DMG Mori Five world premieres and 6,000 visitors at the anniversary in-house exhibition

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For many machining professionals, the in-house exhibition of DMG Mori in Pfronten (Germany) is the first event of the year. On its 30th anniversary, the event is themed "Machining Transformation Strategy."

The plant in Pfronten (Germany), which is now part of DMG Mori, opened its doors for the first time 30 years ago for an in-house exhibition. Today, this event has a permanent place in the schedules of many machining companies. A lot of practical knowledge and numerous technical innovations attract many trade visitors to the Ostallgäu region (County in Bavaria, Germany) every year.

Wide range of exhibits

Under the term "Machining Transformation Strategy," the company showcases its vision for the future of metalworking. Additionally, the world's largest machine tool manufacturer presents five exclusive world premieres—ranging from the highly rigid CTX 750|1250 universal turning machine for 6-sided complete machining, an ultrasonic-assisted 5-axis machine for high precision, and two robust entry-level 5-axis vertical machining centers to the new generation of a proven 5-axis universal machine. This is the range of innovations presented at the in-house exhibition.

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All these innovations support DMG Mori's Machining Transformation approach as a window into fascinating possibilities. At its core, it is about an optimal connection of people, machines, technologies, automation, and digitization. With this, the machine manufacturer aims to provide a comprehensive approach to optimizing process chains, increasing productivity, and promoting sustainability.

High-rigidity universal lathe

One of the world premieres presented is the highly rigid CTX 750|1250 universal turning machine—the novelty that represents the sixth generation of the CTX universal turning machine series, promising users top performance and precision thanks to 6-sided complete machining. The machine combines high performance with excellent precision and energy efficiency. It is built very compactly, offering users a workspace on just 11.7 m² (approx. 14 sq yd) that can accommodate workpieces with a diameter of up to 700 mm (approx. 27,5 inches) and a length of up to 1290 mm (approx. 50,7 inches).

Machining Transformation is based on four essential pillars: process integration, automation, digitalization, and green transformation.

Cornelius Nöß, Managing Director in Pfronten (Germany) at DMG Mori

The machine is equipped with powerful spindles on both the right and left sides. It can be optionally fitted with a Y-axis offering a +/- 85 mm travel range (approx. +/- 3,3 inch travel range) and provides driven tools with up to 6000 rpm. Thanks to the integrated processes, it enables productive and highly precise 6-sided complete machining of complex geometries. With its highly rigid machine concept, linear guides up to 55 mm wide (approx. 2,2 inches wide), comprehensive cooling measures, and direct measuring systems from Magnescale, the CTX 750|1250 can achieve positioning accuracies of 6 µm and 12", according to the manufacturer.

Ultrasonic-assisted machining center

Another world premiere is the ultrasonic-assisted machining center Ultrasonic 20 linear in its 3rd generation—according to the tool manufacturer's officials, the most precise 5-axis machine from DMG Mori. The new machine for ultrasonic-assisted grinding has been completely redesigned. The developers benefited from the experience of 600 installed predecessors. The high positioning accuracies of 3 µm in the linear axes and 3" in the swivel axis reportedly surpass even the µPrecision technology, according to the manufacturer.

Supported by Ultrasonic technology, DMG Mori's most precise 5-axis simultaneous machining center is designed to enable ultrasonic-assisted milling and optionally grinding of advanced materials such as glass, ceramics, and challenging composites for the semiconductor industry. The ultrasonic overlay of the tool rotation with amplitudes of up to 15 µm promises a 50 percent reduction in process forces. This allows for higher feed rates, improved surface quality, and longer tool life, depending on requirements.

Universal machining centers for a wide range of components

Two other world premieres presented for the first time at the in-house exhibition are the universal machining centers DMX 60 U and DMX 80 U. The machines are based on the proven and robust design of the three-axis DMV vertical milling machines. The developers at DMG Mori have adapted the concept for the DMX 60 U and DMX 80 U for five-sided machining of complex workpieces weighing up to 300 and 350 kg, respectively. The DMX 60 U offers travel paths of 600 x 600 x 510 mm (approx. 24 x 24 x 20 inches), while the DMX 80 U provides 800 x 600 x 510 mm (approx. 31 x 24 x 20 inches). With this, the two new universal machining centers are intended to be suitable for a wide range of components in general mechanical engineering, tool and mold making, as well as other demanding industries.

The foundation for high precision requirements is laid by the monolithic machine bed made from solid cast components and the wide roller guides. These ensure that the DMX-U machines have 45 percent higher rigidity compared to the previous series. This allows for dynamic machining with rapid traverses of up to 42 m/min (approx. 138 ft/min). With sophisticated temperature compensation measures, the developers achieve high thermal stability in the machines. Additionally, direct measuring systems and direct drives in the X and Y axes enable high positioning accuracy. DMG Mori specifies the roundness accuracy at 6 µm.

