Precision material removal at the frontiers of physics – 13 μm volumetric accuracy.

Mr. Baumeister, DMG MORI has installed a total of five processing centres as a turnkey project at Koenig & Bauer. What has been your biggest challenge to date?

MR. BAUMEISTER ____ Our aim was to produce high-precision volume components with a length of up to 2,525 mm in a more productive way than was possible with the resources previously available – while, naturally, taking the high quality requirements into account.

How were these objectives achieved in practical terms?

MR. BAUMEISTER ____ Based on our workpieces, DMG MORI implemented a process which is very productive thanks to the use of pallet changers. The DMC 270 U has an RS 4 pallet pool; the DMC 210 U can accommodate five pallets. The remaining machining centres all use single pallet changers. This means that we can prepare many orders while machining is in progress and utilise our machines over 3 shifts.

And how is the machining accuracy?

MR. BAUMEISTER ____ The highlight in this project is the DIXI 270. With its scraped guideways it achieves a volumetric accuracy of 13 μm. A powerful cooling unit that controls the heat-generating components ensures the required thermal stability. In addition, a climate chamber was built around the DIXI 270 so that the temperature can be kept at a constant 22 °C. Given the enormous size of the component, this is a globally unique machine configuration. In precision machining, we are thus pushing the limits of what is physically possible.