journal nº 1 – 2017 the dmg mori magazine for existing and prospective customers. dmg mori software solutions – solutions for the digital transformation: celos®, technology cycles and power tools. customer first – we have been listening! 5 service promises for the highest quality service at fair prices. clx / cmx: attractive base machine with maxi- mum precision and a multitude of options. integrated technology solutions for the die & mould and medical industry. journal nº 1 – 2017 virtual becomes real the digital path from the idea to the finished part more on page 2 new new automation automation more on page 10 new new new additive additive additive manufacturing manufacturing more on page 24 shape the future with manufacturing and automation solutions for industry 4.0 come and see us at the dmg mori open house in bielefeld 09 – 12 may 2017 dmg mori promotes automated technology and sector solutions for small, medium and large customers and invests in pioneering processes and digital solutions for the shop floor of the future. read more on this topic on page 2

software solutions - celos® editorial 3 dr. ing. masahiko mori, president, dmg mori company limited and christian thönes, chairman, dmg mori aktiengesellschaft successful new alignment and exciting innovations dear customers, partners and potential customers, dmg mori is developing dynamically. for your benefit, we are reorgani- sing ourselves and are concentrating on our core business with machine tools and services. we hope to impress you with our innovations and integrated technology solutions and continue to be a leader in this field. our objective is your success! if you are satisfied, then we are too! you, dear customers and partners, are at the centre of our customer focus and therefore our “customer first” programme. take advantage of our 5 service promises! you can now get original spare parts with a “best price” guarantee and highest availability, new call-out fees, all-round carefree contracts and much more. please see page 6 of this journal for more details. we are continuing to work on our “first quality strategy” with great passion. as a “global one company”, with dmg mori components we are combining quality, accuracy and robustness. the 18-month warranty with unlimited hours for all speedmaster® spindles is an example of how you can benefit directly from our global quality offensive. in 2017, we are concentrating on emo hannover. our new developments are aimed at this industry highlight. nevertheless, right at the start of the year, we are now able to present to you three world premieres and important innovations: + we are strengthening our expertise in additive manufacturing! in collaboration with realizer, dmg mori will in future also be offering selective laser melting and with it a perfect addition to our advanced technologies. + we will be promoting digitalisation! we are further expanding our software with innovative solutions. these are based on celos®. with 26 apps, we already support networked intelligent production. our 26 exclusive dmg mori technology cycles enable shop floor programming to be carried out quickly and easily. in production engineering, our dmg mori powertools simplify the automatic production of programs. you will see that, as a “global one company”, we are highly diversified and possess great technical expertise, innovation and global presence. make use of our power. we are here for you – no matter where, no matter when! please get in touch with us! our staff throughout the world are always ready to help! (cid:28)(cid:14)(cid:13)(cid:28)(cid:19)(cid:19)(cid:28)(cid:24)(cid:13)(cid:28) (cid:20)(cid:24) (cid:12)(cid:29)(cid:30)(cid:11)(cid:22)(cid:13)(cid:27)(cid:20)(cid:30)(cid:24) digital factory + integrated production planning and control with digital solutions from dmg mori tool / clamp celos® machine job manager pallet manager control status monitor performance monitor job assistant clamp check job manager messenger service agent tool handling job scheduler job assistant net- services energy saving robo2go documents settings settings condition condition analyzer dr. ing. masahiko mori, president dmg mori company limited christian thönes, chairman dmg mori aktiengesellschaft

software solutions - technology cycles 5 three times as many parts from the machine thanks to power tools from dmg mori! we would not have been able to realise the growth of the last 2 years without this solution. christian ruhland, managing director aytec automation gmbh cam programming with exclusive dmg mori power tools technology library reliable production based on your expertise! save and retrieve whole sequences and tool tech- nologies at the press of a button. + recognised features are specified with familiar tools and technology parameters + approved cutting parameters are automatically assigned in new programs highlights + automatic program creation in production engineering + new: technology library, adaptive process, cam agent + new: 24 dmg mori experts assist you with the introduction of siemens nx, autodesk featurecam and esprit + exclusive modular dmg mori software solutions virtual machine avoid real problems in the virtual world! multi-machine control and unmanned production by controlling your nc programs + 1:1 simulation with numerous new functions + simple handover to the simulation software using dmg mori interfaces for: – clamping devices – zero points and table positions – tools and nc programs adaptive process quality under control! fully automatic in-process alignment of components, machining of fits and recording + easy-to-use input screens enable … – fits to be produced with high accuracy – measuring probes to be calibrated – measurements to be recorded + adaptive process control + all directly on the controller without interfering with the machine +0.05 -0 92 cam agent nc programs without end! component families from your cad software once learned automatically generate nc pro- grams to your requirements for any variants. ø 58h7 + dmg mori smart programming enables: – learning of a template from any cad system – automated program creation while main- taining all previously defined procedures and technologies – automatic matching of programs to existing tools and technologies when changing machines

