Mobile and stationary ULTRASONIC-machining. of COMPOSITES for MRO and Production. surface cleaning for MRO. production; accurate scarfing and

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1 Production / Maintenance, Repair & Overhaul (MRO) Perfect edge trimming for series production; accurate scarfing and surface cleaning for MRO. Mobile and stationary -machining 1. Production 2. Maintenance, Repair & Overhaul (MRO) Your contact // High Performance Cutting of COMPOSITES. Stationary 5-axis Machining ++ Surface cleaning through integrated atmospheric pressure plama ++ Flexible integration of technology components ++ Surface measurement through integrated laser scan ++ Lightweight construction with CFRP components ++ High-performance exhaust system ++ Highest precision and reproducibility ++ Longterm stable machine concepts ++ Universal use for production and MRO Florian Feucht Head of R&D COMPOSITES Tel: Fax: Mobile: florian.feucht@dmgmori.com Technology Benefits % reduced process forces: prevention of built-up edges ++ Double feeds due to ++ Excellent component quality without delamination FLY.D6418_0115UK Mobile 5-axis Milling Unit Mobile and stationary -machining of COMPOSITES for MRO and Production. mobileblock // 85 / 260 / 360 Scarfing by accurately exposing the individual laminate layers Trimming and drilling of CFRP / GFRP / AFRP components for series production MRO Production ++ Trimming with optimum surface quality without chipping or chatter marks for the subsequent joining processes ++ Drilling holes e.g. rivet holes with the best possible roughness values in the channel, diameter tolerances in the μm-range and reduced outbreaks on the initial drilling surface as well as the through-pierce side ++ Feasibility of through drilling holes and tapped blind holes, threads, grooves, pockets and other geometric free forms ++ Scarfing in a full section without fibre tearing or delamination ++ Reverse engineering: Integrated laser scanner for surface recognition, feedback and re-measuring ++ Integrated atmospheric pressure plasma: Surface activation / cleaning for optimal preparation for the subsequent reconstruction process ++ Stationary and mobile ++ Machining in a full section without fibre tearing or delamination DMG MORI SEIKI Deutschland GmbH Riedwiesenstraße 19, D Leonberg Tel.: +49 (0) / , Fax: +49 (0) / info@dmgmori.com,

2 Production / Maintenance, Repair & Overhaul (MRO) Perfect edge trimming for series production; accurate scarfing and surface cleaning for MRO. Mobile and stationary -machining 1. Production 2. Maintenance, Repair & Overhaul (MRO) Production MRO Trimming and drilling of CFRP / GFRP / AFRP components for series production Scarfing by accurately exposing the individual laminate layers Mobile and stationary -machining of COMPOSITES for MRO and Production. mobileblock // 85 / 260 / 360 Your contact // High Performance Cutting of COMPOSITES. Mobile 5-axis Milling Unit Stationary 5-axis Machining ++ Universal use for production and MRO ++ Longterm stable machine concepts ++ Highest precision and reproducibility ++ High-performance exhaust system ++ Lightweight construction with CFRP components ++ Surface measurement through integrated laser scan ++ Flexible integration of technology components ++ Surface cleaning through integrated atmospheric pressure plama Technology Benefits ++ Trimming with optimum surface quality without chipping or chatter marks for the subsequent joining processes % reduced process forces: prevention of built-up edges ++ Double feeds due to ++ Excellent component quality without delamination FLY.D6418_0115UK Florian Feucht Head of R&D COMPOSITES Tel: Fax: Mobile: florian.feucht@dmgmori.com ++ Drilling holes e.g. rivet holes with the best possible roughness values in the channel, diameter tolerances in the μm-range and reduced outbreaks on the initial drilling surface as well as the through-pierce side ++ Feasibility of through drilling holes and tapped blind holes, threads, grooves, pockets and other geometric free forms ++ Machining in a full section without fibre tearing or delamination DMG MORI SEIKI Deutschland GmbH Riedwiesenstraße 19, D Leonberg Tel.: +49 (0) / , Fax: +49 (0) / info@dmgmori.com, ++ Scarfing in a full section without fibre tearing or delamination ++ Reverse engineering: Integrated laser scanner for surface recognition, feedback and re-measuring ++ Integrated atmospheric pressure plasma: Surface activation / cleaning for optimal preparation for the subsequent reconstruction process ++ Stationary and mobile

3 Application areas // Production and MRO Efficient machining of high-end components made of fibrereinforced composite materials (e.g. CFRP, GFRP, AFRP) as well as fibre-reinforced ceramics with. Holistic solutions for Production and MRO Fibre composites are ideally suited for the production of lightweight components, due to their high strength and minimal weight. The use of CFRP and GFRP in civil aviation continues to grow and all premium manufacturers in the automotive industry produce important structural components out of fibre reinforced plastics. Even in the field of wind energy, all aerodynamic components today are made of composite materials. In addition to the actual production applications, there is also an ever-growing demand for automated, economical machining options for maintenance, repair and overhaul (MRO) of damaged fibre composite components. In both fields, the use of technology along with SAUER s comprehensive process approach, offers a breakthrough solution for a most efficient machining of these high-performance materials with optimal component quality. Primary Target Markets Aerospace Automotive Renewable Energies Ship Building Lifestyle Rotor Blade Segment / CFRP Centre Console / CFRP Rotor Cover / CFRP Dashboard Panel / CFRP Frame Swing Arm / CFRP Scarfing in airfoil Adaption on car roof Repair of a damaged rotor blade Milling of the bull-eye Watch Housing / CFRP DMG MORI offers the mobile as well as the stationary processing solution for both categories Production and MRO.

