Product category:
Miscellaneous machine tools, gear cutting machines and equipment
News Release from: DMG (UK) | Subject: DMS Ultrasonic
Edited by the Manufacturingtalk Editorial
Team on 26 April 2002
Ultrasonics machine glass, ceramics and
stellite
a revolutionary and economical cutting method that boasts a fivefold increase in productivity, when compared to conventional methods, machines ceramics, glass and stellite.
Ceramics, glass and stellite may have brought the benefits of low weight and improved resistance to chemicals, temperature and wear but machining components from these materials is notoriously difficult, time-consuming and costly Now, thanks to its acquisition of Herman Sauer GmbH and Co KG, Gildemeister has introduced a revolutionary and economical cutting method that boasts a fivefold increase in productivity compared to conventional methods, excellent surface quality and assured process safety
This article was originally published on Manufacturingtalk on 11 May 2005 at 8.00am (UK)
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Herman Sauer has over 30 years experience in ultrasonic technology which has now been combined with the metal cutting prowess of the Gildemeister Group.
The result of this collaboration is the new DMS Ultrasonic, offered in two variations with 350mm and 500mm X-paths.
Deckel Maho is responsible for the manufacture of the basic machines and Sauer, for equipping them with highly developed ultrasonic components.
Further reading
CNC miller-drillers cut 20% off machining times
With the highly productive DMU 50 / 70 eVolution, DMG has added a new dimension to universal milling and drilling machines designed to save up to 20% on machining times.
Gildemeister lathe programme covers all
The lathe programme run by the GILDEMEISTER group has now become so extensive that there really is no machining job any more that these machines cannot do.
These include the ultrasonic spindle and generator, oscillation sensors and the diamond tooling.
Special requirements such as micro-machining can also be accommodated within the product programme.
The DMG/Sauer combination allows a milling, boring or grinding tool studded with self-sharpening industrial diamonds to be driven into a workpiece at a frequency of 20kHz or 20,000 times per second.
As a result, even the hardest materials can be machined at high feed power with low contact forces.
This protects both workpiece and tool and dramatically reduces process costs.
The ultrasonic process starts as a high-frequency electrical signal that is converted to a mechanical movement.
A booster subsequently amplifies the oscillation amplitude, in effect causing the diamond cutting tool to expand and contract in a pulsing action.
At peak of amplitude, the diamonds impact on the workpiece, breaking the surface into miniscule particles.
The simultaneous rotation of the tool, at speeds of between 3,000 and 40,000 rpm mainly achieves workpiece roundness but also removes excess workpiece particles from the working zone.
These are eventually removed simply with water.
Rinsing is deployed during grinding whilst rinsing and cooling respectively are achieved through the spindle during milling and drilling.
Process safety and accuracy, even for precision drilling of up to 0.3mm in diameter, is ensured by the CNC control.
Intelligent control algorithms guarantee smooth functioning through continuous process monitoring and the minute adjustment of process variables such as amplitude, feed and rotational speed.
Two types of process control are employed by the DMS Ultrasonic machines to measure physical parameters constantly.
The ADR adaptive control monitors the tool to achieve an optimum feed rate whilst the ACC acoustic control monitors the acoustic process signals emitted by the workpiece.
Thanks to ACC, a surface quality of Ra<0.2mm can easily be achieved.
ADR and ACC can be employed individually or in combination for maximum flexibility.
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