manufacturer service - customer first 7 3 4 5 service significantly reduced service costs preventive service to minimize downtimes reconditioning new service prices dmg mori service plus re-establish performance up to 100 % + fixed-price call-out fees + no more expenses based on engineer's travelling time + no mileage charges + no expenses or small parts costs + inspection plus: cost-efficient service entry pack- age with detailed report on machine status + maintenance plus: full 2,000 hour maintenance with replacement of all necessary wear parts + servicecompetence plus: we help you maintain your machine and show you all you need to know about performing your own maintenance + safeguard productivity and established processes + maintain and increase performance + re-establish the machine accuracy + refurbishment by experienced experts with exclusive manufacturer know-how + warranty on full scope of service this is a great initiative from dmg mori. defi nitely a plus and an important argument for your business. it facilitates our day to day work as a customer. fredrik gordon (managing director), svarvmekano i malmö ab, sweden dmg mori’s maintenance plus is the right choice for us. this gives us both assurance and a price benefi t. eamon lyons (managing director), midland aerospace, united kingdom c a l l - o u t f e e s w i t h u p t o 5 0 % n e w p r i c e a d va n ta g e 1 0 % s p e c i a l d i s c o u n t o n a n y a d d i t i o n a l s e r v i c e s a n d r e p l a c e m e n t pa r t s * before - after b e f o r e a f t e r do you have any questions? we will get back to you by return. simply send an email to: customer.first@dmgmori.com find out more about predictabel and lower operating costs at: serviceplus.dmgmori.com are you interested? we will get back to you by return. simply send an email to: lothar.sommer@dmgmori.com *only in combination with dmg mori maintenance plus or inspection plus

ctx tc 9 ctx tc turn & mill complete machining compactmaster® with 120 nm + 530 cm³/min chip removal rate (ck45) < 5 µm thermal stability + excellent surface quality thanks to spindle length compensation … to turn & mill up to 80 tools + unlimited flexibility and shortest set-up times technology cycles examples turn & mill technology cycles examples turn & mill protection package* protection package* + increased efficiency due to reduced + increased efficiency due to reduced idle times idle times + machine protection control – vibration sensor on the milling spindle – rapid shutdown < 10 milliseconds + easy tool monitor 2.0 – tool monitoring system *package comprising mpc and easy tool monitor 2.0 ctx beta 800 tc + universal package with chuck, chip conveyor, internal coolant supply and multi-tools as standard + turning diameter up to 500 mm + turning length up to 800 mm + 5-axis simultaneous machining + intelligent movement guidance for perfect surfaces + free-form surfaces using 5-axis interpolation + 5-axis movements programmed using customer’s cad/cam system + look-ahead function for continuous processing

automation 11 examples of standard automation examples of cells ctx beta 800 tc with robo2go modular cell system + available for all dmg mori universal lathes with celos® + no robot knowledge required, control via celos® + free accessibility for the operator + workpiece and tool handling + standardised 710 mm module width for easy cell matching + wide range of peripheral modules, e.g. – deburring – washing – measuring – tool handling milltap 700 with wh3 + workpieces up to a maximum of 7 kg + working radius of 892 mm working radius of 892 mm + 15-way workpiece-carrier circulating system 15-way workpiece-carrier circulating system 710 mm 710 mm 710 mm nrx 2000 with robotic loading incl. position detection for bulk material + gantry loader for transfer from buffer to process 1 and 2 2x ctx alpha with gantry loading 2x ctx alpha with gantry loading + integration of up to 8 machines + standardised, function-oriented modules + modular system + workpiece, pallet and tool handling cpp – carrier pallet pool lpp – linear pallet pool + extendable for up to 4 machines with up to 2 set-up stations + up to 29 additional pallet positions + extendable for up to 8 machines with up to 5 set-up stations + up to 99 additional pallet positions on 2 levels