4 Technology Benefits Efficient -machining of high-end components made from COMPOSITES. Into the future with Common machining methods for fibre com posite raw parts have technical shortcomings, caused by high-tool wear, inad equate component quality and usable feed limitations. This is precisely where DMG MORI can help you to reach the next level, with the technology. Benefits Prevent built-up edges through optimal tool design and + Up to 40 % reduced process forces to prevent delamination and fibre tearing + Double feeds possible through + Longer tool life by preventing built-up edges + Optimal particle removal from the active zone + Excellent component quality: Sharp edges, clean exposure of the individual laminate layers, perfect surfaces In close partnership with the leading tool manufacturers in this field of application, carbide tools were optimally developed for machining with special cutting geometries. The defined superimposition of the tool rotation with an oscillation in the longitudinal direction leads to a significant reduction of the process forces, an increase of tool-life as well as an optimized chip breakage and removal. This way, allows to cut the material fibres with an increased cutting speed and therewith meets the requirements of productivity and workpiece quality. The reduction of the process forces by up to 40 % enables clean edges and prevents fibre tearing and delamination on the part. Due to the optimisation of the mechanical machine components as well as the integration of application-specific technologies (e.g. surface detection / feedback by laser, surface cleaning / activation by atmospheric pressure plasma), mobile and stationary machining solutions are developed that are specialized for the series production of COMPOSITE-components as well as for the repair of damaged surfaces in the MRO sector. with Oscillation Sharp edges and prevention of fibre tearing with Process forces are significantly reduced through the use of technology, enabling high edge quality without process-induced thermal damage, fibre tearing or delamination. Tool rotation with Operating Principle The conventional rotation of the tool is superimposed (piezoelectric effect) via the HSK / A63 interface of the actuator recording with an additional oscillation in the axial direction. without without

5 Long-term Stable Machine Design + Rigid and thermo-symmetrical machine design for maximum precision during continuous operation + All drives and guides (except of Y-axis) encased outside of the work area + Specially adapted COMPOSITE milling spindle with permanent grease lubrication with 18,000 rpm (24,000 / 35,000 rpm optional) 85 / 260 / 360 Stationary high-performance machining of fibre composites with holistic machine concept. 5-axis / Device Design + Integrated technology framework: Dynamic machining through the gantry drive in the A-axis combined with the B-axis swivelling head (5-axis machining) + Weight-optimised device design: Simple, ergonomic loading and unloading through vacuum clamping and a rotating device Extraction Design + Ideal for the integrated room extraction design through the enclosed work area + High-performance extraction design with integrated fine particulate monitoring, as well as heat recirculation + Explosion-proof filter system with stable filter performance Tool Design + Optimal tool design: Use of very abrasive and viscous materials; different materials in the core and outer layer + Tool change on demand : The self-learning system monitors the process itself by varying process forces (integration into HMI of the control system) Integrated Laser Scan // Reverse Engineering + Performing a surface scan via laser to accurately determine the repair geometry + Automatic feedback of the acquired data Technical Data Machine Design Travelling Column Design Travelling Column Design Travel mm 850 / 850 / 650 2,600 / 700 / 700* 3,600 / 1,100 / 900 Max. Speed (Standard / Option) rpm 18,000 (24,000)** 18,000** (24,000 / 35,000)*** 18,000** (24,000 / 35,000)*** HSK-A63 HSK-A63 HSK-A , **** 3,000 1, ,500 2,150 / 500***** 5,000 / 1,200 Tool Holder (Standard / Option) 85 monoblock Design Max. Workpiece Dimensions mm Max. Load (3-axis / 5-axis) kg * Machine version with travel in Y (1,100 mm), Z (900 mm) ** Max. speed : 18,000 rpm *** 35,000 rpm spindle only available for version with HSK-E50 **** Machine version with 2,000 1, mm ***** Machine version with 4,000 / 1,200 kg Integrated Atmospheric Pressure Plasma + Activating and cleaning of the surface for the subsequent joining process on the same machine + Inductive energy transmission + Module mounted on HSK-A63 integrable via tool changer

