LASERTEC 65 DED hybrid
Hybrid Complete Machining: Additive Manufacturing and Milling in one Machine
Highlights
Flexibility through combination of additive and milling machining process for 3D-parts in finished quality
- The laser head is handled by a fully automatic shuttle - without manual intervention
- 5-axis material deposition by coaxial nozzle for homogeneous powder distribution, independent from direction of laser deposition welding
- Full 5-axis milling machine in rigid monoBLOCK-design with < 12 m² footprint
AM Assistant for the best process reliability and comprehensive traceability
- Integrated thermal imaging camera for observation of the whole working area, adapive process control and constant monitoring of the working distance
- Powder feed rate sensor as well as automatic powder calibration.
- AM Evaluator for visualisation of the relevant process data (e. g. meltpool size, powder mass flow) as a digital 3D-model as well as in the chronological sequence
Siemens NX: Complete Hybrid CAD / CAM – Module for additive and subtractive programming
- One software package for the complete process chain (design, additive process, substractive machining, finishing)
- Exclusive LASERTEC build-up strategies - fully integrated in the CAD / CAM software incl. 3D-simulation of machine and movements for collision prevention
- Shorter time-to-market due to completete integrated PLM software integration
Using Multi-Materials and Gradient Materials for Improved Part Performance
- Selectively adding materials with more than 60 Rockwell to avoid heat treatment processes
- Improving cooling performance by using bronze material in the mould core
- Better materials and improved reliability in the repair process for increased service life
- Improved performance of exisitng tool designs by adding wear resistant coating
- Material gradients between hard and soft, magnetic and non-magnetic, etc.
Application Examples
Control & Software
- Visualization of relevant process data (for example, melt pool size, powder mass flow) as a digital 3D model and over time
- Detailed analysis of process data
- Direct comparison of processes for quality assurance
- Creation of part reports
- Simplification of process development
- Support in quality control
- Enables individual analysis and work up of process-relevant data
- Easy retrofitting of the software within the AM-Analyzer product package (Existing software can still be used)
- Non-contact measurement with the laser scanner
- Measurement and evaluation of gears according to common standards analog to coordinate measuring machines
- Fast measurement with max. 70,000 points / sec. or up to 200,000 points / sec. depending on the laser source
- Technology and measurement system integration eliminate unnecessary handling of components
- High flexibility in gear measurement and reduction of reaction times during process start-up
- Measurement of gear teeth and scanning of free-form surfaces possible
Turning
- Turning, milling and grinding in one clamping
- Grinding cycles for internal, external and face grinding as well as dressing cyclesn
- Body-borne sound sensors for start-up and dressing
- Full integration of measurement module for relative and absolute LIVE-Measuring – parallel to main time
Milling
- Better surface quality through integration of the grinding technology
- Grinding cycles for internal, external and face grinding as well as dressing cycles
- Body-borne sound sensors for start-up and dressingn
- 1,300 l Cooling system with integrated centrifugal filter for The filtration of particles > 10 μ
- AKZ nozzle unit optionally available for best possible Flushing of the grinding gap
- Expansion of the technological limits of the CTX TC
- Surface accuracy < 0.4 μm
- Roundness < 5 μm
- Quality IT5 for ø > 30 mm
- Surface accuracy < 0.4 μ
- Roundness < 5 μ
- Quality 5 for ø < 120 mm
- Quality 4 for ø > 120 mm
- Measurement of webs and grooves on components
- Measurement of diameter in difficult to access places
- Available with manual and retractable Calibration unit Package content
- L-Measuring probe according to Customer-specific design
- Flexible application possibilities
- In process measurement
- Straight and helical external or internal spur gears and splines
- Arrow teeth with tooth offset Turn-mill machines
- Ball-shaped toothing by mathematical transformation of the 6th virtual axis
- Balancing of tools in the machine for high surface requirements and machine protection
- Checking the balancing quality of the spindle
- Balancing quality up to 0.3 g/mm
- Better surfaces due to balancing of the entire system in the clamped state
- Balancing of the tool under machining conditions (machining position -vertical / horizontal, with / without internal cooling supply, speed)
- Economical, as no external balancing device is required
- Easy to operate through three parameters and without additional sensors
- Avoiding vibrations by means adaptation of the speed
- Application for the main spindle and counter spindle, or for milling machines with FD tables with Direct Drive
- No manual intervention by the operator
- Identical repeatability for all components
- Increased process safety for special applications by avoiding vibrations. example, When using long thin drills or for milling parts with critical clamping
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
- With interpolation turning, the tool cutter follows a circular movement, where the cutter is always oriented towards the center Of the circle.
- Possible for external and internal machining
- Synchronization and tool path controlled by the cycle
- NEW: in version 2.0 complex turning contours are possible (currently only available on the DMU 50, other machine types will follow)
- Easy manufacturing of sealing surfaces where milling operation might not be possible.
- Complete component processing in one clamping possible
- Reduced investment costs for tools
- Measuring with tilted tool axis
- Dialog-guided programming of the measuring cycles
- Positioning of the measuring points with rotary axis
- Highest flexibility in the machining of structural components due to variable alignment of the angle head
- Automatic CAD / CAM programming
- Automatic calculation of the TCP and combination with existing control functions
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight
- Productive complete processing
- Cost-effective gear cutting on standard machine with standard tools
- Flexible for different gear geometries
- Quality inspection in the process
- Program creation based on blank drawings and gear data
- Optimization of workpiece orientation e.g. after heat treatment
- Interface for coordinate measuring device (Klingenberg, Leitz, Zeiss)
- Chip detection on plan pad and tool cone
- Monitoring of pull-in force
- Cutting edge control in process by symmetry monitoring of the bending moment per cutting edge
- Visualization of the bending moment over time via Graph
- Automatic recognition of tool pull-in force for consistently high process stability.
- Predefined cycle for automatic lubrication, every 75h or after 20,000 tool changes.
- Detection of leakage and measuring of usage of pneumatics system.
- Efficient and timesaving lubrication without operator intervention
- High transparency by displaying the lubrication cycles and the current pull-in force.
- Data recording in combination with the optionally available Condition Analyzer for additional analyzes of air consumption and changes of the pull-in force
- Superposition of the turning movement by additional X- and Y-traverses
- Applicable for turning and milling
- Eccentric geometries easy to manufacture
- Exact axis coupling and synchronization in the background
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
- Efficient use of multi-tip turning tools with more than one cutting edge on turn & mill
- Several "sister tools" on one main tool holder
- Reduction of tool change times
- Saves tool magazine space
- Geometric fingerprint of the machine Volumetric calibration at the touch of a button
- Detection and compensation of geometrical, positioning and angular errors of all axes
- Easy handling and implementation by the customer directly at the machine
- Solutions for a safe process and for the efficient use of important machining steps
- Applications: cone cleaning, tool data monitoring, safe withdrawal movement, tapping, deep hole drilling, external thread and spigot milling, internal thread and circular milling, reverse countersink cycle
- 12 stored machining strategies for stock removal, deep hole drilling, Pocket milling machines*
- Runtime optimization according to individual application
- Safe retraction after program break
- Tool data monitoring
Service & Training
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