The DMS35 Machine:

Developed by Sauer & Company, (Stipshausen, Germany) the DMG DMS35 Ultrasonic machine’s integrated Siemens 840D power line allows for maximum performance throughout 4-axis applications through process monitoring by way of ADR and ACC that automatically adjust the machine’s rate of movement as it machines.

How Ultrasonic Technology Works:

The machine uses, and then converts, a high frequency electrical signal into an oscillating motion through electrically polarized motors that are amplified by a booster. This process causes the diamond-coated cutting tool to expand and contract at 20 kHz or 20 000 cycles per second while at the same time, rotating at speeds between 20 and 6000 rpm and up to 60 000 rpm on optional spindles. Cutting then takes place at the highest point of amplitude or expansion of the tool. Machining is done wet using low concentration water based synthetic coolant that floods the work piece, center of the tool, and machining area. As the diamond particles collide with the work piece surface, the material is broken up and flushed away.

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Benefits of Ultrasonic Technology:

Workspace of the DMS35

• Can machine engineered materials such as fired ceramics, (alumina, and zirconia oxides), glass, silicon nitride, graphite, composite materials and precious stones. Including work pieces made from these advanced materials ranging in hardness from 55 Rc to just softer than diamond.
  
  
• Can yield an increase in productivity three-to-five-fold as compared to conventional machining methods and machine complex geometries and tolerances so that post-fired materials can be readily machined.
  
  
• Is capable of surface finishes of 0.2 micrometers and on average readily produces roughness of 0.8 micrometers.
  
  
• Can machine solid-fired billets to high tolerances in a variety of sizes, (127mm in diameter by 19.05mm in width) attain positional tolerances of 0.0127mm, and controlled diameters as small as plus or minus 0.005mm.
  
  
• Can reduce time-to-market and prototyping as machining begins as soon as the piece of fired material is available.

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Ultrasonic Technology and the Future:

Many engineered materials are a challenge to machine. 

Many parts or components can be difficult or costly to manufacture because of short runs, close tolerances, processing and/or tooling requirements. 

Using ultrasonic technology these hurdles can be overcome.  Unique parts can be used in a range of unusual applications. 

For instance, ceramic components are extremely hard and resist wear.  Many are also inert and can be used in a variety of situations from the human body to insulators.

Ultrasonic precision machining sets the stage for new applications with various advanced materials. The future of precision machining is friendly with the arrival of ultrasonic technology with optimum benefit going to the medical and space sciences, oil, gas and nuclear industries.

BCI’s EMMS succeeds in using ultrasonic technology because the EMMS has mastered all four of the critical success factors associated with ultrasonic technology. 

Critical success factors: Ultrasonic equipment, diamond-cutting tools, engineered material knowledge and manufacturing technique.

They have the DMS35 ultrasonic machine, equipped with the Sauer spindle that gives them extremely high accuracy and the ability to manufacture components in advanced engineered materials.

They have the critical diamond cutting tools that when combined with the Sauer K System on the spindle enable 100 percent of the ultrasonic frequency to transfer directly to the tool.

They have the knowledge. The EMMS has over 40 years of combined business and hands on highly skilled trades experience and a solid understanding of the materials and how they machine.

Our Commitment to You We can provide you with an innovative solution or alternate method of manufacturing to meet your engineered materials requirements.

They have, and can effectively use and apply, the appropriate cutting technique and/or methodology for cutting.  Sound methodology, insightful tooling and work holding combined with proven processes is key to project successfulness, and even more so in the early project development phase.

The Tandem (USB 12.2) sub spindle is an available option for the DMS35 ultrasonic machine that the EMMS offers to its customers.  The sub spindle allows BCI’s EMMS to offer their clients the manufacturing of holes ranging in diameter from 6mm down to 0.3mm at a maximum of 12,000 RPM’s.  It is equipped with high pressure through tool coolant and a core ejector system. 

This option is ideal for customers with a need to: drill high precision holes within plus or minus .0254mm and 0.05 concentricity and perpendicularity.

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Tandem Sub Spindle

• High pressure through tool coolant
• 12,000 RPM
• Ultra sensitive
• Little or no edge chipping on entry or exit
• Through tool core ejection mechanism

SK40 Sub Spindle

The SK40 sub spindle is an optional spindle offered for the DMS35 ultrasonic machine that BCI’s EMMS has available for its clients’.  The SK40 cartridge spindle is easily exchanged on the DMS35, (approximately 30 minutes) and is ideal for customers with a need for final machining accurate fixture locations on high tolerance projects.

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With this new technology on hand, the EMMS is revamping the ceramics industry by the hour.

Ultrasonic precision machining sets the stage for new applications with various advanced materials.

The SK40 sub spindle is an optional spindle offered for the DMS35 ultrasonic machine that BCI’s EMMS has available for its clients’. 

The EMMS of BCI is the first in North America to successfuly install and use DMG’s Ultrasonic machining technology, the DMS35.