More than 690 exhibitors converged on the Tokyo International Exhibition Center (Tokyo Big Sight) for JIMTOF 2012, which drew nearly 118,000 visitors over the course of the event. Since JIMTOF is only held every two years, the previous 2010 event was the first JIMTOF since the two companies launched their business collaboration; since then, DMG products have proven so popular in the Japanese market that half of the machines featured at JIMTOF 2012 this year were from the DMG line.

Machines Take Center Stage

The machines took center stage at this year’s event, and the stars of the show were the five World Premiere and three Japan Premiere offerings. Thirty-two machines were grouped by type throughout the booth, offering JIMTOF attendees from every industry the chance to compare capabilities and see each machine in action.

The full lineup of NLX high-precision CNC lathes was on display; JIMTOF 2012 marked the World Premiere for the NLX 1500Y/500, the NLX2000SY/500, and the NLX3000Y/700. These new offerings join the NLX2500 and NLX4000 to provide customers with an expanded range of sizes and capabilities. The NLX is already an extremely popular series with customers – more than 10,000 have been sold worldwide. The series’ BMT (Built-in Motor Turret) technology has evolved to achieve new maximum rotary tool spindle speed of 10,000 min-1, with the added benefit of increased energy efficiency.

Also featured was the MILLTAP 700, the first machine that is a joint development between Mori Seiki and Gildemeister. This next-generation compact machining center offers a combination of high precision and high performance, with a small footprint, 4-axis machining, and improved energy efficiency. The MILLTAP 700 has a large work envelope and a powerful tool changer with 15 (optional 25) tool magazine pockets.

Press Conference Highlights

Journalists representing industry publications from around the world were on hand for an exclusive press conference featuring Mori Seiki President Dr. Masahiko Mori and Dr. Rüdiger Kapitza, Chairman of the Executive Board of Gildemeister Aktiengesellschaft (DMG). They were pleased to report that, since the cooperative agreement between the two companies began in 2009, each year more countries have been added to the list of areas where DMG and Mori Seiki cooperate to provide sales and service.

Spotlight on ‘Cutting Dream’

Visitors to the DMG/Mori Seiki booth also had the opportunity to view the Cutting Dream Contest entries on display. Sponsored by Mori Seiki Co., Ltd. and now in its ninth year, the Cutting Dream Contest is open to companies, schools and research institutions engaged in machining with machine tools in Japan, and rewards innovative design. This year’s contest drew about 100 entries, and showcased the skill and creativity flourishing in the modern machine tools industry.

A panel of five judges reviewed entries in several categories, including prototype and test cut machining, die and mold/free form machining, and micro machining. Winning entries received cash prizes and awards at a ceremony held during JIMTOF.

JIMTOF is one of Asia’s most comprehensive events for the manufacturing industry. Held biannually, JIMTOF is organized by the Japan Machine Tool Builders’ Association, with support from Japan’s Ministry of Foreign Affairs and the Ministry of Economy, Trade and Industry, as well as the cooperation of many other Japanese professional associations.

On 7th November 2012 the president of Mori Seiko Co. Ltd., Dr. Masahiko Mori, inaugurated his company’s new US manufacturing facility in Davis in the presence of numerous customers and sales staff from DMG / MORI SEIKI USA as well as representatives of the international press, local politicians and of course the proud employees at the plant. Mori Seiki Manufacturing USA Inc. is MORI SEIKI’s first manufacturing facility in the USA. In the initial expansion phase its 20,600 m2 manufacturing and assembly area provides a capacity of up to 100 high-tech NHX4000, NHX5000 and NHX5500 horizontal centers.

The Davis location in California not far from Sacramento and only one hour’s drive away from San Francisco already has a long and successful tradition for Mori Seiki, because the home of the Mori Seiki Digital Technology Laboratory (DLT for short) is right next door. As a centre for research and development the DTL with its more than 80 employees collaborates closely with the R&D colleagues at the Mori Seiki headquarters in Japan. Due to the great time difference this transpacific development network works more or less round the clock on the tool machines and manufacturing systems of the future.

