Ultrasonic machining system, using linear motor powere axes, combines hard machining of advanced, normally 'unmachinable' materials and conventional HSC-milling on a single machine.

Micro, precision machining of carbide, glass and ceramics is now in demand in a range of sectors. Tool and mould making, electrode manufacturing, medical and optical technology, watch making, the sensor and semiconductor industries and aerospace are typical customers for this technology And it is to meet their specific needs that DMG introduced the Ultrasonic 20 linear. The Ultrasonic 20 linear combines hard machining of advanced materials and conventional HSC-milling on a single machine and offers exceptional performance.

Its wide-ranging capability allows this addition to be used to machine materials that could not previously be considered.

For example glass materials such as germanium, mono- and poly-crystalline silicone present no problem to this machine; nor do carbon fibre, carbide, sapphire, ruby, mother of pearl or agate, the list is considerable.

Linear drives provide 1.4G acceleration in X, Y and Z, a positioning accuracy of +/-2.5 micron (+/-0.0001in), and a repeat accuracy of as little as +/-1 micron (+/-0.00004 in).

Excellent surface quality - Ra < 0.2 micron - is assured.

The option to expand the machine for three to five axes working, with a torque motor in the C-axis and servo motors with free-float transmission in A, brings unrivalled flexibility.

The Ultrasonic 20 linear benefits from exceptionally fast tool exchange thanks to the Ultrasonic Aktor system based on a modified HSK fitting.

This allows the use of both ultrasonic and conventional tools on the same water-cooled, 40,000 rev/min USB spindle.

The 16-station automatic tool changer - optionally 32 - can accommodate milling tools from 0.1 to 16mm and grinding tools from 0.1 to 30mm in diameter.

The cast mineral monobloc base provides excellent vibration absorption and stability.

On the standard machine the Y-portal is made from aluminium but as an option it can be of carbon fibre for even higher rigidity, lower weight, reduced thermal expansion and acceleration up to 2G.

A further option is a three-chamber coolant system with slurry tank.

Major beneficiaries of this technology are expected to be tool and mould makers.

For example on the Ultrasonic 20 linear embossing tools can be made from carbide in a single process without the need for die-sinking.