The trend towards complete machining continues unbroken.On the one hand, the diversity of products and variants is growing across a multitude of different industries and this in turn leads to a reduction in lot sizes on an increasingly wider scale. In view of such conditions, complete machining in a single setup quickly becomes the only economic alternative. On the other hand, the workpieces are getting more and more complex while at the same time placing higher demands on precision. Adding to this, global competition is aggravating the earnings situation in manufacturing plants. DMG MORI has been revolutionizing turn-mill complete machining with its turn & mill machines in the CTX TC series ever since their first presentation eight years ago. These machining all-rounders have now entered their second series. With the CTX gamma 2000 TC, DMG MORI will be presenting one of its most recent turn & mill machining centres of the second generation with the new turning/milling spindle compactMASTER at the Innovation Days in Chicago from May 17 – 20, 2016.
DMG MORI now producing the smaller CTX beta TC already in its second generation, the larger sister models CTX gamma 1250 TC and CTX gamma 2000 TC were also further developed for the EMO 2015. The outstanding features of these two models are the X-travel, which has increased by 5.9 in.to now 31.5 in., and the compactMASTER spindle of the B-axis, developed together with the Japanese engineers as a cooperation project. Its unique selling point above all is the torque increased by 120 percent to162.3 ft lbs.
With a diameter of 8 in., the length of the compactMASTER spindle has been reduced by 2.8 in. so that it now measures only 17.7 in. – and all this with a 120 percent higher torque. The interplay of the 5.9 in. larger X-axis (-1 / +30.5 in.) and the 0.8 in. longer Y-travel of ± 8.3 in. brings an enormous gain in freedom for users. It means, for example, that radial machining of workpieces with maximum diameters of 27.6 in. is possible with 6.7 in. long tools (with the B-axis in a vertical position). The 2nd generation of the CTX gamma TC also has advantages where horizontal machining is concerned: workpieces measuring up to a good 11.8 in. in length can now be completely drilled out horizontally or hollow turned with no problem at all on the CTX gamma 2000 TC. The respective turning length is 80.7 in.
The core element of the two new CTX gamma TC models is still the B-axis with its swivel angle of ±120°, which is mounted on a highly stable travelling column and ensures milling performance right through to the field of 5-axis simultaneous machining. The machine concept has been radically revised with just such stability and precision in mind. The machines now have an integral thermal concept. This includes among other things integrated bed cooling as well as cooling of the linear guides of the travelling column, the spindle motors and the drive of the B-axis. Combined with the MAGNESCALE magnetic measuring systems, the thermal displacement of the machine is now ≤ 10 µm.
In addition, DMG MORI has completely redesigned the travelling column. The U-shaped basic construction with 3+2 guide shoes in the Z-axis increases stability enormously, a feature that has a great impact on machining with the Y-axis. Linearity has been improved here by over 60 percent to now stand at ≤ 2 µm. Another indication of the innovative character of the machine is the up to 65 percent faster feed rate of 1,968.5 ipm in all axes. It can also be optionally equipped with a linear drive in the Z-axis, which with 1 g acceleration increases the feed to 2,362.2 ipm and ensures maximum long-term accuracy; including a 5-year warranty granted for the linear drive.