Thanks to an investment of around 50 million euros it has been possible to construct an over 20,000 m2 manufacturing and assembly facility for the production of horizontal machining centers within just a few months, a facility that even judged on global standards will set new benchmarks in the efficient production of high-tech tool machines. Dr. Mori then stressed in his speech the dramatic impact the new plant will have on the further growth of DMG / MORI SEIKI in the USA and therefore in one of the most important markets for tool machines worldwide. The future might see 5-axis machines from DMG or the MILLTAP700 milling and boring machines developed jointly with GILDEMEISTER being produced in Davis as well as the horizontal centers.

Dr. Mori went on to explain that seen in this context the facility in Davis constitutes far more than simply a manufacturing facility. In cooperation with the neighboring DTL it will in fact foster a highly dynamic hub of innovative machining technologies and manufacturing automation and in this function as a partner for all customers in the USA set vital impulses for the future.

The visitors at the opening ceremony were then taken on a tour of the company where they were able to see for themselves just how perfectly and efficiently state-of-the-art manufacturing methods can be implemented. They could marvel at the two enormous MPC 5-axis machines from Toshiba that have a maximum loading capacity of 20,000 kg and are used for the machining of large parts. Whereby the machine beds for the horizontal centers produced here are positioned automatically on pallets by a huge 6.5-ton gantry loading system with travel ranges of (in X, Y and Z) 48 m x 12 m x 2.2 m and then loaded and unloaded within 1.5 minutes.

Two highly automated and flexible manufacturing systems have also been installed in Davis for medium-sized parts. The smaller of the two systems encompasses two NH6300 horizontal centers from MORI SEIKI with a wash station and pallet pool for 40 workpieces. The larger FMS system includes three NH10000 horizontal centers from Mori Seiki with wash station and a capacity for 60 pallets. The workpieces and pallets are both fed into the manufacturing systems by huge Fanuc robots that can each lift up to 1,200 kg.

It is not, however, just the dimensions of the machines used, the high level of automation and extreme precision of the finished components that make the manufacturing systems so impressive, but also the consistent use of dry machining and minimal lubrication. This reduces wear, ensures clean working conditions and saves valuable resources on the one hand and on the other enables disposal of the chips exclusively via the powerful vacuum system.

The machined components are controlled on high-precision 3D-coordinate measuring systems before they are moved on to the assembly sequence. This applies equally to important components from suppliers such as machining tables or critical parts of the tool system and tool changer.

Assembly itself is then affected according to the flow line principle in which the machines are moved successively from one assembly station to the next. No rigid, mechanical transport system is used here, instead the complete machines are lifted by air cushions similar to those of a hovercraft allowing them to be slid over the shop floor with very little force and positioned exactly in the next assembly box.

Once final in-line quality testing is completed the finished horizontal centers are loaded directly onto the trucks after a throughput time of only two weeks and, thanks to order-based production, transported straight to the customer without any interim stops.

The spindle uses a belt-less, built-in motor structure with a 37/30 kW high-output motor as standard. The 11/7.5 kW motor for rotary tools are adopted for Turret 1 with milling capability that incorporates the BMT (Built-in Motor Turret) technology. The high machine rigidity and high-output motors double the turning capability and give a milling capability rivaling that of machining centers. The spindle motor and rotary tool motor are equipped with a cooling jacket, lessening the effects of thermal displacement on accuracy. The X-axes of Turret 1 and Turret 2 are equipped with scales as standard, achieving a positioning accuracy of 1.9 µm.

With the Y type the Y-axis function (stroke: ±70 mm) is featured, enabling multi-axis machining including key slot machining. The machine can make use of its high cutting capability and process integration to realize high-precision and high-efficiency machining of large-diameter, long workpieces such as shafts for aircraft jet engines, marine crankshafts, and pipes for the oil and energy industries.

