 % wider, highly stable flat tracks allow high performance turning. highlights of the nlx series _ Integrated coolant circulation in the machine bed for improved thermal stability _ Slideways in all axes for better dampening characteristics _ With BMT technology (turret with integrated drive motor), the milling performance is comparable to that of machining centres _ Available in various configurations (e. g. with directly driven tools, Y-axis, powerful counter spindle) NLX 2500/500 Perfect 2-axis turning on 3.5 m 2 for workpiece lengths of up to 500 mm The success model of the NLX series, the NLX 2500 is now also offered by DMG MORI with 500 mm turning length. A maximal turning diameter of 460 mm as well as traverses of 260 mm and 500 mm in the X- and Z-direction make the NLX 2500/500 one of the most versatile instruments for turning. The optimised machine design has a small footprint (3.5 m 2 ). The successful NLX series with more than 1,200 installed machines per year. NLX1500/500 MC, Y, SMC, SY NLX2000/500 MC, Y, SMC, SY NLX2500/500* NEW! Turning NLX2500/700 Turning, MC, Y, SMC, SY NLX2500/1250 MC, Y, SMC, SY NLX3000/700 Turning, MC, Y NLX3000/1250* NEW! MC, Y NLX4000/750 MC, Y // A/B configuration NLX4000/1500* NEW! MC, Y // A/B configuration Available immediately with MAPPS IV and 10.4" TFT display.** * Available from April 2014 only in new design and CELOS ** 19" for NLX4000 technical data Maximum turning diameter: 460 mm, max. turning length: 500 mm, bar capacity: 80 mm, speed: 3,500 rpm, drive power rating: 18.5 kw, 10-fold turret (optional 12-fold turret)

15 Journal n B Three world premieres of the new DMG MORI design complement the successful NLX series at EMO. Since the market introduction of the NLX series at the end of 2010, more than 2,500 units were 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 NLX- 3000MC/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 rest with a maximum diameter of 350 mm as well as the option with the Y-axis with a turning diameter of up to 500 mm. The NLX4000BY/1500 also convinces with a very compact construction for the machining of large workpieces with driven tools up to 4,000 rpm (10,000 rpm*) and Y-axis. All three NLX world premieres will be presented on EMO with CELOS with 21.5" ERGOline and MITSUBISHI, and are available from April BMT Built-in Motor Turret Improved milling performance with up to 100 Nm torque and improved milling precision. * Optional NLX 3000MC/1250 Precision high performance turning and milling with BMT turret up to 1,250 mm turning length BMT technology for outstanding milling performance of driven tools with 10,000 rpm, bar capacity up to ø 103 mm, machining of long workpieces up to 1,250 mm NLX 4000BY/1500 Efficient full machining of large workpieces up to 500 mm diameter (600 mm diameter without Y-axis) BMT technology for outstanding milling performance of driven tools with rpm (10,000 rpm optional), M30 tapping with up to 100 Nm torque, wide slideways in the Z-axis, long traverse in the X-axis, steady rest up to a maximum ø 350 mm white version The new design of DMG MORI is available at no extra cost, either in black or in white. technical data Maximum turning diameter: 430 mm, max. turning length: 1,250 mm, bar capacity: 103 mm, speed: 3,000 rpm, drive power rating: 22 kw, 10-fold turret (optional 12-fold turret), speed of driven tools: 10,000 rpm technical data Maximum turning diameter: 500 mm (600 mm diameter without Y-axis), max. turning length: 1,500 mm, bar capacity: 164 mm, speed: 1,500 rpm, drive power rating: 37 kw, 10-fold turret (optional 12-fold turret), speed of driven tools: 4,000 rpm with 100 Nm specification (10,000 rpm optional)

16 16 emo 2013 celos world premieres ecoline systems lifecycle services ecoline turning technology CTX 450 ecoline, CTX 650 ecoline: Smallest footprint of its class for chuck sizes of 250 mm and 400 mm with 3D control technology. CTX beta 2000 TC: Turn-Mill complete machining with the largest Y-traverse of 300 mm in its class. More turning power in the entry class The two world premieres CTX 450 ecoline and CTX 650 ecoline are now continuing what ECOLINE has already been promoting for years: top technology with proven components at the best price. In relation to the small compact footprint of 4.9 m² or 9.8 m², the large working area has been constructed for maximal work piece machining. The optional highly dynamic servo turret with up to 12 driven tool stations, the short cycle times, the large bar capacities, optionally up to 75 mm or 110 mm, as well as the wide guideways and linear guides for the best rigidity values and positioning precision are just some of the technical highlights. Turn-Mill complete machining The new CTX beta 2000 TC complements the successful CTX TC series and additionally offers a favourable entry into Turn-Mill complete machining of parts up to 2 m turning length. Among other things the world premiere convinces with the large working area with work pieces up to ø 550 2,050 mm, with 300 mm the largest Y-traverse in its class and the ability to use steady rests up to ø 350 mm. For demanding full machining up to 770 Nm torque is available at the main and counter spindle. In addition the powerful turn-mill spindle with speeds up to 18,000 rpm allow production of complex structures right up to 5-axis simultaneous machining. More in the ECOLINE section from page 31 CTX 450 ecoline Small footprint for chuck sizes of 250 mm 3D control system 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 from MITSUBISHI* VDI 40 servo turret* with up to 12 driven tool stations*. Large bar capacity up to 65 mm / 75 mm*. Optional available rear chip conveyor for a space-saving installation. Small compact footprint 4.9 m². CTX 650 ecoline Up to 2,000 Nm torque and chuck size 400 mm 3D control system technology: _ 15" SLIMline with Operate 4.5 on SIEMENS 840D solutionline _ 15" SLIMline with HEIDENHAIN CNC PILOT 640 VDI 50 servo turret* with up to 12 driven tool stations*. Large bar capacity up to 102 mm / 110 mm*. Water-cooled motor spindle and up to 2,000 Nm torque at 230 rpm, without gearbox support. Small compact footprint 9.8 m². * Optional * Optional technical data Swing diameter, max.: 650 mm, turning diameter, max.: 400 mm, longitudinal travel (Z): 600 mm, bar capacity: 65 mm (optional 75 mm), torque: 370 / 280 Nm (40 / 100 % DC), 17.5 / 12.5 kw (40 / 100 % DC) technical data Swing diameter, max.: 860 mm, turning diameter, max.: 600 mm, longitudinal travel (Z): 1,150 mm, bar capacity: 102 mm (optional 110 mm), torque: 2,000 / 1,700 Nm (40 / 100 % DC), 48 / 41 kw (40 / 100 % DC)

17 Journal n Large working area for the use of chucks up to ø 400 mm and steady rests up to ø 350 mm. Turn-Mill complete machining of work pieces up to 2 m turning length with powerful B-axis milling spindle; speed up to 18,000 rpm and ±120 swivel range. Up to 60 % time saving thanks to easy programming with exclusive technology cycles. CTX beta 2000 TC Turn-Mill centre for work pieces up to ø 550 mm and 2,050 mm turning length with Operate 4.5 on SIEMENS 840D solutionline Operate 4.5 the new system platform of DMG MORI for all machines with SIEMENS control system _ From entry up to the high-end class _ Operate 4.5 comprises the entire automation technology of a machine tool, from the drives to the CNC control system _ Uniform operator interface for all technologies _ Holistic performance package for maximal productivity in machining highlights of the ctx beta 2000 tc technical data max. workpiece length: 2,050 mm, max. workpiece diameter: ø 550 mm, max. swing diameter: ø 630 mm, Y-traverse: ±150 mm, main spindle ISM 76 with 5,000 rpm, 380 Nm and 34 kw, turn-mill spindle with 12,000 rpm, 100 Nm and 22 kw, tool disc magazine with 24 positions, optional chain magazine with up to max. 100 positions _ 6-side full machining thanks to main and counter spindle* _ Off-centre machining with Y-axis with 300 mm traverse _ B-axis with Direct Drive for up to 100 rpm rapid traverse _ Optimal accessibility thanks to reach to the main spindle of 530 mm _ Full machining with main and counter spindle* up to 5,000 rpm or up to 770 Nm torque _ Only 17.7 m 2 space requirement _ HORN / LMT / SCHUNK tool package for turning, milling and drilling * Optional

18 18 emo 2013 celos world premieres ecoline systems lifecycle services turning technology CTV 315 linear: Vertical turning of large work pieces up to ø 300 mm and linear drive for the shortest non-productive times. CTV 315 linear: Automation with integrated prism conveyor belt for work pieces up to ø 300 mm and 25 kg. Large working area for machining of work pieces up to ø 300 mm and a function plate (optional) for the use of additional tools. The new benchmark in vertical turning At EMO, DMG MORI presents the 2 nd generation of the CTV series with the CTV 315 linear. The new CTV 315 linear allows machining of work pieces up to 300 mm diameter, 210 mm height and 25 kg weight. The large working area offers sufficient space for a 12-fold VDI 40 turret and additional tools or for a milling spindle, which can be mounted on a function plate (optional). In addition the turret is also available for driven tools as Direct Drive turret up to 10,000 rpm or with VDI 50 holder. The production-optimised STEALTH design with the integrated 15" SLIMline panel offers a small footprint as well as optimal accessibility to the working area and automation. In conjunction with the (optional) Y-traverse and the large Z-traverse, a wide work piece spectrum between 20 mm and 300 mm diameter can be machined with high precision, quickly and dynamically. This is ensured by the linear drive of the X-axis, which minimises non-productive time during tool change with its 8 m/s² and guarantees high long-term precision. DMG MORI offers a 60-month warranty on the linear drive. The CTV 315 linear is equipped with Operate 4.5 on the SIEMENS 840D solutionline. Operate 4.5 is the new consistent system platform of DMG MORI for all machines with SIEMENS control system. Operate 4.5 offers significantly more performance, starting with the drive technology, via the PLC up to the control system user interface. Shortest non-productive times thanks to linear drive with 100 m/min rapid traverse. CTV 315 linear Integrated automation for up to 52 work pieces or work pieces up to 300 mm diameter highlights of the ctv 315 linear _ Customised automation optional, e. g. as integrated prism conveyor belt for work pieces up to ø 300 mm or for up to 52 work pieces _ Large working area with a function plate* for additional tools or a milling spindle _ Short non-productive times due to a linear drive in the X-axis with 0.8 g acceleration and the highest long-term precision _ Machining of complex work pieces thanks to the optional Y-axis with ±50 mm traverse stroke _ Direct Drive* turret for driven tools up to 10,000 rpm * Optional Maintenance-free linear drive in the X-axis for the highest long-term precision, 60-month warranty on the linear drive. Automotive Automotive Hub carrier Material: 41 CrMo4 Dimensions: ø mm Machining time: 164 / 173 sec. (OP10 / OP20) Steering nut Material: 42 CrMo4 Dimensions: ø mm Machining time: 138 / 158 sec. (OP10 / OP20) technical data ø 300 mm max. work piece diameter and 210 mm max. work piece height, chuck up to ø 315 mm, X / Y / Z traverse: 1,100 / ±50* / 300 mm, 12-fold turret VDI 40 (VDI 50*), driven* tools up to 4,000 rpm, or as direct drive* turret up to max. 10,000 rpm (* optional)