dmu 13 +110 ° +110 ° +110 ° -35 ° -35 ° new protime – display for: + remaining runtime + coolant warning + hydraulic oil warning + imminent tool change warning control options celos® from dmg mori with 21,5" ergoline® and siemens 19" dmg mori ergoline® control with heidenhain tnc 640 highest accuracy thanks to integrated cooling concept tool handling pallet handling automation options thermal control + cooling of ball screw nuts, guides and bearings + spindle cooling + cooling of table bearings e.g. wh 10 + full machining thanks to additional operations + flexible system with maximum storage capacity e.g. ph 150|8 + inexpensive entry level + integral pallet magazine with 8 pallet set-down positions (option: up to 30 positions) + integral workpiece magazine for loading in parallel with production + pallet setup station with intuitive touch screen control panel

clx 15 customisation new new technology cycles e.g. easy tool monitoring + damage prevention by controlled stopping of spindles and axes in the case of broken or overloaded tools + immediate feed stop: spindle stop after one second (tool cutting free) + no sensors thanks to innovative evaluation algorithms + automated learning of load limits for turning, milling and drilling operations new y-a xis* with ± 6 0 m m new options + differential pressure clamping for main spindle + direct measuring systems (x / z) + tool measurement + chip conveyor at rear + automatic door + automation package + automation package + parts catcher + parts catcher + nc tailstock + nc tailstock *available for the clx 450 *available for the clx 450 *available for the clx 450 find out more about the clx range at clx.dmgmori.com new 19" dmg mori slimline® multi-touch control with operate 4.7 on siemens highlights + 19" multi-touch display + import dxf files directly to the nc controller + extended storage capacity with 4 gb and additional extended storage capacity with 4 gb and additional 8 gb on the dmg mori smartkey® 8 gb on the dmg mori smartkey 8 gb on the dmg mori smartkey 8 gb on the dmg mori smart ® + 45° swivel range for optimum ergonomics + 45° swivel range for optimum ergonomics

cmx modular system 17 19" dmg mori slimline® multi-touch control with operate 4.7 on siemens 15" dmg mori slimline® with mapps iv on fanuc 15" dmg mori slimline® with heidenhain tnc 620 new customisation new new new new automation solutions + automation solution wh 10 with 6-axis robot + load capacity 10 kg or 25 kg new options + lehmann 5-axis attachment table for the cmx v range + pressurised air through the spindle centre + process stability and precision thanks to measuring probe and tool measurement + internal coolant supply with 12, 20 or 40 bar in the production packages new technology cycles + atc – application tuning cycle for the cmx v range: minimum machin- ing time combined with maximum component quality! + 3d quickset® for the cmx u range: quick and easy for maximum 5-axis precision!

die & mould 19 die & mould matrix xxl > 2,700 mm large 1,500 - 2,700 mm small / medium < 1,500 mm 3-axis 5-axis universal 5-axis high precision new technology dmu 340 p, dmu 600 p dmf 360/600 dmu 600 gantry linear dmu 210/ 270 dmf180/260 dmu duoblock® dmu monoblock® dmu evo linear dmu 270 µprecision dmu 210 µprecision dmu 125 µprecision nvd hsc linear lasertec 210 shape lasertec 75 shape lasertec 45 shape dmc v nvx 5-axis high precision new technology dmu duoblock ® / dmu portal hsc 30 / 70 linear dmu 600 gantry linear lasertec shape + machining of large workpieces of up to 3,000 x 6,000 mm + also available as µprecision for highest accuracies + linear drives for maximum long- term accuracy and ra < 0.15 μm + high-gantry design with table loading up to 150 t + hsc spindles up to 40,000 rpm with + 3 m/s2 path acceleration thanks to shaft, flange and sleeve cooling linear drives on all axes + texturing of geometrically defined surface structures + low space requirement thanks to integral laser press tool for car wings press tool for car wings machine: dmu 340 p machine: dmu 340 p material: 1.2343 material: 1.2343 dimensions: 1,000 × 1,800 × 400 mm injection mould for headlamps machine: hsc 70 linear material: 1.2312 dimensions: 680 × 400 × 350 mm, ra < 0.15 µm mould insert for car bumpers machine: dmu 600 gantry linear material: 21crnimo2 dimensions: 2,500 × 1,000 × 1,400 mm injection mould for tablet pc cover machine: lasertec 75 shape material: aluminum dimensions: 290 × 220 × 65 mm