NZX4000CY/2000

The turning specification (L type) where Turret 1 is dedicated to turning is also available. Three choices of through-spindle hole diameter are available – type A at ∅145 mm, type B at ∅185 mm and type C at ∅285 mm – along with two choices of maximum turning length: 1,000 mm and 2,000 mm. So customers can select the model best suited to the workpieces they machine.

Unique to large lathes, there is also the oil well pipe machining specification (with a front chuck, rear chuck, work stopper and centering chuck), providing strong support for machining for the oil and energy industries.

The operation panel incorporates the “MAPPS IV” high-performance operating system. In addition to the automatic conversational programming function, it also comes with a user license for the ESPRIT® CAM software. This makes it easy to program the machining of complex geometries at a personal computer connected through a network to the machine.

<Highlights>

• Turret 1 features the Y-axis function and Built-in Motor Turret technology, giving machining centers a close run in terms of milling capabilities.
• Three choices for the through-spindle hole (A: ∅145 mm, B: ∅185 mm, C: ∅285 mm)
• Adopting a high-rigidity trapezoidal bed
• Long, I.D. boring with the long boring bar possible (option)

Featuring a high-performance spindle that provides a maximum spindle speed of 10,000 min^-1 as standard (option: 24,000 min^-1) and a maximum output of 25 kW, which is more than twice as high as our conventional models, the MILLTAP 700 demonstrates outstanding cutting capability even for steel materials. The machine structure that has been optimized using FEM analysis minimizes vibration around the table, offering static rigidity more than 1.5 times higher than ordinary tapping machines. The MILLTAP 700 also achieves the fastest rapid traverse rate in its class on all axes (60 m/min) and Z-axis acceleration of up to 1.6 G.

With a robust construction and a high performance spindle required for milling, this compact machining center is ideal for milling and fine boring of automobile parts, electrical parts, and hydraulic/pneumatic equipment. Thanks to the large work envelop, it can handle a wide range of machining from multiple small parts machining that makes the most of its high-speed feed to simultaneous 4-axis control machining of complex workpieces made available by using the DDRT-200X (Direct Drive Rotary Table).

MILLTAP 700

The high-speed ATC (automatic tool changer) incorporated into the spindle head allows for cut-to-cut tool changing time of 1.5 seconds, significantly reducing non-cutting time and dramatically increasing productivity.

In order to reduce environmental burden and running costs, the MILLTAP 700 combines the drive technology with superior dynamic performance with the high-efficiency CNC machining, and as a result standby power consumption has been reduced by approximately 30% compared to conventional machining centers in the same class.

At JIMTOF 2012, the MILLTAP 700 equipped with a 24,000 min^-1 spindle and the DDRT-200X rotary table will be on display. The superior performance of the high-speed spindle will be demonstrated through small-diameter (less than φ1 mm) hole machining on aluminum as well as high-speed pocket cutting, and cycle time reduction solutions will be offered by machining demonstrations at a rapid traverse rate of 60 m/min and with the high-speed ATC.

<Highlights>

• Outstanding milling performance with robust construction and high-performance spindle
• Maximum spindle output 25 kW, maximum torque 45 N・m
• Rapid traverse rate 60 m/min for all axes, Z-axis acceleration 1.6 G
• DDRT available as an option
• Structure that minimizes vibration around the table is made possible by dynamic FEM analysis
• Machine construction designed for efficient chip removal

As for the construction, it adopts a robust bed with flexural rigidity much improved over existing machines, and a three-point support structure, which is less affected by secular changes in the foundation over time. It can maintain high-precision machining over the long term.

The Spindle 1 of the NTX2000 is a zero-center headstock that is designed to maintain its center at a constant height. On the tool spindle, DDM (Direct Drive Motor) technology is used for the B-axis drive, and ORC (Octagonal Ram Construction) technology is used in the Y-axis construction. The DDM, which directly drives the B-axis without using reduction gears, dramatically improves the transmission efficiency, achieves zero backlash, gives a maximum indexing speed of 100 min^-1, and allows high-speed, high-precision indexing with the minimum indexing angle of 0.0001°. With the ORC technology, the regular octagonal shape of the ram means that the sideways are located diagonally opposite each other and distort symmetrically, keeping the center of the moving body in the same position and enabling high-accuracy machining with thermal displacement suppressed.