19 Journal n turning technology Working area with three turrets and B-axis at the lower turret. SPRINT 65: Up to three turrets with three Y-axes and unique B-axis with Direct Drive The SPRINT 65 is built at the completely modernised site of GILDEMEISTER Italiana, Brembate di Sopra and complements the successful SPRINT series. The SPRINT 65, which is presented on EMO, is equipped with three turrets, of which the lower turret has a unique B-axis for automated production turning machines. The swivel range of the B-axis from 23.5 to degrees allows machining of negative angles with cost-effective standard tools. Alternatively the SPRINT 65 can also be equipped with three turrets without a B-axis. In the cost-effective entry level option the machine has two turrets, including the patented and thousand-fold proven TWIN concept. This unique working area concept with two turrets and the cross traverse of the counter spindle-tailstock combination allows parallel machining in two independent working areas. The focus of the SPRINT innovation is on highly efficient production turning in series production. The 12-fold VDI 30 turrets are consistently equipped with driven tool stations, including Direct Drive technology, and thereby offer speeds of up to 12,000 rpm (9,000 rpm as standard). The TRIFIX precision quick change interface for set-up times of less than 30 seconds and a repetition precision of < 6 µm is also standard. The application field of the SPRINT 65 models is full machining of bars up to 65 mm or (optional) 90 mm diameter. Three tool holders for highly productive machining of short work pieces, collision-free machining with three turrets on the main and counter spindle. SPRINT 65 with B-axis Unchallenged thanks to the lower turret as B-axis for machining of negative angles highlights of the sprint 65 with b-axis _ Bar machining up to ø 90* mm, 65 mm as standard _ Large working area, deep hole drilling of 350 mm on the main and counter spindle possible _ 12-fold VDI 30 turret with TRIFIX quick change system for < 6 µm repetition precision _ Highest machining performance due to direct drive turret with up to 12,000 rpm _ Optimal chip discharge for wet, oil and dry machining thanks to vertical or steeply inclined covers in the working area * Optional Machining of long work pieces 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. technical data Bar machining up to ø 90* mm, 65 mm as standard, main spindle with 5,000 rpm, 210 Nm and 31 kw, counter spindle with 7,000 rpm, 135 Nm and 24 kw, 3 VDI 30 Direct Drive turret with 9,000 rpm and 20 Nm (12,000 rpm optional), B-axis with 23.5 to swivel range

20 20 emo 2013 celos world premieres ecoline systems lifecycle services milling technology The duoblock 4 th generation for 30 % more precision, performance and efficiency. Unique! New B-axis with 20 % higher rigidity due to larger bearing, extended swivel range and integrated cable carrier. The DMU 80 P duoblock of the 4 th generation from DMG MORI in the new uniform design offers 5-axis machining at the highest level and unique performance features. Highest long-term accuracy and precision with up to 5 μm positioning precision and up to 30 % higher part precision are achieved due to comprehensive cooling system. Another highlight is the powermaster 1000 motor spindle with up to 1,000 Nm torque and 77 kw power rating. The 30 % higher rigidity provides the best prerequisites for maximal machining performance. Highest flexibility and productivity is offered by the new compact wheel magazine with up to 363 tools, shortest tool change Highest precision, maximal performance and compact construction with wheel magazine for highest productivity. times of 0.5 seconds and the possibility of parallel set-up during main time. Highest rigidity due to larger bearing and shortest machining times are also guaranteed by the new B-axis with 250 swivel angle with integrated cable carrier. The list of impressive features of the DMU 80 P duoblock is complemented by requirements-based power supplies, which reduce energy consumption by up to 30 %. CELOS from DMG MORI with 21.5" ERGOline and SIEMENS will be available for the DMU 80 P duo BLOCK from the 2 nd quarter 2014 onwards. In addition this machine can be supplied with Operate 4.5 on SIEMENS 840D solutionline or with HEIDENHAIN TNC % improved temperature stability thanks to more intensive cooling measures. highlights of the dmu 80 p duoblock _ Precision: up to 30 % higher part accuracy and precision due to fully fluid-cooled feed drives _ Performance: 30 % higher rigidity for maximal productivity with the powermaster 1000 motor spindle with max. 1,000 Nm torque and 77 kw power rating _ Efficiency: 30 % reduction of energy consumption due to requirements-based power supplies _ Highest flexibility and shortest machining times with the new B-axis with 20 % more rigidity, 250 swivel range and integrated cable carrier _ INGERSOLL tool package for milling and drilling Standard cooling measures Precision package Headstock X / Y / Z ball screw nut NC rotary table X-axis motor Basic construction Cooling strips on the machine bed and column Thermo shield

21 Journal n milling technology DMC 85 FD monoblock : Mill-Turn with 3-fold pallet changer for maximal productivity. The DMC 85 FD monoblock complements the success series of the universal monoblock machines. With 5-axis simultaneous machining, pallet changer and Mill-Turn equipment the DMC 85 FD monoblock is among the most versatile machining centres. Compact with a footprint of only 22 m², the machine can accommodate work pieces with a height up to 600 mm, 800 mm diameter and 800 kg weight. A spindle with a speed of 18,000 rpm is available for machining as standard. The FD swivelling rotary table offers a speed up to 800 rpm for demanding turning operations as well as a swivel range of ±120 for complex milling operations. The DMC 85 FD monoblock also features the attribute of optimal accessibility, both of the pallet changer and the working area and tool magazine. Compact, patented, intelligent technology allows quick chip-to-chip times and short set-up times. Mill-Turn machining: FD swivelling rotary table with a speed of 800 rpm. DMU 80 P duoblock duoblock in 4 th generation: excellence redefined DMC 85 FD monoblock Full machining with Mill- Turn (FD) for work pieces up to 800 kg 5-axis milling and turning with pallet changer 3 pallets, up to 800 kg max. loading weight per pallet. Work pieces up to ø 800 mm. Best accessibility and ergonomics on the market: full accessibility from the front to the working area and crane loading from above up to the centre of the table. Only 22 m2 space requirement (including standard chip conveyor) complete package including swivelling rotary table and chip conveyor. Full machining with milling and turning on one machine in one clamping operation with direct drive technology. technical data Traverse X / Y / Z 800 / 1,050 / 850 mm, B-axis with 250 swivel range, table loading up to 1,500 kg technical data NC swivelling rotary table with swivel range of ±120 as standard, spindle with 18,000 rpm, workpiece weight: max. 1,500 kg via crane, max. work piece diameter ø 800 mm, max. work piece height 600 mm

22 22 emo 2013 celos world premieres ecoline systems lifecycle services milling technology Large working area for work pieces up to 800 kg. DMC 650 V: Unique machine concept for powerful machining with up to 303 Nm. More technology for less money The DMC 650 V with CELOS from DMG MORI and in the new design as a machining centre of the 3 rd generation combines the experience from more than 10,000 successful installations of this series. Even in the standard version the DMC 650 V has a 14,000 rpm basic spindle with 121 Nm torque, rapid traverses up to 36 m/min and is designed for machining work pieces of up to 800 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 pockets are also available. Significantly higher precision is achieved thanks to cooling of the drives and guides. Stable construction and SK50 spindle up to 303 Nm The milling performance of the DMC 650 V can be adapted to the relevant applications with the aid of a large selection of spindles. From the standard spindle with 14,000 rpm and 121 Nm via motor spindles with up to 24,000 rpm to the SK50 or HSK100 spindles with 303 Nm torque the kit comprises solutions for both precision and heavy-duty machining. Large field of application Die and mould industry Die and mould industry DMC 650 V The new vertical machining centre with a unique machine concept for more performance and flexibility highlights of the dmc 650 v _ Powerful equipment, already in the standard version Basis spindle with 14,000 rpm / 121 Nm, 36 m/min rapid traverse _ SK50 spindle with 303 Nm (optional) _ Tool magazine with up to 120 pockets _ Work piece weight up to 800 kg _ 30 % higher precision thanks to cooled drives and guides _ With experience from more than 10,000 supplied vertical machining centres _ SANDVIK COROMANT tool kits for milling, drilling and tapping Forging die for connecting rods Material: steel Dimensions: mm Form plate for injection moulding Material: steel Dimensions: mm Machine construction Automotive With CELOS and SIEMENS from the 2 nd quarter 2014 onwards. Planet carrier Material: GGG30 Dimensions: ø mm Cross member Material: forged part C45 Dimensions: approx mm technical data Travel X / Y / Z: 650 / 520 / 475 mm, rapid traverse: 36 m/min spindle speed 14,000 rpm, power rating: 14.5 kw, torque: 121 Nm, table size: mm, workpiece weight: 800 kg, tool magazine: 20 (30 / 60 / 120) positions

