DMG Mori ULTRASONIC 20 linear 3rd Generation

On the DMG MORI ULTRASONIC 20 linear 3rd Generation the tool does two things at once: it rotates in a high-frequency spindle, and it carries an ultrasonic oscillation of up to 15 µm in amplitude on top of that rotation. The machine around this process is small, with travels of 220 mm (8.7 in) in X, 370 mm (14.6 in) in Y and 290 mm (11.4 in) in Z.

DMG MORI integrates the ultrasonic function through the HSK-E32 interface and puts a number on its effect: process forces reduced by up to 50%. Lower force is the purpose of the whole design. With less load on each cutting edge or abrasive grain, a small tool can be fed harder before it deflects or breaks, and a fragile feature is less likely to chip. The manufacturer names three outcomes, each qualified as depending on requirements: higher feed rates, improved surface finishes down to Ra < 0.1 µm, and longer tool service life. It also states that the advantages are kept even with non-optimal tools and that a stable process window gives reproducible, consistent results.

Spindle speed is the other half. The spindles are high-frequency units on the HSK-32 interface: 42,000 rpm, with max. 60,000 rpm reached by an optional spindle. Small tools need that kind of speed to arrive at a workable surface speed, so decide early whether the optional spindle belongs in the quotation.

The structure is built to hold position over long cycles: a FEM-optimized cast bed, temperature management that DMG MORI calls finely tuned and highly sensitive, and linear drives with acceleration of up to 1.2 g. The workpiece limit is Ø 220 x 283 mm at 15 kg (33.1 lb). For bigger parts the ULTRASONIC 60 eVo linear offers 750 mm (29.5 in) of X and 550 mm (21.7 in) in both Y and Z.