die & mould dmu monoblock® now with 4 new options > 4 , 0 0 0 m a c h i n e s i n s ta l l e d w o r l d - w i d e 21 spindles 1 motorised spindles up to 40,000 rpm + best quality surface finishes thanks to maximum speeds of up to 40,000 rpm + hsk-e50 / 20 kw (40 % duty cycle) / 16 nm hsk-e50 / 20 kw (40 % duty cycle) / 16 nm (40 % duty cycle) (40 % duty cycle) shaft, flange and shaft, flange and jacket cooling jacket cooling drive 2 direct drive technology on the c-axis + dynamic c-axis with up to 80 rpm rapid traverse ++ dynamic c-axis with up to 80 rpm rapid traverse + water-cooled direct drive on the c-axis ++ water-cooled direct drive on the c-axis 3 direct drive technology direct drive technology direct drive technology on the a and c-axes + maximum dynamics thanks to direct drive on the a-axis (tandem drive) and c-axis a-axis (tandem drive) and c-axis + best positional uncertainty on the a and c-axis (7ws) ++ best positional uncertainty on the a and c-axis (7ws) you will find more on the dmu monoblock® range at monoblock.dmgmori.com package machine dmu 75 monoblock ® block® highlights 4 celos® with mapps on fanuc now available for the dmu 75 monoblock® + equipped with simple and easy-to-follow dialogue programming function + rapid access to required information and manual data thanks to search function + 6-window display for checking all necessary machine information at once + two multi-touch panels also available with: celos® with siemens heidenhain itnc 640