23 Journal n milling technology Linear drive in the X-axis for high precision and rapid traverse speeds up to 80 m/min. DMF linear: Dynamic travelling column centre with linear drive and 6 m X-traverse for work pieces up to 10 t. Travelling column centre in XXL-format The DMF linear supplements the programme of the DMF series with traverses of 6,000 mm 1,100 mm 900 mm and 10,000 kg loading weight. A characteristic feature is the linear motor in the X-axis for high precision, fast rapid traverses of up to 80 m/min and short non-productive times during tool change. The rapid traverses in the Y- and Z-axis is 60 m/min. The HPC casting machine bed and the thermo-symmetric travelling column guarantee high rigidity and long-term stability. The optional working area separation wall, offers unattained user flexibility and productivity thanks to pendulum machining in two large working areas. 3 rd generation DMC V: _ Highly stable construction with rigid table and slide unit arranged on top _ Cooled guides and drives for high temperature stability DMF linear 6,000 mm traverse in the X-axis and 10,000 kg workpiece weight highlights of the dmf linear _ Linear drive in the X-axis for highs traverse speeds and precision with a 60-months warranty _ Large working area up to 6,000 mm traverse in X, 1,100 mm in Y and 900 mm in Z for long work pieces or the most efficient pendulum machining _ Workpiece weight up to 10,000 kg _ 5-axis machining and mill-turn technology with B-axis* and integrated NC table* _ Large spindle variety up to 18,000 rpm or 10,000 rpm with SK50 / HSK-A100 and 413 Nm _ INGERSOLL performance package for milling and drilling * Optional With Operate 4.5 on SIEMENS 840D solutionline from November With HEIDENHAIN TNC 640, from November technical data Travel X / Y / Z: 6,000 / 1,100 / 900 mm, speed: 8,000 rpm, power rating: (40 / 100 % ED) 20 / 13,5 kw, torque: (40 / 100 % ED) 128 / 185 Nm, rapid traverse: 80 / 60 / 60 m/min, table loading: 10,000 kg

24 24 emo 2013 celos world premieres ecoline systems lifecycle services milling technology Linear drives with up to 80 m/min rapid traverses in all axes in the standard version. HSC spindle with shaft, flange and jacket cooling. HSC 30 / 70 linear: Higher precision and surface quality for the die and mould industry. The two EMO world premieres HSC 30 linear and HSC 70 linear set new standards for precision and surface quality in the die and mould industry. DMG MORI takes its 20-year HSC-history to a new dimension at high speed: Starting in 1993 with the DMC 70 V via the first use of linear drives for the HSC 75 linear 10 years ago up to the current EMO world premiere with CELOS of DMG MORI and in the new joint design. Outstanding features are the unique long-term precision of less than 5 μm thanks to the innovative cooling concept and the thermo-symmetric design as well as the perfect surface qualities of Ra < 0.15 μm thanks to HSC spindles with shaft, flange and jacket cooling. On top of that come the known advantages of linear motors in all axes for highest dynamics and with a 60-month warranty. 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 2014 onwards. Even in the 1 st quarter of 2014 both machines are available with Operate 4.5 on SIEMENS 840D solutionline or HEIDENHAIN TNC 640. The new appearance of the machines from DMG MORI in the new design provides the perfect visual backdrop for showcasing the innovative highlights that help produce perfect components. highlights of the hsc 30 / 70 linear _ Highest level of long-term precision < 5 µm thanks to innovative cooling concept and thermo-symmetric design _ Best surface qualities Ra < 0.15 μm thanks to HSC spindles with shaft, flange and jacket cooling _ Linear motors in all axes in the standard version for highest dynamics and precision with up to 80 m/min rapid traverse and a 60-month warranty _ Haimer tool holder package for highest precision in the area of workpiece clamping HSC 30 linear Highest precision on 4.5 m² Thermo-symmetrical design for highest part precision: < mm: Linear drives in all axes with 12 m/s² acceleration and 40,000 rpm HSC spindle with shaft, flange and jacket cooling in the standard version with 5-axis version and swivelling rotary table. Innovative cooling concept: Thermo-symmetric design, HSC spindle with shaft, flange and jacket cooling. technical data Travel X / Y / Z: 320 / 300 / 280 mm Rapid traverse: 50 m/min Spindle speed: 40,000 rpm Table loading: 200 kg

25 Journal n Thermo-symmetrical portal construction and innovative cooling concept. Cooling of machine bed and portal Cooling of linear drives Cooling of guideways via pressure clamps Cooling of Z-slide Coolant temperature control* * Optional HSC centre, Geretsried near Munich More than 2,500 visitors annually rely on our know-how and get information in the HSC centre about the latest technologies and strategies in the die and mould process chain. The range of services comprises an extensive range of seminars and workshops, operator training and customer-specific test machining. We also offer our customers support with problems regarding HSC machining. From October the new HSC series is available for presentation in the HSC centre. Arrange an appointment and benefit from the know-how of our experts! Contact: Andreas Rossberger Lausitzerstr. 7, Geretsried, Germany andreas.rossberger@dmgmori.com HSC 70 linear Precision in a new dimension Thermo-symmetric design for highest part precision: < mm: Linear drives with 80 m/min and 10 m/s² in all axes in the standard version, precision spindles with up to 40,000 rpm with shaft, flange and jacket cooling. Innovative cooling concept temperature control of the machine bed, drives and guides. Machining a mould on the HSC 70 linear. Available control systems for the HSC 30 linear and HSC 70 linear: With CELOS and SIEMENS from the 2 nd quarter 2014 onwards. technical data Travel X / Y / Z: 850 / 600 / 450 mm Rapid traverse: 80 m/min Spindle speed: 18,000 rpm (28,000 / 40,000 rpm)* Table loading: 700 kg * Optional With Operate 4.5 on SIEMENS 840D solutionline from 1 st quarter 2014 onwards. With HEIDENHAIN TNC 640, from 1 st quarter 2014 onwards.

26 26 emo 2013 celos world premieres ecoline systems lifecycle services ultrasonic 5-axis precision machining of watch components made of zirconium oxide and sapphire. milling technology ULTRASONIC 30 linear: 5-axis precision mach ining of advanced materials with up to 40 % reduced process forces. DIXI 270: Precision machining up to 12 t with 3-fold higher volumetric precision. With the ULTRASONIC 30 linear, DMG MORI pre sents a new 5-axis precision machine for advanced materials at EMO, with long-term stable gantry construction and holistic temperature management for highest precision and perfect surface quality. Due to ultrasound-supported hard machining with minimal process forces, surface qualities of Ra < 0.1 μm have become possible with the ULTRASONIC 30 linear. Linear drives in X, Y, Z with acceleration of > 1.2 g and 50 m/min rapid traverse ensure highest dynamics. The ULTRASONIC technology of SAUER is based on a standardised HSK interface, which allows flexible integration into almost all 5-axis milling machines from DMG MORI. ultrasonic oscillation khz ULTRASONIC operation principle: Overlaying the standard tool rotation with an additional oscillation in Z. The high-end precision machine DIXI 270 from DMG MORI has an enormous working area of 2,700 2,700 1,600 mm (X Y Z) and achieves a 3-fold improved volumetric precision of < 60 μm. The highly precise portal machine with 3-point support and GGG-60 castings offers maximal rigidity and stability for demanding machining, for instance of large aerospace parts or in the field of precision mould manufacturing. Huge and heavy parts of up to 3,000 mm diameter, 1,600 mm height and 12 t max. weight can be efficiently roughed (for instance with the powermaster 1000 motor spindle with up to 1,000 Nm torque and 77 kw power rating) and can be finished with high dynamics (5 m/s 2 ) and fast feeds (60 m/min) and a 3-fold higher volumetric precision. The high flexibility of the DIXI 270 can primarily be highlights of the ultrasonic 30 linear Medical ULTRASONIC 30 linear Maximum contour precision and surface quality of Ra < 0.1 µm for advanced materials _ Complex geometries in precision parts for the optical / watch / medical industry as well as precision mould construction, e. g. made from Zerodur, ceramics _ Up to 40 % reduced process forces thanks to ULTRASONIC _ < 5 µm long-term stability thanks to highly precise gantry construction and holistic temperature management _ Highly dynamic, actively cooled linear drives in X, Y, Z with > 1,2 g _ Flexible 5-axis simultaneous machining with optimal swivel range of ±120 in the B-axis DIXI 270 Mega-centre for highest precision: < 60 µm volumetric precision Implant screw Material: hipped zirconium oxide Machining time: 25 min Watch industry Watch housing Material: sapphire glass Machining time: 58 hours technical data Travel X / Y / Z: 320 / 300 / 280 mm Rapid traverse: 50 m/min Acceleration: 12 m/s 2 Spindle speed: 40,000 rpm Table loading: max. 80 kg (5-axis) technical data Travel X / Y / Z: 2,700 / 2,700 / 1,600 mm Standard spindle: 12,000 rpm, 288 Nm, 44 kw Table loading: 12,000 kg Tool magazine: 63 slots

