for a total of 48 live tool positions. Complex work can be completed in just one operation with 7.5-hp (5.6-kW) BMT- 65 tools on every tool station. The machine is also available in the smaller 52-mm bar capacity for “done-in-one” capa- bility on Ø 2" (51-mm) bar work on the Cyclone 52-3TMY. Both machines are also available with just two-tool turrets with 32 live tool positions. The Cyclone 78-MSY can do “done-in-one” work with

one live tool turret machining up to Ø 3" (76-mm) bar stock or using 10" three-jaw chucks. This 16-station BMT-65 servo turret can handle over 30 tools. Radial and axial-driven tools have full access to the fully synchronized main and subspindle. The 30-hp (22.3-kW) 4000-rpm main spindle and 7.5-hp (5.6-kW) milling spindles are optimized for ef-

ficient metal removal. The above heavy-duty machines are equipped with roller-bearing linear ways that provide twice the rigidity as ball-bearing ways, for more aggressive cut- ting with improved surface finish and superb tool life. The seven-axis Cyclone CS-32 can machine up to Ø 1

3/8" (34.9-mm) bar work using 27 tools, including 11 driven tools and nine backworking tools, in this very popular Swiss-style CNC lathe for efficient complete “done-in- one” machining. Work that has no, or very limited, live tool requirements can be efficiently processed on the six-axis Cyclone GTS-42 gang-tooled CNC lathe with a full-sized subspindle for work up to Ø 1 5/8" (41.2-mm). A shorter version of this article appeared in the May issue of Manufacturing Engineering magazine.


DMG MORI introduces two hybrid machines DMG MORI has expanded the

MG MORI (Hoffman Estates, IL) developed an advanced hybrid multitasking technol-

ogy combining laser deposition welding using a powder nozzle with conventional subtractive machin- ing. The firm introduced two hybrid machines, the Lasertec 65 3D and the Lasertec 4300 3D. The blown powder deposition welding pro- cess with laser has long been used in principle for repair work in the tool making or turbine technology branches. In this process, the pow- der is melted onto the base mate- rial by the laser beam. DMG MORI builds up the part or surface layer by layer but only uses the powder where it is actually needed, reduc- ing how much powder is needed. Also, buildup is said to be about 10 times faster than other processes. The basic machine platform for the Lasertec 65 3D is a DMU 65 monoBLOCK five-axis machine for high-precision milling operations with up to five-axis simultaneous machining. The integrated laser head is equipped with a 2.5-kW diode la- ser. It is automatically exchangeable and during the milling operations it is moved completely out of the working envelope of the machine. The machine is ideally suited for the complete hybrid production of com- ponents, as well as for repair work and applying partial or full coatings.

additive manufacturing program with the introduction of the Lasertec 4300 3D, which will add the possibil- ity of turning operations to laser de- position welding and five-axis milling. As a result, rotation-symmetric com- ponents can now also be produced with the hybrid process. Equipped with a mirrored C-axis, the 4300 can machine workpieces on the rear side with the counter-spindle thus enabling in total six-sided complete machining of the finished part. With Ultrasonic 20 linear 2nd

generation technology, including spindle speeds op- tionally up to 60,000 rpm, DMG MORI has increased its high-preci- sion capability for users in the optical, clock and watch, medical and high-precision mold construction industries. High-speed cutting and highly efficient Ultrason- ic grinding of advanced materials are combined on one machine. Ultrasonic results in a

higher removal rate, ac- curate edge machining and up to 40% reduced process forces in the machining of advanced materials, such as glass,


ceramics, corundum, composite materials and hard metal. Deflec- tions are minimized while workpiece accuracy and process reliability are increased. In addition, this oscillat- ing contact interruption results in better lubrication and cooling of the cutting edge, as well as opti- mum removal of particles from the active zone. This enables longer tool service life, as well as excellent surface qualities of up to Ra

<0.1 ѥm

for hard-brittle, high-performance materials, such as glass, ceramics, corundum and other materials that are difficult to machine.

Summer 2016

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