premium partner 14 dmg mori systems premium partner 23 haimer gmbh – now also with tool presetters zahoransky ag wada machine manufacturing co., ltd. “thanks to the new manufacturing cells consisting of three 5-axis machining centres with a total of 580 tool pockets and 112 pallet positions, we can now manufacture more than 4,000 different workpieces highly flexibly and fully automatically.” premium partnership of dmg mori and haimer – takeover of microset gmbh joint sales of tool presetters the long-established partnership between dmg mori and haimer is becoming closer. with effect from 1st january, 2017, haimer has taken over tool presetting technology from dmg mori and with it the company microset gmbh, which will now be known as haimer microset gmbh. for haimer, this is the perfect addition to its market-leading assortment in the fields of tool clamping technology and tool management. all microset products and services can still be obtained from dmg mori as a provider of integrated solutions. all dmg mori tech- nology and solution centres as well as suppliers‘ works through- out the world will be equipped exclusively by haimer with products in the fields of tool presetting, balancing and shrinking, including shrink chucks and tool rooms. from left to right: dr. maurice eschweiler, board member dmg mori aktiengesellschaft, claudia haimer, managing partner haimer gmbh, christian thönes, chairman dmg mori aktiengesellschaft, andreas haimer, managing director haimer gmbh haimer portfolio in the dmg mori technology- and solution centres flexible manufacturing cell with two dmu 60 evo, one dmu 70 evo, one robot on the 7th axis and cad / cam connection to the process control computer for controlling the machine and tooling requirements as well as order prioritisation. tooling technology tool management shrinking technology cell has space for 130 additional tools, which can be supplied to any of the machines fully automatically. “the same flexibility exists for the pallets”, explains lothar wagner: “dmg mori systems have set up 112 shelf positions.” with only six stand- ardised clamping devices, all components can be covered. “all pallets fit into every machining centre.” thanks to the six loading stations, idle times during loading are reduced to a minimum. “we now have sufficient buffer capacity, so that employees can load without having to wait.” zahoransky works in two shifts, but the manufacturing cell is loaded so that it can autonomously run overnight and into the weekend. the manager production states: “we aim for 6,000 running hours per year on each machining centre.” since the start of the 20th century, zahoransky ag has been acknowledged as the leader in automated manufacture of brushes. at the head office in todtnau-geschwend, approximately 300 employees attend to the development and manufacture of special machines for the production of twisted brushes, household brushes, technical brushes, toothbrushes and their packaging. small batch sizes and one-off production are the order of the day. “this requires a high degree of flexibility, especially regarding swarf management”, according to lothar wagner, manager production of zahoransky ag. this flexibility was expanded in 2015 with a manufacturing cell from dmg mori. during the turnkey project, automation experts from dmg mori linked three 5-axis machining centres – two newly installed dmu 60 evo and one dmu 70 evo dating from 2007 – via a robot. “this was carried out while production continued”, remembers lothar wagner. for zahoransky, this automation is a bespoke solution with strin- gent demands on the flexibility with which workpieces must be produced. the range of components presently comprises more than 4,000 part numbers, with components made of aluminium, steel and even stainless steel in varying sizes. therefore a large number of tool positions and pallet positions is required. haimer microset tool presetting technology will complement the existing portfolio with high-precision tool (clamping), besides the 120 or 210 tool positions in the machines, the robot shrinking and balancing equipment. this will make haimer a tool management system provider for all aspects of machine tools. measuring- and presetting technology balancing technology balancing technology zahoransky ag anton-zahoransky-strasse 1, d-79674 todtnau info@zahoransky.com, www.zahoransky.com „rpp system-integrated nhx 4000 improves efficiency of high-mix low-volume production.“ m o r e t h a n 5 , 0 0 0 u n i t s o n t h e m a r k e t medical equipment component machined by comprehensive features of the nhx 4000 with a max workpiece swing diameter of 630 mm. uno smart executive director shuhei wada has every confidence in dmg mori’s prompt service and machine stability and accuracy. uno premium advantages wada machine manufacturing co., ltd., established in 1957, vio linear expanded into the medical equipment field after relocating to numazu iron industrial park in 1973. since then the company has specialised in machining of precision parts for cutting- edge medical equipment for a major medical equipment company. “we have been commended by the customer several times for keeping to strict delivery schedules despite our distance from them, while maintaining high product quality,” says yoshihisa wada, president of the company, looking back on the company history. advanced medical equipment such as mri and ct scanners requires quick responsiveness to high mix, low volume production as well as high precision. + your dmg mori contacts will still be responsible for “for the first time in japan, we employed the 5-pallet rpp the sales and servicing of microset products (round pallet pool)-integrated nhx 4000.” a normal pallet pool system requires a footprint twice as large as the size in all technology centres and at exhibitions of a machine. with the rpp-integrated nhx 4000, the floor space requirement is 50 % less. the decisive factors for tool management sector our purchasing the machine are the capability for unmanned operation during the night; high reliability, durability, sta- bility and precision that the dmg mori machine is offering haimer is opening a new technology and solution centre at and prompt service,” explains shuhei wada, executive direc- the bielefeld factory. experience the complete tool-manage- tor of the company. “we previously used multiple machines ment in all aspects of machine tools live on site. and set up multiple processes to meet quantity requirements. but with the nhx 4000 + 5rpp, which is able to perform unmanned operation during night, the required number can be achieved on one machine. we now can respond to urgent requests to machine a single component by always having one of the five pallets available and ready.” + haimer as a comprehensive system provider for the + we will continue to present haimer microset units + joint developments for digital production haimer gmbh wada machine manufacturing co., ltd. weiherstraße 21, d-86568 igenhausen numazu iron industrial park haimer@haimer.de, www.haimer.de 294-26, ashitaka, numazu city, shizuoka 410-0001 www.wada-machine.co.jp reliability & availability - worldwide thk provides original technology in the highest quality for smooth and accurate movement. lm guide ball screw cross roller ring japan japan japan japan japan japan thk co., ltd. z�+81-3-5434-0351 z�+49-2102-7425-555 z�+86-21-6219-3000 z�+91-80-2340-9934 z�+65-6884-5500 +86-21-6219-3000 z +91-80-2340-9934 z +65-6884-5500 www.thk.com/jp www.thk.com china china china china china china thk (shanghai) co., ltd. thk india pvt. ltd. (shanghai) co., ltd. thk india pvt. ltd. europe europe europe europe europe europe thk gmbh www.thk.com/cn www.thk.com/sg www.thk.com/in india india india india india india singapore singapore singapore singapore singapore singapore thk lm system pte. ltd. thk america, inc. thk lm system pte. ltd. thk america, inc. america america america america america america z +1-847-310-1111 z +1-847-310-1111 z +1-847-310-1111 z www.thk.com/us