27 Journal n hours manual scraping of the contact surfaces. DIXI Switzerland ascribed to its genius design, the powerful spindles and the technical skills of DIXI employees. Only after more than 500 hours of manual scraping the precision-determining contact surfaces are so flat, straight and square, that minimal form and position tolerances of the part become possible in the highly precise interaction of all linear and round axes. Intensive cooling measures of the DIXI 270 contribute towards the highest long-term precision of the high precision machine: The headstock together with its housing, B-axis motor and motor spindle form part of these cooling measures, as well as the C-axis motor in the NC rotary table, the X-, Y- and Z-axis motor and the feed axes, the machine bed as well as the linear guides in the X-, Y- and Z-direction. A so-called spindle growth sensor monitors and compensates temperature- and speed-related displacement of the spindle. The DIXI 270 is equipped with Operate 4.5 on SIEMENS 840D solutionline. Operate 4.5 offers users a uniform user interface for all technologies and convinces as holistic performance package for maximal productivity in machining. 3-fold higher volumetric precision of the DIXI 270. < 60 µm > 200 µm 5-axis machines of other manufacturers 1,600 mm Aerospace: Gearbox housing for a helicopter made of magnesium with form and position tolerances in the range of µm. 2,700 mm 2,700 mm highlights of the dixi 270 _ +80 % volumetric precision < 60 μm _ Position precision in X / Y / Z: 6 µm _ Position precision in B / C: 4 arcs _ Temperature control of all heatgenerating machine components _ Highest rigidity for maximal milling performance (GGG-60 castings) _ High power motor spindle powermaster 1000 with max. 1,000 Nm and 77 kw _ Maximal workpiece weight of 12,000 kg with a max. diameter of 3,000 mm and max. height of 1,600 mm _ Individual optimisation at the customer: Compensation of thermal expansion and volumetric compensation under individual ambient conditions

28 28 emo 2013 celos world premieres ecoline systems lifecycle services milling technology i80l: Perfection for engine components in the automotive sector. i-concept // i50 Up to 50 % lower space requirement with 100 % more flexibility thanks to linking of two machines. With the i80l, DMG MORI presents an ultra-compact horizontal machining centre for highly productive large series production of engine components in the automotive sector. The high level of compactness was achieved, among others, by the arrangement of the tool magazine in the upper portion of the machine. In the base configuration of the machine the option of pallet change has been omitted in order to be uncompromisingly open for customer-individualised linking solutions, for instance by means of portal loader or transfer systems. In addition the i80l has been designed so that it can be configured with other machines and machining centres to form a highly automated production line, for instance for cylinder heads or engine blocks. Another special feature of the i80l is the option to be able to clamp two workpieces in the working area and subsequently to optimally machine them one after the other. This reduces the number of required machines and therefore minimises the investment requirement. Besides this, the machining table can be traversed in the Z-axis, which improves accessibility of the work piece in case of manual access to the working area. On the other hand the low construction height of the machine or the working area orients itself to the automation requirements, which equally reduces the loading height and the loading time. 2,700 mm 1,700 mm 3,100 mm 3,650 mm Only 11.3 m² space requirement for the linking of two i50s; operation of both machines via one control system. i80l Compact horizontal machining centre for series production of engine components in the automotive sector Parallel loading of two workpieces. highlights of the i80l _ Horizontal machining centre without pallet changer for serial machining of a cylinder head and cylinder block _ Tool table moves in the Z-axis and allows good accessibility _ Lower machine width thanks to arrangement of the magazine above the machine _ Improved rigidity thanks to the the Z-axis in the table _ Double-arm tool changer _ Highly dynamic A-axis thanks to the use of direct drive motors technical data Travel X / Y / Z: 800 / 550, 850 mm Table clamping area: 1, mm Spindle speed max.: 8,000 rpm Rapid traverse: 60 m/min, tool magazine: 20 positions, footprint: m 2

29 Journal n Use as double-spindle cell Only 11.3 m² footprint for a combination of two machines as 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 tool set-up UNO 20 40: Entry into efficient tool set-up. With the UNO 20 40, DMG MORI presents an entry level model for tool set-up, which combines optimal ergonomics with comprehensive technical equipment and will particularly appeal to cost-conscious customers. The unit is offered with traverses in X / Z of 200 / 400 mm. An integrated infinitely variable fine adjustment as well as a clear 19" display forms part of the standard equipment. The possibility of measuring reamers up to a diameter of 100 mm with a traverse of +200 mm to 50 mm in the X-axis is unique. The new MICROVISION UNO software offers intuitive operation and quickly leads to precise measuring results with helpful functions, like for instance its own focus window. 1,490 mm Only 5.4 m² space requirement and low construction height of the working area for short loading and unloading times. The possibility of measuring reamers up to a diameter of 100 mm with a traverse of +200 mm to 50 mm in the X-axis is unique. UNO Unique high-tech features for the entry level of tool set-up devices Additional information on page 48 DMG MORI offers the new entry level model UNO in a new design with improved ergonomics at a very attractive price. The UNO already has a 19" colour monitor in the standard version, a stable 3-point support and the new MICROVISION UNO software. The wide variety of options and the associated, extraordinary individualisation options are unique in this segment. 2,550 mm technical data Measuring range: X = +200 to 50 mm Z = 400

30 30 emo 2013 world premieres celos ecoline systems lifecycle services The benefit of trochoidal milling is its ultraefficient machin Adaptive feed control (AFC) automatically regulates the feed of slots of all kinds. The roughing process is with circular mo rate of the TNC, taking into consideration the respective spindle superimposed on a forward linear motion. Trochoidal milling i power. These are the benefits of AFC: greatest advantage during the machining of high-strength or Total machining time is shortened because AFC increases the materials: feed ratethe in theheidenhain machining zones withcontrol less material removal. TNC systems during heavyhardened machining. Machining times Engagement of the entirelife cutter The tool have is monitored because AFC constantly compares the a multitude of useful functions, which are reduced significantly, tool service is length Significantly higher axial infeed (as opposed to full-section spindle power consumption and feed rate. If tool wear is on the one hand simplify the work of the increased decisively and machine loading cutting) detected, a replacement tool can be inserted. The effect of ACC is particularly positive during heavy cutting. machine operator andmechanical on the other hand is lowered considerably. Higher chip volume It reduces load on the machine s system because Significantly better cutting power also themaximum production processes faster, Less vibration, which reduces strain on the machine whenever themake learned spindle power consumption Higher metal removal rates (up to 25 % and more) mechanics and the tool is exceeded, AFC reduces the feed rate to protect the spindle Low forces on the tool thereby increasing service life more stable and more predictable in Integrated finishing of the side wall against overloading. Smaller load on the machine. short more efficient. During rough mathe benefit of trochoidal milling is Better its ultraefficient Adaptive feed control (AFC) automatically regulates the feed e into play during roughing (power conditionsmachining for chip removal This application exam on spindle your machine tool the of material of slots all kinds. The roughing process is with circular motion Dynamic Efficiency rate of the TNC, taking into consideration thechining respective e tool spindle speed, the resonances removal rate is decisive forsuperimposed economic effion a forward linear motion. Trochoidal milling is of conventional metho power. These are the benefits of AFC: he chip volume (cutting power during greatest advantage during the machining of high-strength or with AFC. Total machining time is shortened becauseciency. AFC increases the etimes begin to chatter. To reduce the The TNC control system with its hardened materials: feed rate in the machining zones with lessfunctional material removal. HEIDENHAIN now offers an effective scope Dynamic Efficiency Engagement of the entire cutter length Conventional millin The tool is monitored because AFC constantly compares the Chatter Control (ACC) control function. theisdecisive advantage, especially Significantly higher axial infeed (as opposed to full-section Machining time 96 s spindle power consumption and feed rate.provides If tool wear Strong milling forces come into play during roughing (power milling). Depending on the tool spindle speed, the resonances heidenhain inperformance the machine toolpartner and the chip volume (cutting power during milling), the tool can sometimes begin to chatter. To reduce the inclination to chattering, HEIDENHAIN now offers an effective antidote with the Active Chatter Control (ACC) control function. Dynamic Efficiency the HEIDENHAIN solution for efficient machining with TNC control systems. cularly positive during heavy cutting. ng power ates (up to 25 % and more) thereby increasing service life chine. cutting) 1 Full cuts in four in Higher chip volume 2 Sectional cut Less vibration, which reduces strain on the machine mechanics and the tool Integrated finishing of the side wall Better formachining chip removal This application example clearly illustrates the benefits of The benefit of trochoidal milling conditions is its ultraefficient detected, a replacement tool can be inserted. It reduces load on the machine s mechanical system because whenever the learned maximum spindle power consumption is exceeded, AFC reduces the feed rate to protect the spindle against overloading. Adaptive feed control (AFC) automatically regulates the feed TNC functions theinto consideration the respective Combination exponentiates of slots of all kinds. The roughing process is with circular motion rate of thefor TNC, taking spindle superimposed on a forward linear motion. Trochoidal milling is of power. These are the benefits of AFC: advantages optimisation of heavy machining greatest advantage during the machining of high-strength or Total machining time is shortened because AFC increases the Strong milling forces come into play during roughing (power milling). Depending on the tool spindle speed, the resonances in the machine tool and the chip volume (cutting power during milling), the tool can sometimes begin to chatter. To reduce the inclination to chattering, HEIDENHAIN now offers an effective antidote with the Active Chatter Control (ACC) control function. hardened materials: feed rate in the machining zones with less material removal. Engagement of the entire cutter length The tool is monitored because AFC constantly compares the Significantly higher axial infeed (as opposed to full-section spindle power consumption and feed rate. If tool wear is cutting) detected, a replacement tool can be inserted. The effect of ACC is particularly positive during heavy cutting. Higheralready chip volume It reduces load on the machine s mechanical system because Significantly better cutting power Dynamic Efficiency combines performance-increaseach function by itself brings advantages for Less vibration, which reduces strain on the machine whenever the learned maximum spindle power consumption Higher metal removal rates (up to 25 % and more) ing control functions with time-saving machining the for the machining process. combination of the mechanics and The the tool is exceeded, AFC reduces the feed rate to protect the spindle Low forces on the tool thereby increasing service life strategies. In thisagainst way overloading. ACC (Active Chatter Control) Dynamic efficiency functions leadsofto realwall efficiency Integrated finishing theaside Smaller load on the machine. conditions milling for chip removal reduces the tendency to chatter, while AFC (Adappush. The linking Better of trochoidal with adaptive Without ACC Withensures ACC the best possible tive Feed Control) always machining feed. The trochoidal milling strategy serves tool-saving roughing of grooves and pockets and can very easily be used as a cycle. ACC Active Chatter Control ACC feed control AFC is an example: Because the tool is moved in a circular motion during trochoidal milling, no engagement with the material takes place over a portion of this track. In this situation AFC moves the tool with a significantly higher feed. During the machining process with these combined control system functions an enormous time advantage results % more material removal rate is possible a clear advantage for economic efficiency. Dynamic Efficiency. This slot is machined first with the conventional method and then with trochoidal milling combined with AFC. Conventional milling Machining time 96 s 1 Full cuts in four infeed depths 2 Sectional cut Trochoidal milling w Machining time 58 s Position [mm] Trochoidal milling with AFC Machining time 58 s AFC Adaptive Feed Control Vorschub Feed rate Trochoidal milling Compared with con Efficiency increases With ACC Without ACC Vorschub Feed rate Compared with conventional machining methods, Dynamic Efficiency increases productivity by 40 %. With ACC Position [mm] Position [mm] er Control AFCAFC Adaptive Feed Control Adaptive Feed Control TrochoidalTrochoidal milling millingmachining example The new TS 460 touch probe The touch probe for setup and calibration of workpieces in the working space of a machine tool. The innovation is the additional mechanical buffer between the touch probe and the clamping shank. In the event of a light collision of the TS with the workpiece, the anti-collision buffer enables the touch probe to absorb the shock. At the same time, the control stops the probing process. The device remains undamaged and fully operable. The All-Around Protected Touch Probe DR. JOHANNES HEIDENHAIN GmbH Angle Encoders Linear Encoders Traunreut Contouring Controls Germany Digital Readouts phone Length Gauges Machinin Touch Probes Rotary Encoders UK ACC Active Chatter Control

