Product category:
Miscellaneous machine tools, gear cutting machines and equipment
News Release from: DMG (UK) | Subject: DMS Ultrasonic ultrasonics machining centre
Edited by the Manufacturingtalk Editorial
Team on 11 May 2005
Ultrasonics machines hard, brittle
materials
Ultrasonics diamond machining system offers a five-fold increase in productivity for working advanced materials such as ceramics, glass, silicon, composites and precious stones.
Advanced materials such as ceramics, glass, silicon, composites and precious stones have important performance benefits Typically, they are low in weight and provide improved resistance to chemicals, temperature and wear
This article was originally published on Manufacturingtalk on 21 Jun 2001 at 8.00am (UK)
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Herman Sauer has over 30 years experience in ultrasonic technology that has now been combined with the metal cutting prowess of DMG.
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The result of this collaboration is the new DMS Ultrasonic, offered in four variations.
The '35' and '50' are both 3-axis machines with up to 500mm of travel.
The 5-axis models are the '50-5' and the '70-5' with up to 750mm of X-axis travel.
A further option allows the integration of conventional milling and ultrasonic machining in a single combination machine.
An obvious advantage is reduction in tool exchange times to just 10 seconds.
DMG is responsible for the manufacture of the basic machines and Sauer, for equipping them with highly developed ultrasonic components.
These include the ultrasonic spindle and generator, oscillation sensors and the diamond tooling.
Special requirements such as micro-machining can also be accommodate 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 rev/min - optionally 60,000 rev/min - 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<0.2 microns can easily be achieved.
ADR and ACC can be employed individually or in combination for maximum flexibility.
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