NTX2000/1500SZ

The machine also adopts BMT (Built-in Motor Turret) technology, whereby a motor is incorporated inside Turret 2. This minimizes heat generation and vibration while also improving transmission efficiency and substantially increasing cutting capacity, speed, surface quality and accuracy. The output of 18.5/11 kW rivals that of the spindle of a machining center, and the highest level of performance can be obtained even when milling with the turret 2.

In addition to the conventional cooling of the motor periphery, cooling circuits have been added at the end faces of the motors in Spindle 1, Spindle 2 and the tool spindle, giving a cooling system that prevents generated heat from propagating externally. The feed axes (X, Y and Z axes) are equipped with a ball screw core cooling system as standard, restricting displacement of the ball screws due to heat generation to the minimum. The adoption of three original technologies and measures to prevent thermal displacement enables high-accuracy machining, and as a result the NTX2000 achieves a contouring accuracy of 2.40 µm, equivalent to that of a high-accuracy machining center.

At JIMTOF2012 we will display the machines equipped with the S-Quad high-speed in-machine coordinate measuring system and a 14 MPa ultra high-pressure coolant system to introduce new possibilities for integrated mill turn centers.

<Highlights>

• B-axis equipped with a Direct Drive Motor and a Built-in Motor Turret (M type)
• Reducing installation area by 30% compared to conventional machines
• Adopting a zero-center headstock that maintains a constant spindle center height (Spindle 1)
• Adopting the Octagonal Ram Construction on the Y-axis to enable high-accuracy machining with high-speed travel
• A wide range of model variations with Spindle 2, Turret 2 and so on

The NHX5500 is equipped with further evolved DCG (Driven at the Center of Gravity), one of the MORI SEIKI’s original technologies. The DCG employs newly developed structure while inheriting the concept of driven at the center of gravity to successfully improve rigidity and save weight of the moving parts. This contributes to increasing acceleration and enhancing positioning accuracy at a higher level.

What’s more, the machine achieves a 20% faster rapid traverse rate of 60 m/min, realizing high-speed feeding. For the pallet full indexing specification, the DDM (Direct Drive Motor) technology is used. As the DDM transmits the drive power directly to the rotary axes without using gears, it enables high-speed indexing, shorter non-cutting time and greater productivity.

The NHX5500 is equipped with the direct scale feedback on each axis as standard and uses lightweight column and moving parts to offer high-accuracy positioning.

NHX5500

Another feature of the NHX5500 is an improved design to enhance workability. The height from the floor to the lower end of the operation door has been lowered from 1,250 mm to 870 mm. In addition, the distance between the operation door and the center of the spindle has been almost halved to 260 mm, allowing easy access to the spindle and improved workability. The NHX5500 is compatible with the RPP (Round Pallet Pool) system which is a simple and space-saving system equipped with five pallets. At a low installation cost, the RPP system provides high productivity; the number of pallets per unit area is higher compared to other systems. The NHX5500 uses the operation panel with the MAPPS IV, a high-performance operating system. The MAPPS IV is one of the MORI SEIKI’s original systems equipped with the conversational automatic programming function and the MORI-NET Global Edition Advance which provides remote maintenance service using Internet.

The NHX5500 achieves an approximately 50% reduction in standby power consumption to mitigate environmental burden and the running costs.