31 Journal n nº World premieres at EMO, Hanover: CTX 450 ecoline and CTX 650 ecoline The first joint development in the field of universal turning machines according to the latest standards The complete ECOLINE series Suitable 3D control technology for every user ECOLINE ctx 650 ecoline ctx 450 ecoline

32 32 emo 2013 celos world premieres ecoline systems lifecycle services ctx 450 ecoline and ctx 650 ecoline: Smallest footprint of its class for chuck sizes of 250 mm and 400 mm with 3D control technology. Most powerful technology in the entry class! Servo turret* VDI 40 / 50 turret* equipped with up to 12 driven and 6 block tool stations*, MST (MORI tool) turret with 12 MST 40 tool holders** Bar capacity 65 mm / 75 mm* for CTX 450 ecoline 102 mm / 110 mm* for CTX 650 ecoline Automatically moveable tail stock for shaft machining. Linear guides in X- and Z-axis to guarantee high machine dynamics. 4-track cast iron bed The high-quality 45 slant bed made of cast iron is small, firm and shock resistant. The design of the 4 individual linear guides allowes a collision-free tailstock movement while the Z-axis guide protection increases reliability and durability. * Optional, ** Only available for CTX 450 ecoline with MAPPS IV ctx ecoline The choice is yours, we have the programme The two novices in the ECOLINE success team. The new CTX 450 ecoline and CTX 650 ecoline complete the ECOLINE success team in the field of CNC universal turning machines. CTX 450 ecoline CTX 650 ecoline

33 Journal n The suitable 3D control technology for every user. The 3D control systems with ergonomi - cally shaped and swivelling control panel offer optimal and user-oriented operating comfort. The SMARTkey is already contained in the standard configuration. _ 15" SLIMline with Operate 4.5 on SIEMENS 840D solutionline _ 15" SLIMline with HEIDENHAIN CNC PILOT 640 _ 10.4" TFT display with MAPPS IV from MITSUBISHI* (only available for CTX 450 ecoline) Two success models, which will pay off for you! Judged by their compact footprint area of 4.9 m² or 9.8 m², both the CTX 450 ecoline and the CTX 650 ecoline offer a generously dimensioned working area. Large turning diameters (ø 400 mm / 600 mm***) and in its class unique bar capacities from ø 65 mm / 102 mm*** (optional ø 75 mm / 110 mm***) guarantee flexibility for chuck and bar machining. Performance, which helps you on. Both models have a turret for 12 tools with VDI 40 / 50*** holder and rapid traverses of 30 m/min in all axes. Furthermore the use of 6 block tools is possible. 1,905 mm High performance. Small dimensions. Ideal for series production. Thanks to the optional rear chip conveyor, the installation width of the machine front side is reduced by up to 35 %, so that the production area can be utilised significantly more efficiently (available for CTX 450 ecoline). 1,833 mm 2,690 mm With a precision, others would love to have. Thanks to its stable construction and high thermo-stability, the new ECOLINE models offer unique precision, even under heavy machining conditions. Thanks to a FEM-optimised cast iron bed, large-dimensioned ball screws (40 10 mm, mm***) and wide linear guides (size 45 ball bearing guide, size 55 roller bearing guide***) best rigidity values and positioning precision of 0.02 mm with the direct distance measurement system even mm are achieved. Quality, focusing on diversity. The comprehensive equipment of the CTX 450 ecoline / CTX 650 ecoline promises maximal efficiency in the entry level segment. An upgrade of the complete machine right up to turn and mill full machining is possible thanks to the task-optimised configurations. * Optional, *** Data for CTX 650 ecoline Modern lathes must be productive, flexible and easy to operate. The two world premieres CTX 450 ecoline and CTX 650 ecoline are now continuing what ECOLINE has already been promoting for years: top technology with proven components at the best price. Innovative new developments according to the latest standards 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 robust construction guarantees highest precision, the comprehensive equipment promises maximal efficiency, the 3D control system technology from SIE- MENS, HEIDENHAIN and MITSUBISHI ensures flexibility and the task-optimised configurations allow an upgrade of the machine up to turn and mill complete machining.

34 34 emo 2013 celos world premieres ecoline systems lifecycle services ecoline series CTX ecoline: Optimised technology with a fast servo turret and 30 m/min rapid traverse. Innovative new development expansion of the CTX ecoline series. The ECOLINE concept is based on the idea of supplying the accustomed high quality of DMG MORI at the best price, thanks to consistent standardisation and reliable construction as well as latest 3D control system technology. ECOLINE serves a broad field in turning and milling with a holistic machine programme. Ergonomic design and assemblies by renowned manufacturers stand for the highest quality, down to the smallest detail. The CNC universal turning machines of the CTX ecoline series offer performance standards at a high level and on top can be adapted to every manufacturing environment with numerous options. The CTX 310 ecoline / CTX 510 ecoline distinguish themselves with large turning diameters (ø 200 mm / ø 465 mm) and in this class unique bar capacities (optionally up to ø 65 mm / ø 90 mm) and thereby provide more flexibility for chuck and bar machining. At EMO 2013 the ECOLINE success team is completed by the two innovative new developments CTX 450 ecoline / CTX 650 ecoline. The CTX 650 ecoline with its high-torque drives focuses mainly on high-power machining, while the CTX 450 ecoline can accomplish the most diverse demands as a fast all-rounder. The vertical machining centres DMC 635 V ecoline and DMC 1035 V ecoline set new standards in the entry level field of 3-axis milling with their technical equipment. Even the standard version convinces with modern technology at a high level, like for instance the powerful 8,000 rpm spindle, the 20-position tool magazine with fast double gripper and rapid traverse of 30 m/min. Maximal reliability, ergonomic handling and the large working area are additional convincing features, which convince in shop-floor environment as well as in small- and mediumsized production. DMU 50 ecoline: 5-side machining with patented NC swivelling rotary table. CTX ecoline series CNC universal turning machines No compromises during turning operations DMC V ecoline series Vertical machining centres Powerful natural talents for flexibility and highest precision The complete ecoline programme VDI 30 / 40 turret now optionally with up to 12 driven tool stations Large bar capacity up to ø 65 mm / 90 mm for more flexibility Y-axis* on the CTX 510 ecoline for efficient turning and milling production in one setup Servo turret with a synchronous motor for 50 % faster tool change time and hydraulic clamping Powerful spindle [8,000 rpm / 83 Nm (40 % ED) / 13 kw (40 % ED)] / motor spindle [12,000 rpm / 83 Nm (40 % ED) / 13 kw (40 % ED)]* Tool magazine with 20 tool stations (30 stations*) with a fast double gripper Reduced non-productive time: 30 m/min rapid traverse, 1.6 second tool changing time The greatest rigidity and precision plus lower space requirements thanks to the C Frame design CTX 310 ecoline DMC 635 V ecoline DMC 1035 V ecoline CTX 450 ecoline NEW! CTX 510 ecoline CTX 650 ecoline NEW! * Optional

35 Journal n Journal n ecoline series MILLTAP 700 with optional integrated 4 th / 5 th axis efficient and cost saving for maximal productivity. The PROGRESSline visualises the progress in machining. Remaining time and number of items of a complete machining process are displayed. MILLTAP 700 now available with optional integrated 4 th / 5 th axis. With the DMU 50 ecoline, the universal genius of the entire series, DMG MORI open the door to 5-side machining for their customers. The integrated, patented NC swivelling rotary table with digital drives thereby allows 5-side machining of simple to highly complex work pieces that require complex shape and position tolerances. The DMG MORI spindle concepts and the modern drive technology with rapid traverses speeds of 24 m/min provide the matching performance. The compact MILLTAP 700 machining centre convinces with top values in all performance areas. This applies to the SIEMENS 840D solutionline Operate 4.5 just as much as for the fast tool magazine with tool change times of 0.9 seconds and a chip-to-chip time of less than 1.5 seconds. In addition, high axis acceleration of up to 18 m/s² and rapid traverse of 60 m/min ensure high dynamics. Besides the 10,000 rpm standard spindle, additional spindles with 10,000 rpm high torque, 18,000 rpm with grease lubrication for application in the medical industry and a spindle with 24,000 rpm for steel and aluminium are available. And on top of that, the MILLTAP 700 is the most energy-efficient machine of its class! With this holistic portfolio, ECOLINE has successfully established itself in the market with international standing within a few years. Besides this, worldwide sites underline the high value DMG MORI places on service: ECOLINE is there, where the customer is. Optics Optical housing Material: Steel Dimensions: mm Machining time: 19 min. 45 sec. Drive technology Motor housing Material: Cast aluminium Dimensions: mm Machining time: 16 min. 35 sec. DMU ecoline series CNC universal milling machine 5-side machining with patented NC swivelling rotary table Highest efficiency NC swivelling rotary table with digital drives for 5-side machining of simple to highly complex work pieces Powerful spindle [8,000 rpm / 83 Nm (40 % ED) / 13 kw (40 % ED)] / motor spindle [10,000 rpm / 83 Nm (40 % ED) / 13 kw (40 % ED)]* Tool changer with 16 positions in the pick-up magazine (30 positions*) Direct measuring scales and centrally lubricated recirculating roller guides for high consistent accuracy MILLtaP Highly productive compact machining centre Stunningly fast and unfailingly precise NEW: Operate 4.5 on SIEMENS 840D solutionline NEW: Even more efficient thanks to optional integrated 4 th / 5 th axis or work piece handling WH 2 WH 3 Patented tool changer with 0.9 seconds tool change time and a chip-to-chip time of less than 1.5 seconds Highly dynamic spindle with a maximal torque of 45 Nm and a speed of 10,000 rpm (10,000 rpm high torque*, 18,000 rpm*, 24,000 rpm*) High axis acceleration of 18 m/s², 60 m/min rapid traverse and size 35 linear guides Direct measuring system in X / Y / Z* for highest level of repeat and long-term accuracy DMU 50 ecoline MILLTAP 700 * Optional