additive manufacturing 25 realizer gmbh cooperation strengthens expertise in additive manufacturing dmg mori is specifically expanding its future technologies: with a majority shareholding of 50.1 % in borchen-based realizer gmbh, the group has now strengthened its position in the field of additive manufacturing. with sauer gmbh, dmg mori already has extensive know-how in the laser metal deposition field with powder nozzles. for its part, realizer has more than 20 years experience in “selective laser melting” (slm). here, the powder material is deposited layer-by-layer and specifically melted using a laser, thus successively building up the component. the incorporation of realizer into the sauer product range therefore now enables dmg mori to offer the main generative manufac- turing processes for metal workpieces from a single source. “selective laser melting in a powder bed opens up completely new applications for our custom- ers. it is therefore an ideal complement to our lasertec 3d machines in the field of advanced technologies,” says christian thönes, chairman of dmg mori aktiengesellschaft. christian thönes (right), chairman of dmg mori aktiengesellschaft, and dr. matthias fockele, managing partner of realizer gmbh, look forward to the future collaboration. complex, metal components can be manufac- tured from powder using additive manufactur- ing. a wide range of weldable materials, extend- ing to multi-material applications, are used for this purpose depending on the application. realizer gmbh hauptstraße 35, d-33178 borchen www.realizer.com globally unique – additive manufacturing with powder nozzle and in the powder bed from a single source powder bed powder nozzle watch the video on additive manufacturing dmgmori.com/en6461 lasertec 30 slm lasertec 30 slm lasertec 65 3d lasertec 4300 3d laser structuring laser structuring + milling / turning nx hybrid additive manufacturing nx hybrid additive manufacturing die durchgängige software-lösung für die additive fertigung, the integrated software solutions for additive manufacturing, inklusive simulation und programmierung für laserauftrag- incl. simulation and programming of laser metal deposition schweißen und selektives laserschmelzen. and laser metal fusion. siemens.com/plm/additivemanufacturing siemens.com/plm/additivemanufacturing

medical expertise 27 2 tooth implant tooth implant dimensions: ø 10 × 7 mm dimensions: ø 10 × 7 mm material: titanium (ti6al4v) material: titanium (ti6al4v) 4 knee prosthesis knee prosthesis dimensions: 62 × 70 × 68 mm dimensions: 62 × 70 × 68 mm material: cocr material: cocr milltap 700 milltap 700 highly productive compact machining centre for the economic mass production of implants and bone plates dmu 40 evo linear dmu 40 evo linear dynamic 5-axis simultaneous machining of implants and dynamic 5-axis simultaneous machining of implants and joints made from difficult-to-machine materials joints made from difficult-to-machine materials 3 3 bone screw bone screw dimensions: ø 10 × 85 mm dimensions: ø 10 × 85 mm material: titanium (ti6al4v) material: titanium (ti6al4v) 5 bone plate bone plate dimensions: 60 × 18 × 3 mm dimensions: 60 × 18 × 3 mm dimensions: 60 × 18 × 3 mm material: titanium material: titanium material: titanium sprint 20|5 swisstypekit ® sprint 20|5 swisstypekit ® for the short and long turning of high-precision for the short and long turning of high-precision implants on one machine ultrasonic 20 linear ultrasonic 20 linear 5-axis ultrasonic and hsc machining for prototypes and 5-axis ultrasonic and hsc machining for prototypes and 5-axis ultrasonic and hsc machining for prototypes and 5-axis ultrasonic and hsc machining for prototypes and automated mass production up to 200 mm component size automated mass production up to 200 mm component size