<Highlights>

• Increasing acceleration and enhancing machining accuracy by mounting the evolved DCG (Driven at the Center of Gravity), the MORI SEIKI’s original technology
• Increasing the machine rigidity by up to 38% with a thick bed. Exclusively designed for a No. 50 taper spindle.
• 70 mm longer X- and Y-axes strokes.
• Adopting a bearing with a large diameter of φ120 mm to increase 15% spindle rigidity.
• Improving a rapid traverse rate by 20% compared to the existing model to realize a rapid traverse rate of 60 m/min on all axes.
• Equipped with the direct scale feedback as standard to enable high-accuracy positioning.
• Reducing standby power consumption by 50% to save energy.

The NVX5000 II series offers three different machine models: the NVX5060 II, NVX5080 II and NVX5100 II with the X-axis travel of 600 mm, 800 mm and 1,050 mm, respectively. Each model can use a No. 40 or a No. 50 taper spindle. The HSC (High Speed Cutting) specification with a maximum spindle speed of 20,000 min-1 is also available for the machine with a No. 40 taper spindle. Customers can choose the ideal machines from nine different variations according to their workpiece sizes and materials.

The newly designed cover offers better accessibility, operability and visibility. The single door with a larger window allows operators to easily check the spindle center, machining points and interferences. Additionally, the position of the lower end of the front door has been lowered by 66 mm to improve access to the spindle and table. The external chip conveyor which is designed in-house (option) and is capable of handling any amount or shapes of chips also contributes to drastic improvement of productivity.

NVX5100II/40

Each model can be equipped with the DDRT series, the MORI SEIKI-manufactured high-speed, high-precision rotary tables. The NVX5000 II series equipped with the DDRT (one additional axis specification) or 5AX-DDRT (two additional axes specification) realizes machining of complex-shaped workpieces that require simultaneous 4-axis and 5-axis control.

At JIMTOF 2012, the NVX5080 II will be equipped with our new technology ZEROCHIP®, which sucks powdery chips such as CFRP and ceramic for aircraft parts from the tool tip. Our effort to improve machining environment enhances maintainability and prevents potential health damage to operators.

<Highlights>

• Adopting slideways for all axes to realize high-rigidity structure.
• Improving spindle rigidity by 20% by enlarging spindle inner diameters.
• Offering three variations of the X-axis travels: 600/800/1,050 mm.
• Improving reliability and productivity with the high performance chip conveyor designed in-house.
• Realizing simultaneous 4-axis and 5-axis machining by installing high-speed, high-precision rotary table DDRT series (option).
• Reducing standby power consumption by 21% compared to the existing models.

The new NLX series employs the MORI SEIKI’s original thermal displacement control method realized with various technologies including the one that circulates coolant inside castings. This reduces thermal displacement to less than one third. While being a large lathe, the NLX4000 achieves the accuracy level equivalent to that of small lathes.

As for guideways, the NLX4000 adopts slideways as with the existing model. The machine realizes high-rigidity and high damping performance by doubling the slideway width to endure reaction force of cutting during machining of large workpieces. The high-rigidity machine structure maximizes the high output spindle capability with a maximum output of 37 kW and a maximum spindle speed of 2,000 min^-1(A type) and 1,500 min^-1(B type).

NLX4000AY/750

The NLX4000 is equipped with BMT (Built-in Motor Turret), which minimizes heat generation and vibration and improves conductivity to significantly enhance cutting capability and speed, surface quality and accuracy.

The high-output BMT specification with a maximum torque of 100 N・m is also available as an option. The milling function is drastically improved compared to the existing model, allowing the use of a M30 tap.

The NLX4000 has a robust construction to enable high-efficiency machining of large workpieces in an installation area of 9.9 m2 which is the smallest in its class.

On the other hand, the machine provides a wide work envelop, allowing the strokes equivalent or longer compared to the existing model: 365 mm on the X-axis and 875 mm on the Z-axis. The slant bed with a tilt angle of 45° contributes not only to improving chip disposal but also to reducing the distance between the spindle center and the door opening to 367 mm. The NLX4000’s machine structure with a wide work envelop and improved accessibility is one of the outstanding features for lathes of the same class which require attaching and removing of large diameter workpieces.