36 36 emo 2013 celos world premieres ecoline systems lifecycle services ecoline control systems and energy efficiency The suitable 3D control technology for every user. Irrespective of what your demands for performance of a modern control system may be and what your preferences are. Do not settle for compromises: time is money. Therefore ECOLINE offers the suitable control system technology with the fastest systems for every user. Whatever you wish and need, we will supply optimal hardware and software solutions for the entire process chain from the drawing up to the completed work piece. This is what modern and responsible work places look like at ECOLINE. 15" SLIMline with HEIDENHAIN CNC PILOT 640 / TNC " TFT display with MAPPS IV from MITSUBISHI ecoline: more performance and less consumption Energy efficiency 30% Energy requirements for machine tools 1) DMG MORI has always been striving to develop, design and build innovative and technically high quality machine tools of the latest state of technology and scientific insights. The focus is increasingly placed on energy consumption of the machines. Our products distinguish themselves with a significant reduction of energy consumption and the prevention of energy losses. 1) The actual energy saving essentially depends on the application and utilisation of the machine tool. The above statements merely identify potentials, which are possible by using latest generation machines compared to previous machine concepts for the relevant use and application.

37 Journal n slimline with operate 4.5 on siemens 840d solutionline Latest control system technology with Operate 4.5 The functionality and productivity of a machine tool is also co-determined by the CNC this applies to the field of universal machining, and especially to the operating and programming interface. In their new Human-Machine-Interface (HMI), SIEMENS has now combined the experience gained from individual, small and large series production with the current state of milling and turning technology in a practical way and completed it consistently. The result is called Operate 4.5 on SIEMENS 840D solutionline and provides intuitive access to all the production-relevant functions of the machine, which makes almost all working steps easier, faster and more efficient. Operate 4.5 on SIEMENS 840D solutionline combines the functionality of ShopMill and Shop- Turn as well as numerous new features in one future-oriented user interface for all turning and milling operations: Intuitive access to machine functionality Animated elements, dynamic line art Real-time zoom in 2D and 3D simulations Workshop software with integrated standard operation Uniform and consistent view of all data carriers Operate 4.5 on SIEMENS 840D solutionline HEIDENHAIN CNC PILOT 640 TNC 620 CTX 310 ecoline CTX 450 ecoline CTX 510 ecoline CTX 650 ecoline DMC 635 V ecoline DMC 1035 V ecoline DMU 50 ecoline MILLtaP 700 MAPPS IV DMG SMARTkey with transponder The customised authorisation with this DMG SMARTkey allows the assignment of access rights to all operators according to their knowledge. These access rights are divided into machine operation (operating modes) and control system operation (access level). Standard Optional DMG MORI Messenger: Permanent on-line monitoring of your DMG MORI machines for more productivity as a result of reduced down-times. More details on page 50 suitable tool packages 1. Linear guidance technology 2. Energy recovery! 4. Innovative 400 V technology 5. DMG AUTOshutdown Your ECOLINE machines profitable and ready for use right from the start with the Sandvik Coromant tool packages. Linear guide technology ensures lower friction coefficients, therefore: Reduced energy consumption with smaller motors Less environmental impact through reduced lubricant use Regenerative braking energy from the drive axes and main spindle are recirculated back into the grid for energy savings of approx. 10 %. efficient dynamics kwh + 3. Auxiliary units with IE2 Energy savings of 5 % compared to IE1.4 through the use of auxiliary units, such as pumps and chip conveyors that have an energy efficiency class of IE2. 50 Hz Eff: IE % 60 Hz Eff: IE % IE2 19 % less heat and reactive power loss in the control area and drive components with the innovative 400 V technology Heat dissipation in W 711 w 200 v 598 w 400 v Maximal energy efficiency thanks to configurable machine. Automated and unmanned: Switch-off of energy consumers (pumps, pneumatics, screens, light, etc.) Wake-up switch-on according to time schedule Starting of a warm-up programme ENERGY SAVING CTX ecoline tool package 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. DMU ecoline / DMC V ecoline tool package 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.

38 38 emo 2013 celos world premieres ecoline systems lifecycle services performance partner siemens Milling in the royal class SINUMERIK in mould construction. Ever more CNC machine tools for mould construction are offered with SINUMERIK, despite the fact that this application was previously occupied by specialists. SINUMERIK is known as the leading CNC system, but not yet with a focus on mould construction. Why does SIEMENS venture into this application, which up to now has been served by specialists? m. brückner Our customers demand more from a machine tool than just pure work piece machining. Production efficiency, IT integration and consistent solutions are becoming key factors for economical production. Therefore many end customers approach us regarding mould construction. But also machine manufacturers who offer their customers advantages with standardisation and technology integration, want to find solutions to their mould construction applications with SINUMERIK. SINUMERIK MDynamics is our answer, to excellently comply with the mould construction requirements. The SINUMERIK control system operating philosophy was previously regarded to be too complicated for many end users. What has changed in this respect? W. marx In fact, the world has changed completely with SINUMERIK Operate. Comparable to the introduction of the PC and stand-alone programmes, for instance for word processing and spreadsheet calculations, one can today only imagine working with a complete package for all office applications. Thanks to integrated technology functions, supported by numerous graphics and animations, it is easy to learn and it quickly converts confirmed SINUMERIK sceptics to enthusiastic machine operators the result of many years of cooperation with DMG MORI. That is all well and good, but can SINUMERIK 840D sl now convince with technology in mould construction and at the same time offer added value? m. brückner With perfect surface quality, fastest possible machining time and precision of the workpiece this has convincingly been proven with the latest innovations of DMG MORI, the HSC 30 linear and HSC 70 linear. With SINUMERIK MDynamics and the CNC performance of our latest SINUMERIK 840D sl the balance between surface, precision and speed can be adjusted in the right proportion and renders the required results. With this step, SINUMERIK stands for user-friendliness and productivity in all applications for the sectors production, shop floor and mould construction. In addition DMG MORI already today offers own added value functions with Operate 4.5 based on the latest SIEMENS CNC unique and consistently for all machines. Michael Brückner, Manager Business Development SINUMERIK Highend (left); Wolfgang Marx, Application Technician (right) Easy parametrisation allows a balance between surface, precision and speed. Increase productivity using SINUMERIK SINUMERIK is always the optimum control from turning to mold making siemens.com / sinumerik UK Whether in the automobile industry, aerospace industry, job shop environment, tool and mold making or energy and medical technology SINUMERIK is the ideal CNC system for machine tools. As seamless system platform, it meets all of the specific requirements of your sector, with well-proven and innovative functions, a seamless and integrated range of components and supplementary services. You profit from outstanding machining results with perfect surface quality, precision, quality and speed with optimum usability and a seamless and integrated process chain. The result: higher productivity in your production environment. Answers for industry.

39 Journal n nº DMG MORI Systems processes perfectly automated Competence in all automation segments: Machine-integrated automation, standard automation, flexible production cells and production lines Systems Two 6-axis robots with 20 kg loading capacity each ctv 250 with rotary cycle storage and integrated centring equipment nzx2500 Production turning machine with 2-axis gantry dmc 55 h duoblock with pallet storage Cycle conveyor for loading and unloading the entire system Additional devices Measuring, cleaning, embossing device Flexible production cell + 2 nzx2500 with gantry loading + 2 ctv 250 with robot loading + 1 dmc 55 h duoblock with pallet storage and robot loading

40 40 emo 2013 celos world premieres ecoline systems lifecycle services Competence in all automation segments. DMG MORI Systems processes perfectly automated. segment 1 segment 2 Machine-integrated automation Standard automation It is our task to improve the productivity and quality of machining production with the help of individual automation solutions, says Uwe Kling, Managing Director of DMG MORI Systems, about their core business. According to him, the performance spectrum has continuously been developed over the years, Currently the focus is not only on standard automation systems, but also on solutions for the linking of two or more machines, up to complete production planning. In the end, the entire material flow could be largely automated. For Uwe Kling the essential arguments for automation are obvious, For most users productivity is most important, because it plays a major role in the competitiveness of a machining company. It is a matter of producing more per time unit usually with higher quality and to reduce production costs. Automation complies with both factors, because it supports less personnel intensive production and allows additional shifts out of regular working hours. Our customers are even using it to reduce staff shortages, because skilled employees can be assigned to more demanding tasks instead of handling workpieces, the Manager notes. If the utilisation corresponds, the invest will pay off in a short period of time, promises Uwe Kling. In the best of cases, the costs will be amortised in less than one year. With their range of services, DMG MORI Systems pursue an allround approach, so that their customers can maximise their profit due to automation. Today we concentrate on entire manufacturing processes and their optimisation, explains Uwe Kling. That includes workpiece handling as well as the linking of machining centres, or parallel machining and deburring or measuring. In the end DMG MORI Systems do not only address DMG MORI customers. In principle every machine can be automated. Uwe Kling demonstrates that this has been common practice for a long time, with a glimpse into order distribution, Almost one third of our customers have third party products automated by us. Rotary and linear storage As optional equipment for the machine a selection of machine-integrated automation systems is available ex works. segment 3 segment 4 Flexible manufacturing cells Workpiece or pallet handling Efficient robot or gantry solutions with additional modules (cleaning, measuring, brushing, etc.) are available as Plug & Play solutions or as customised versions. Production lines Uwe Kling Managing Director Contact: DMG Automation GmbH Seemühle 5, Hüfingen, Germany Tel.: +49 (0) 771 / automation@dmgmori.com Find out more about automation and the services of DMG MORI Systems online at Linking of multiple process sequences Portal solutions, fixed or mobile robots and additional modules for multi-machine loading with the integration of additional operations. Overall solutions in line production Planning and implementation of pallet, gantry and robot handling as production line, including host computer system.