Our users need to continue evolving to remain sustainably competitive.

Cornelius Nöß, Managing Director in Pfronten (Germany) at DMG Mori

With its fifth new introduction, the machine tool manufacturer aims to set new standards in 5-axis universal machining. The DMU 60 eVo of the 2nd generation is intended to excel, particularly in precision and productivity. The engineers at DMG Mori expanded the concept with its special table kinematics to include the ability to integrate machining processes such as mill-turning, gear milling, and grinding processes. This process integration extends the machine into a multifunctional machining solution, allowing users to respond flexibly to a wide variety of workpieces, materials, and increasing demands. With automation tailored to the users' needs, spindle run times can be optimized, making the machine's hourly rates more economical.

Machining Transformation Strategy

Although each of these world premieres is already a good step towards optimized process chains, higher productivity, and more sustainability on its own, the innovations only reveal their full potential when integrated into a "Machining Transformation Strategy." What lies behind this?

We aim to provide maximum support to users with our technological expertise and our specialists.

Cornelius Nöß, Managing Director in Pfronten (Germany) at DMG Mori

"Our Machining Transformation Strategy is based on four key pillars: process integration, automation, digitization, and green transformation," explains Cornelius Nöß, Managing Director at DMG Mori in Pfronten (Germany). "We believe our users will need to transform. They must continue to develop to remain sustainably competitive. And we want to provide maximum support with our guiding principle of 'Machining Transformation'."

Process integration is based on 5-axis technology

One of the pillars of the Machining Transformation Strategy is process integration. "It is generally based on 5-axis technology—essentially, it is about trying to integrate as many manufacturing processes as possible into one machine or system. For example, as turn-mill centers or mill-turn centers. Additional technologies can be integrated, such as gear machining, in-process measurement, grinding on the machines, and much more." It is the attempt to pack as much as possible into one machine to complete parts as extensively as possible on a single machine in just a few setups.

Falling quantities are one of the challenges we must face.

Cornelius Nöß, Managing Director in Pfronten (Germany) at DMG Mori

Another pillar is automation—especially challenging in times of decreasing batch sizes down to lot size one. "We have to address this," emphasizes Nöß. "For example, by trying to make automation as flexible as possible for our users, so that they can manufacture automated down to actual lot size one. For instance, with modular concepts that we offer our users, where it's not about the last tenth of a second, but rather about process stability, about spindle run time. It's about keeping the machines running 24/7 around the clock."

Sustainability creates competitiveness

The third pillar, "Green Transformation," revolves around sustainability. "This is important for all of us. In our society in general, but it is also an important topic for our users," explains Nöß. "It's not about a company attaching a green label to itself. It's rather about saving energy, reducing costs in manufacturing, and producing sustainably overall." According to Nöß, this also goes hand in hand with making users competitive. For instance, if they can save up to 30 percent energy and thereby reduce operating costs on the machines: "The goal is, of course, to achieve savings with at least the same performance and, accordingly, manufacture more productively at lower costs."

The goal, of course, is to achieve savings with at least the same performance and accordingly produce more productively at lower costs.

Cornelius Nöß, Managing Director in Pfronten (Germany) at DMG Mori

The last point is "Digital Transformation"—it makes operating the machines more attractive and easier for users and increases process security. "Additionally, it's about making machining itself and the manufacturing industry more attractive for young employees. With Celos X, we have created a platform that allows our controls to be operated app-based. It also simplifies operation for our users, addressing the skills shortage. But it's also about making the machines generally attractive."

Integrate existing solutions

Typically, companies have grown organically, and it's not just new DMG machines present in operations. "Here, we offer appropriate retrofit solutions for existing machines and also integrate third-party machines," adds Nöß. "For instance, through DMG Mori Messenger solutions, which allow users to query the status of machines. We try to raise awareness among users to retrofit where it makes sense and is possible."

In machine transformation, the most important thing is to start and get going—regardless of which topic.

Cornelius Nöß, Managing Director in Pfronten (Germany) at DMG Mori

Furthermore, DMG Mori now prepares its machines for automation as a standard from the factory. In many cases, automation interfaces are already present in the standard to simplify retrofitting when users take the next steps. "In Machine Transformation, the most important thing is to start and get going—no matter which topic," emphasizes Nöß. "But it's crucial to get moving and shape the future. Our specialists can provide effective support. We have the corresponding expertise to advise each user accordingly and offer them the right solution. One that is tailored to fit them perfectly. We want to provide maximum support to users with our technology expertise and our specialists."

Latest trends and developments in metal cutting

In addition to the exhibits from DMG Mori and numerous co-exhibitors, visitors will find plenty of opportunities to learn about the latest trends and developments in metal cutting. The exchange among professionals is also well catered for. Furthermore, the machine manufacturer invites school classes to its in-house exhibition—the youth of today are the future of the industry. The exhibition presents itself as a modern, innovative, and interesting employer for the creative minds of tomorrow.

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