<Highlights>

• The largest through-spindle hole diameter in its class: φ145 mm (A type), φ185 mm (B type)
• The widest slideways in its class
• High-torque BMT to realize the fastest torque in its class
• The Y-axis travel: ±60 mm
• MORI SEIKI’s original thermal growth compensation
• Drastically improving chip disposal by adopting a slant bed with a tilt angle of 45° and offering better accessibility to the spindle and turret

In the new NLX series our original BMT (Built-in Motor Turret) technology has been further “evolved”, achieving a maximum rotational speed of 10,000 min^-1. Despite the substantial increase in speed from the 6,000 min^-1 on existing models, it takes a mere 0.45 seconds to accelerate up to 10,000 min^-1, and this gives a powerful edge when machining aluminum and in machining with small-diameter drills. In addition, the “maturity” resulting from delivery of 12,000 units has made it possible to resolve the issues of vibration and heat generation that are the concern with high-speed machining at 10,000 min^-1. Compared to a gear-driven turret, vibration is kept to less than a third, and the turret temperature rise to less than one tenth, giving a substantial improvement in terms of accuracy as well. These are precision turrets with the top performance in their class, having the same machining capability as those on machining centers. The high-precision, quick-change specification which gives mounting repeatability of 10 µm or better is also available as an option. This specification shortens tool changes and reduces setup time by up to 80%.

NLX1500Y/500

NLX2000SY/500

The NLX1500 and NLX2000 are available in four variations – the MC type (with the milling function), the Y type (MC type plus the Y-axis function), the SMC type (MC type plus Spindle 2), and the SY type (Y type plus Spindle 2), while the NLX3000 is available in three variations: turning, MC, and Y types. With a Y-axis travel of ±50 mm on the NLX1500 and NLX2000 and of ±60 mm on the NLX3000, these machines also support multi-axis machining.

The reliability and durability of the spindle have been increased by a whole series of improvements to ensure that it can be used for a long time with peace of mind. The front door has been lightened to reduce the burden on the operator during setup work. These machines are equipped with various characteristics and functions that make them easy to use, such as the extended tool overhang of 100 mm for O.D. cutting tools. We have created a highly reliable, “mature” machine by reflecting the requirements from customers relating to existing machines in every aspect.

Each model has inherited the characteristics of the existing machines and has adopted highly rigid slideways. The use of the slideways, with their high rigidity and excellent damping characteristics, makes it possible to achieve high surface quality even when machining difficult-to-cut material or in intermittent cutting, where chatter is likely to occur. MORI SEIKI’s original thermal displacement control has also been applied to achieve high accuracy. The amount of thermal displacement has been suppressed to one third of what it was, ensuring high-accuracy machining.

LEDs are used for the built-in worklight and the signal tower, cutting power consumption by at least 30% compared to existing machines. And the newly incorporated function that stops lubricating oil supply during standby has reduced the consumption of lubricating oil by 20% or more. This is a green design that considers reducing the load on the environment and cutting running costs.

NLX3000Y/750

<Highlights>

• Maximum rotary tool spindle speed of 10,000 min^-1 achieved thanks to evolved BMT technology
• Slideways adopted on all axes
• Thermal displacement suppressed to one third by MORI SEIKI’s original thermal displacement control
• Y-axis travel of ±50 mm (NLX1500, NLX2000) and ±60 mm (NLX3000)
• Spindle durability and reliability improved by reflecting customers’ comments
• Support for a variety of automation systems including bar feeders and gantry loaders

DMG / Mori Seiki is once again extending an invitation to its JIMTOF exhibit at Tokyo Big Sight from November 1 – 6, 2012. DMG / Mori Seiki’s theme at JIMTOF is Thinking Beyond Technology, which can be seen throughout the many demonstrations that highlight multi-tasking, process integration and automation solutions. This event will showcase the company’s latest developments, including technical presentations in the DMG / Mori Seiki theater and live cutting demonstrations of over 30 machine tools, including 8 premieres.

Invitation JIMTOF 2012