41 Journal n segment 1 Rotary storage RS 7 for maximum productivity thanks to 7 pallets in the system. Machine-integrated automation. Package solutions from DMG MORI plants highlights _ Little space requirement due to a very compact construction _ Unrestricted access to the work area is possible _ Crane loading at the set-up area as standard _ Complete separation of the set-up area from the rotary storage during set-up work; the rotary storage is not interrupted by set-up work _ Pallet management integrated in the CNC control system of the machine _ High rate of unstaffed machining time due to the large number of pallets _ Rotary storage solutions with 7 to 20 pallets and up to 500 kg loading capacity Rotary storage RS 20 for unstaffed machining time. AWC (Automatic Workpiece Changer) for the NMV series The NMV series in its frame sizes NMV1500 and NMV3000 with its AWC (Automatic Workpiece Changer) offers a machine-integrated automation for long-term machining for highly flexible and less personnel intensive machining of diverse workpieces. highlights awc _ The arrangement of the AWC allows unrestricted access to the work area of the machine and to the loading space of the automation _ Manual loading and unloading of the machine from the front is possible _ Operation and organisation of the AWC via machine control system _ Choose your AWC system (Automatic Workpiece Changer) from three variants: 34 stations, 120 stations and 114 flexible stations in different sizes.

42 42 emo 2013 celos world premieres ecoline systems lifecycle services segment 2 Standard automation: Fast return on investment with robot or gantry solutions. Additional operations e. g. cleaning, measuring or deburring can be supplemented. PH Optimise item costs due to pallet handling. Our linear handling systems are easy to operate, flexible and highly efficient. Our standard product PH with its large number of possibilities for workpieces up to 250 kg on a varying number of pallet storage points is a perfect supplement for almost any milling machine. highlights ph _ Rapid pallet exchange due to 8 pallets and a loading capacity of 250 kg each _ Economical from lot size 1 _ Integrated pallet magazine with 8 pallet unloading positions (optional up to 30 positions) _ Ergonomic loading through crane hatch _ Pallet set-up place with intuitive touch screen control panel Our online amortisation calculator immediately shows you the cost advantages of our standard automation systems. CPP Perfect for small to medium lot sizes. WH top linear Simple and efficient. highlights cpp _ Plug & Play solution _ Automated pallet transfer for machine tools to increase the level of productivity _ Perfect for small to medium lot sizes, single items and repetitive series _ Easy integration in every production due to simple, efficient construction and pre-defined packages _ You can adapt the automation exactly to your requirements with 8 different options _ Perfect supplementation of the NHX series highlights wh top linear _ Loading capacity under vertical axis: 60 / 120 / 250 kg _ Repetitive accuracy ± 0.1 mm _ Scalable stacking cell adapted to the gantry unit _ High level of autonomy _ Low space requirement _ Available for almost every turning machine

43 Journal n segment 3 Automation solutions also for models from other manufacturers Flexible production cells Full machining according to your requirements. highlights _ Our modular building block plant system designed according to your individual demands _ Requirement analysis, planning and implementation from a single source _ Most efficient space utilisation _ Heavy work piece weights possible _ Optimised loading and unloading _ Automation of downstream steps _ Integration of third party machines and additional operations Example from the aerospace sector: This compact cell is an example from our modular building block system for any type of machine tool automation. The cell combines machining in a CTX alpha 500 with a linear gantry with a subsequent machining step in a CTX alpha 300, including the ancillary activities embossing, measuring and cleaning. Supply of unfinished items and discharge of finished products is done by pushing a transport cart into a storage cell. Customer story Schmiedetechnik Plettenberg GmbH & Co. KG Flexible production cell ensures maximum productivity. Maximum productivity due to linking of different machine tools in one production cell. Besides top quality, the automotive industry continuously demands a reduction of item costs. In order to achieve both, all processes must be taken into consideration, tested and optimised. Engineering comprises important cost-cutting measures. With many years of international experience in the field of production planning, the experts of DMG MORI Systems ensure an optimal workflow at Schmiedetechnik Plettenberg GmbH & Co. KG, taking into consideration all required technologies and work steps. With their comprehensive engineering know-how of the construction of machine tools, DMG MORI Systems frequently conceptualises and implements full machining from the unfinished workpiece to the finished item for their customers. Their aim is an optimised value adding chain, which allows highly productive JIT production. When Schmiedetechnik Plettenberg GmbH & Co. KG were looking for a turn-key solution provider at their site in Theley to automate the production of a gearbox part productively and reliably, they found the right partner in DMG MORI Systems. Renowned automobile and utility vehicle OEMs have been calling for the competence of the Plettenberg company for several decades, particularly for the continuous development of heavily stressed engine components as well as gearbox and drive train components. Following their motto Forging to the limit, Schmiedetechnik Plettenberg creates precision parts for an international range of customers with approximately 500 employees and many years of experience. The manufacturing of a gearbox part, which was previously performed on different individual machines, had to be integrated via linking and automating different machine tools in one production cell with maximum productivity. It was the aim to optimise the cycle time and to achieve optimal item costs by means of an intelligent linking of multiple process sequences and automatic handling of parts. The DMG MORI Systems experts planned a production cell as a flexible line, on which either one component type could be machined in parallel on two lines for large quantities, or two different component variants could be machined in parallel on the two decoupled lines. The system combines different steps (outside / inside turning and tooth profile rolling) in one consistent material flow. In the first machining operation two MORI NZX 2500 provide efficient parallel turning. After that, the workpiece is handed over to two CTV 250 vertical turning machines via a tooth profile-rolling machine for final machining. Finished items are removed manually by a worker from a cycling conveyor section. Comprehensive part tracking is possible in the production cell, i. e. the worker knows at any time, when and where the work - pieces were processed. For Schmiedetechnik Plettenberg the automation and the flexible structuring of the production process mean increased competitiveness in an industry which demands a continuous increase of efficiency. Contact: Schmiedetechnik Plettenberg GmbH & Co. KG Daimlerstrasse 9, Plettenberg, Germany

44 44 emo 2013 celos world premieres ecoline systems lifecycle services segment 4 Production lines The future today material flow in fully automatic production. Large production systems, complex process chains or exceptionally specialised production: DMG MORI Systems offer highly efficient solutions in each of those cases, to maximise the throughput of items. Profit from our competence in the fields of engineering and technology for fully automated production with the highest degree of economic efficiency. Welcome to the future at DMG MORI Systems. we plan and implement _ System solutions for large series production _ Integration of multiple machining centres _ Fully automated set-up stations _ Automation of subsequent machining steps (e. g. washing or measuring) _ Complete turn-key solutions Automation system of the company Weber Automotive in Markdorf, Germany. Ten NHX5000 machines from MORI are linked with robots for the production of cylinder heads. SCHNEEBERGER WORLDWIDE COMPETENCE IN LINEAR MOTION TECHNOLOGY AND MINERAL CASTING SCHNEEBERGER provides mineral casting structures with assembled MONORAIL MR profi led linear guideways and absolute integrated AMS distance measuring systems to the machine tool industry. Engineering know-how in linear motion technology and mineral casting includes customer-specifi c, innovative, superior products. Optimisation of logistics, and continuous improvements in manufacturing and assembly processes are essential economical factors for the machine building sector. Schneeberger GmbH I Gräfenau I D Höfen Enz I info-d@schneeberger.com I DMG / MORI expert partner We make the impossible possible. precision parts DesiGn components UK IFR Engineering GmbH s specialty is precision procession in the micrometer range. We are one of the few companies in Germany able to provide you with this level of quality in precision. To us precision means combining all upstream and downstream processes, thus offering you a true long-lasting partnership. We are looking forward to meeting you at IFR Engineering. Please, contact us at any time! ENGINEERING GMBH IFR-Engineering GmbH Gröperstraße Magdeburg info@ifr-magdeburg.de ifr-magdeburg.de

45 Journal n nº Maximum productivity in focus Unique availability of spare parts The new generation of tool presetting Training for higher productivity More than 250 high quality used machines immediately available Software solutions LifeCycle Services

