The ongoing development of ULTRASONIC technology is closely linked to rising quality requirements in high-tech sectors such as the semiconductor industry. In these sectors, the cost-effective precision machining of components—such as stage units made of Zerodur and parts made from other hard-brittle advanced materials, including silicon carbide and cemented carbides—is a decisive competitive factor. In response to the high demands of these and other key industries, DMG MORI unveiled the ULTRASONIC 60 Precision at EMO 2025. The Precision series is now being expanded to include the ULTRASONIC 80 Precision. The working area measures 800 x 600 x 510 mm and accommodates workpieces up to Ø 800 x 400 mm in size and weighing up to 350 kg.
Process Integration: Ultrasonic Milling and Grinding in a Single Setup
The key to efficient manufacturing of these complex components is process-integrated ULTRASONIC milling and grinding in a single setup. Ultrasonic-assisted machining is the foundation for high productivity. Here, the tool is driven by a speedMASTER spindle at 20,000 rpm and set into high-frequency vibration by the proven ULTRASONIC actuator with an HSK-63 interface. The superposition of rotational motion creates a pulsating contact between the tool and the workpiece, which reduces process forces and enables controlled material removal. This reduces the risk of microcracks while increasing tool life.
The swivel rotary table, with a swivel range of -35° to +110°, enables versatile 5-axis simultaneous machining. In addition, thanks to the C-axis with direct drive and a speed of 300 rpm, as well as the standard ULTRASONIC axialGRINDING, the ULTRASONIC 80 Precision can perform reliable cylindrical grinding operations.
Precision: robust construction and intelligent cooling design
The ULTRASONIC 80 Precision offers standard positioning accuracy of up to 5 µm and 6 µm in the circularity test. This precision is made possible by the machine’s highly rigid design and an intelligent cooling system. The monolithic machine bed, solid castings, and wide guides provide the necessary stability, while the precision cooling of the linear guides, for example, minimizes thermal deviations.
Productivity: a wide range of tools and automated manufacturing
To keep setup times short, the ULTRASONIC 80 Precision comes standard with a 60-position tool magazine and can be optionally upgraded to 120 positions. Machine utilization can also be optimized through a wide range of automation solutions—including workpiece handling systems such as the Robo2Go Milling and the MATRIS system, as well as pallet handling systems such as the PH 150 or the PH Cell 300.
Machining Transformation (MX): Future-proof ULTRASONIC machining
Both the process-integrated machining of hard and brittle materials and automated manufacturing meet the key requirements for future-proof production in line with the Machining Transformation (MX). The user-friendly ERGOline X control system with CELOS X on a Siemens SINUMERIK ONE also lays the foundation for fully networked and digitized processes, for example in programming with exclusive ULTRASONIC technology cycles from DMG MORI. In GREENMODE, the ULTRASONIC 80 Precision also consumes over 20 percent less energy than its predecessor, thereby supporting the requirements for sustainable production.
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