5-axis Ultrasonic precision machining

Discovered at EMO, the DMG MORI SEIKI Ultrasonic 30 linear with its highly accurate, long-term stable gantry design with integral temperature control concept opens up new possibilities in 5-axis precision machining of advanced materials for all precision-relevant machine components.

Finishing machining of a watch case from blue zirconium oxide in pendulum grinding with Ra < 0.1 µm.
Finishing machining of a watch case from blue zirconium oxide in pendulum grinding with Ra < 0.1 µm.

The application focus here is on highest dimensional accuracy, contour accuracy as well as surface qualities Ra < 0.1 μm for Ultrasonic grinding of complex geometries in high performance materials for the optical, watch and medical industries as well as precision mould manufacturing. The highly dynamic, actively cooled linear drives in X, Y, Z with up to > 1.2 g acceleration and 50 m/min rapid traverse, 40,000 min-1 as standard as well as the optional swivel range of ±120 ° in the B-axis reinforce the excellent efficiency of this innovation.

Reduced process forces for surface qualities of Ra < 0.1 µm and longer service life
Based on a standardised HSK-40 spindle holder, the special Ultrasonic actuator holders can be exchanged easily and automatically in the milling spindle. These include so-called piezo elements, which are activated with an inductive system via the spindle with a high frequency between 20 and 50 kHz. “The actual tool rotation is superimposed with additional kinematics in longitudinal direction”, explains Ultrasonic Sales Manager Benedikt Brocks. He adds “At the cutting edge an amplitude as high as about 10 µm is generated” .

Reduction of the process forces by up to 40 %
“This oscillating contact interruption achieves better lubrication and cooling of the cutting edge as well as optimum removal of particles from the active zone.” This Ultrasonic superimposition of vibrations at the cutting edge of the diamond tool thus reduces the process forces by up to 40 %, depending on the material.
This results in longer tool service life as well as excellent surface qualities of up to Ra < 0.1 µm for hard-brittle high-performance materials like for example glass, ceramics, corundum and other materials that are difficult to machine such as hard metal or fibre composites.

We will come back in this novelty in more detail in one of Eurotec’s next issues. Do you want to be informed when it’s released? Just send us an e-mail at [email protected] or you can subscribe online here.

Ultrasonic operating principle: Superposition of the tool rotation with additional oscillating kinematics results in significantly reduced process forces.
Ultrasonic operating principle: Superposition of the tool rotation with additional oscillating kinematics results in significantly reduced process forces.

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DMG MORI SEIKI
www.dmgmoriseiki.com
Deutschland : +49 (0)180 5 49 00 22
France : Tel. +33 (0)1 39 94 68 00
Suisse : Tel. +41 44 / 824 48 48

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.Midest 2013

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