46 46 emo 2013 celos world premieres ecoline systems lifecycle services DMG MORI has invested five million euro in the expansion of their Global Parts Centre in Geretsried. LifeCycle Services more than just a machine tool. Spare parts: Maximum availability and rapid delivery worldwide. Dr. Maurice Eschweiler Board of Directors Industrial Services GILDEMEISTER AG We are represented around the world with 143 sales and service sites. With this maximum customer proximity we guarantee extensive personal service and fast availability. Thomas Wolf Managing Director DMG MORI SEIKI Services GmbH Our service products and services guarantee a high degree of availability and maximum machine performance. About 2,500 employees worldwide are working everyday to achieve this aim. With more than 140 employees in their new, modern Service Centre in Geretsried, DMG MORI Spare Parts ensure that customers who require service are provided fast and hassle-free with the necessary wearout and spare parts and that their machines are back in production as fast as possible. In summer 2013, DMG MORI has invested five million euro in the expansion of its Spare Parts Centre Geretsried. Spare parts for DMG and MORI machines are stored there on more than 30,000 m². Increased productivity and highest performance across the entire LifeCycle: With DMG MORI LifeCycle Services our customers benefit from the entire range of exclusive manufacturer know-how. The full service includes 24 / 7 support, spindle service and maintenance as well as original spare parts and retrofit solutions, training, software solutions and used machines. Beyond that, sophisticated high-tech equipment for tool presetting offers additional potential for the optimisation of the production process. All products and services from LifeCycle Services are compatible with the machine portfolio of DMG MORI. This way, our customers are always in good hands for the entire service life of their machine tools. More than 100,000 spare parts in our Global Parts Centre in Geretsried alone. DMG MORI Spindle Service the customer decides. Our competence for your productivity. In case of spindle damage, fast support is required, because every minute counts when your production is down. But not only speed is crucial, technical competence also plays an important role. The DMG MORI Spindle Service combines both: short reaction times and exclusive manufacturer know-how. In reaction to the rising demand in this segment the machine tool manufacturer has consistently developed and expanded its high-tech spindle manufacturing facilities. In case of spindle damage, DMG MORI offers its customers two options: Customised spindle repair or replacement spindle service. Find out more about our spindle service and the products of DMG MORI online at

47 Journal n Customer story Volkswagen Wolfsburg At least 95 % machine availability Global logistics network with 7 large warehouses for spare parts on 3 continents (more than 60,000 m 2 of storage space) Spare part availability of at least 95 % Original spare parts directly from the manufacturer for maximum production reliability Quick supply in 86 countries More than 100,000 different items available in stock in Geretsried alone Lots of spare parts also available for older models dating back to 1970 Order via 24 / 7 service hotline for even quicker dispatch Certified processes according to DIN ISO 9001 Discover our current spare parts offers online The tool-making division of Volkswagen Wolfsburg is responsible to ensure that the complex and high-precision tools for cold or warm forming of chassis and structural parts are delivered on time to the relevant press plants. High productivity and, above all, smooth production processes are a prerequisite for this. Roland Schöbel, Manager of the machine park, places high demands on the almost 20 DMU machining centres of DMG MORI, which form the technological basis: We expect an availability of at least 95 % because every downtime has a serious impact on subsequent production steps. The key to this high machine availability lies in regular maintenance intervals. We thereby prevent unwanted damage in due time and maximise the service life of our machines. Volkswagen Wolfsburg solicits professional support from DMG MORI for the regular on-site maintenance and repair of their numerous machines. One service technician of the manufacturer is in action on our site for more than 30 weeks per year, quantifies Roland Schöbel the commitment of the service. With so many machines and operating hours the demand for wear and tear parts and preventive maintenance is enormous. The close cooperation at this level pays off for the mold and tool construction department, Spare parts are available within 24 hours and unforeseen machine downtimes have become absolutely exceptional since then. Roland Schöbel is more than satisfied with the work performed by DMG MORI Services and not only because it guarantees sound processes: Thanks to continuous maintenance and the timely replacements of wear and tear parts, even older machines can be regarded as virtually new. With this he refers to the long-term precision of the machining centres: We have the machine geometry checked regularly, so that even an eleven year old machine still mills with a precision of ± two hundredths. The conclusion is unambiguous for Roland Schöbel: The machining centres represent big investments for us, and thanks to the service of DMG MORI we benefit from the investments for a long time. Spindle repair with full cost control In the mold and tool construction of Volkswagen Wolfsburg fast and reliable service is essential. With the customised spindle repair by the manufacturer, the customers get a cost-effective solution with full cost transparency. A fixed price for new bearings, including rotary feedthrough and test report is agreed upon at first call. After the spindle has been removed at the customer s, it is transported to the factory and is repaired by the manufacturer within 5 7 working days. Subsequently a service engineer sets up the spindle at the customer s and checks the geometry on-site, if required. Replacement spindles immediately available The DMG MORI replacement spindle service is even faster. Customers can choose between new parts or fully reconditioned replacement spindles at the latest state of technology. The machine tool manufacturer stores more than 1,000 replacement spindles worldwide, which can be immediately delivered. This way, dispatch within 24 hours is guaranteed, so that the defective spindle can be exchanged with a replacement spindle on-site within the shortest period of time.

48 48 emo 2013 celos world premieres ecoline systems lifecycle services uno Enter the world of efficient tool presetting. With the new UNO, DMG MORI now has an attractive, cost-effective entry level model in their programme with professional features for tool presetting, which combines optimal ergonomics with comprehensive technical equipment. The devices are offered in two construction sizes with traverses in X / Z of 200 / 400 mm (UNO 20 40) or 700 mm in the Z-axis (UNO 20 70). Of course all conventional interfaces can be adapted to the spindle. The possibility of measuring reamers up to a diameter of 100 mm with a traverse of +200 mm to 50 mm in the X-axis is unique. The new UNO generation is complemented by various options, like the 21" touch display, the thermal label printer, a vacuum clamping system and the stable comfort base cabinet with many practical storing possibilities. highlights _ FEM-optimised and thermo-stable gray cast iron construction _ Individual design thanks to modular concept _ Reamer according to snap gauge principle, adjustable up to diameters of 100 mm (traverse up to X 50 mm) _ 47 cm (19") screen with 45-fold magnification as standard (optional 21" screen) _ Incident segment light for visual cutter inspection _ MICROVISION UNO software _ Teach-in function _ With many additional options UNO The entry level with professional features DMG MORI offers the new UNO with outstanding ergonomics in two construction sizes: the UNO and the UNO Both offer the highest level of operating comfort for optimal tool presetting thanks to a 19" colour monitor, already in the standard version. The possibility of measuring reamers up to a diameter of 100 mm thanks to a traverse of +200 mm to 50 mm in the X-axis is outstanding for the entry level. Fully reconditioned and ready for operation ctx beta 800, year of manufacture: 2006 Customised training concepts are the main competence of DMG MORI Academy. technical data Measuring range: X = +200 to 50 mm Z = 400 / 700 mm

49 Journal n Used machines we deliver immediately! DMG MORI Used Machines is the world s leading supplier of used DMG and MORI machine tools. our services: trade-in, financing We accept your old machine as down payment and offer you attrac tive financing options for your new investment. reconditioning For maximum productivity and safety, DMG MORI SEIKI Used Machines GmbH will recondition your used machine. sales DMG MORI offer an unmatched selection of turning and milling machines, certified and available at short notice, in all price classes and categories. machine mediation We will find machines according to your requirements thanks to countless contacts worldwide. We will gladly find customers for your machine. Contact: Sandra Weichselberger Tel.: +49 (0) sandra.weichselberger@dmgmori.com More than 250 machines immediately available at training DMG MORI Academy: Increase productivity through knowledge. Teachware The DMG MORI Academy is a world leader in the transfer of CNC technical knowledge and offers comprehensive training with more than 200 innovative courses for the professional training of your employees. 44 highly qualified and certified trainers at 11 locations with more than 50 modern training machines ensure productivity and competitive edge. DMG MORI Academy uses their experience from the training to comprehensively advise training institutions and to provide them with tailor-made offers for CNC training at current industry standard. Customers from the training environment benefit from comprehensive and competent support from the concept over planning to the implementation of their training centre. our services at a glance: User training for efficient programming, installation and operation of your DMG and MORI machines Maintenance training for maximum production reliability Qualification analyses and tailor-made training concepts Training of CNC specialists The latest Teachware products: from controlidentical software to the full equipment of your CNC training rooms Complete solutions for CNC educational institutions and training workshops from a single source at high-tech industry level Train in a future-oriented way and produce more productively: Whether it is industrial production or training with the control-identical 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 Tel.: +49 (0) teachware@dmgmori.com

50 50 emo 2013 celos world premieres ecoline systems lifecycle services DMG MORI Software Solutions DMG MORI Messenger Always up to date with your production progress! DMG Service Agent High availability thanks to timely maintenance! DMG Process Chain The fastest route from the idea to the finished workpiece! 1 : 1 simulation Reduced downtimes increased productivity: The new DMG MORI Messenger allows you to access detailed machine status information live anytime and anywhere. Thanks to permanent online monitoring you can always keep an eye on your production and reduce downtimes significantly. The DMG Service Agent is an intelligent early warning system to increase the availability of your DMG machines. The DMG Service Agent informs you about necessary maintenance in due time. The actual machine running time is automatically read from the PLC and recorded. Based on this data, you are able to plan your maintenance intervals. The worldwide unique solution for your production process: Planning, programming, simulating, producing complete from a single source and configured individually according to your requirements. As your partner we structure, standardise and automate your processes and also provide all necessary software tools. From the planning of the idea with Siemens NX CAD via programme creation with Siemens NX CAM and the subsequent 1 : 1 simulation of the completed NC programme in the DMG Virtual Machine, the DMG Process Chain offers maximum economic efficiency and the highest level of process safety! Establish a futureoriented process chain in your production with the help of our unique competence and our software solutions. Increase efficiency and added value with the consistent key technology the DMG Process Chain. Your vital machine part A new machine is a major investment it should be earning for you right from the start. Our dedicated teams will help you ensure that it is tooled up, optimized and running effectively from day one to minimize your pay-back time. Take advantage of the most vital machine part and see how much you could save with our return on investment calculator. Scan the QR code or visit UK DMG MORI SEIKI Europe AG Lagerstrasse 14, CH-8600 Dübendorf Tel.: +41 (0) 44 / , Fax: +41 (0) 44 / info@dmgmori.com, Imprint: Journal dmg mori Journal for customers and interested parties. Publisher and responsible for the contents: DMG Holding AG (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 German 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.