6 mobileblock Mobile 5-axis milling unit for MRO as well as demanding production tasks. Small, light, mobile with highest performance Repair jobs of damaged fibre composite components are up to now mainly performed as manual operations by hand. In most cases, e.g. the aircraft has to be brought back to the hangar which requires a few days of repair time. In contrast to this time-consuming procedure, the new mobile 5-axis milling unit from DMG MORI enables to handle the actual repair job in only a few minutes, with 100 % constant quality, precision and reproducibility. The 5-axis kinematics with integrated rotary- and swivel-axis allows challenging operations with angles of ± 95. Due to the lightweight construction and the specially designed vacuum system, the mobileblock can be adapted easily and flexible onto the damaged components. Additionally to the repair jobs in the MRO sector, this mobile milling unit can also be effectively integrated in the process chain of challenging production tasks. Technical Data mobileblock Travel X / Y / Z mm 500 / 500 / 200 Max. Speed rpm 35,000 Tool holder DIN ER11 Swivel range (A-axis) degree ± 95 Rotary axis (C-axis) degree 360 (infinite) Rapid traverse m/min 14 Dimensions mm 1,300 1,300 1,000 Weight kg appr. 85 kg Adaption system SAUER 12 / 16 Vacuum feet Suction power N 256 (per foot) 5-axis NC-Control Beckhoff TwinCAT 3 integrated PC for OpenARMS-CompR, 21" Multi-Touch Display + + Powerful, mobile milling unit + + Lightweight construction with CFRP components + + Universal operation: Scarfings and edge trimming for production and MRO + + All composites, aluminum- and magnesium-alloys machinable Kinematics + Powerful kinematical machine layout with X-, Y-, C-, Z-, A-axis + 5-axis simultaneous machining + High performance spindle with 35,000 rpm, with a-axis swivel head (± 95 ), mounted on Z-axis-slide made from CFRP + C-axis: 360 infinite + Highest dynamics due to optimised emphasis Lightweight Design + Selected materials for weight optimisation (80 % CFRP, 15 % aluminum, 5 % tool steel) + Frame, cover of servo motors, Z-axis-slide and adaption arms made from CFRP + Use of CFRP for reduced thermal expansion + Increased damping factor + Easy handling and flexible adaption Control Design + Easy, PC-based control with 21" Touchscreen + Userfriendly due to holistic control guidance from the part drawing, to the definition of the damaged spot and repair job, the laser surface detection, up to the generation of the final NC-files. + Integration into the intranet + Internet access + + Highest precision and reproducibility + + Enormous time benefit + + CAM fully integrated + + Easy and user-friendly, PC-based control + + HSK-interface allows flexible integration of cross-process technology options Powerful Adaption + Double angle compensation possible due to adjustable adaption arms and vacuum feet with ball joint + Specially developed, changeable vacuum feet + Each adaption arm with own valve + Max. adaption range: 400 mm + Only 50 % of the vacuum feet mandatory for adaption Integrated Laser Scan + Two different laser types: Point- and line-scanner + Optimised for CFRP operations + Point-laser-scanner for detection of the workpiece surface in Z: 200 mm measuring range + Line-scanner with up to 640 single points for surface feedback of 3D-forms + Easy assembly / disassembly in a few seconds Highly dynamic Servo Motors + Accelerations of up to 7 m/s² possible + Max. rapid traverse of 14 m/min. + Highest dynamics due to low inertia torque + High torques in the rotary axes + All servo motors with direct drives (Except a-axis) + Homogeneous and aligned drive design for highest efficiency

7 mobileblock MRO / From the damaged component to the surface-activated scarfing Lightweight design with flexible adaption possibilities. Stationary as well as mobile repair solution with holistic process-know-how. Stationary Adaption example // AEROSPACE The flexibly adjustable vacuum feet of the mobileblock generate a vacuum power of 256 N per foot. 12 vacuum feet are in the standard 16 pc. are available optionally. Flexible ball joints allow an easy and quick adaption not only on flat surfaces (e.g. airfoils) but especially on components with radii and complex contours (e.g. frame elements of the aircraft fuselage). Repair steps Mobil disassembly or positioning of the damaged component 1: Damaged CFRP component 1: Positioning of the milling unit on the damaged component 2: Infrared measuring probe / point-scanner / line-scanner 2: Point-laser-scan: Surface detection detecting of the workpiece surface (approx. 5 min.) Airfoil 3: Integrated laser scan / surface feedback 3: Surface feedback by line-scanner 4: Machine Task Programmer 4: Operator assisted definition of the machining task Fuselage Concept study // Automated repair solution Defining the machining strategy, incl. generation of the NC path (approx. 15 min) In the standard, a quick adaption of the mobileblock is possible via crane. Therewith, this mobile milling unit can be docked flexibly to various surface contours. The concept study below shows a possible scenario for an automated positioning of the mobileblock by a mobile transport colly on tires or rails for the universal and automated adaption for MRO as well as production tasks. 5: Final NC-File 5: NC-Path Generator component machining (approx. 2 min) 6: Scarfing of the component 6: -machining Surface cleaning (approx. 1 min) 7: Surface activation / cleaning 7: Integrated atmospheric pressure plasma Mobile transport colly Special mounting device Completion 8: Reconstruction 8: Reconstruction of the laminate layers

8 Production / Maintenance, Repair & Overhaul (MRO) Perfect edge trimming for series production; accurate scarfing and surface cleaning for MRO. Mobile and stationary -machining 1. Production 2. Maintenance, Repair & Overhaul (MRO) Production MRO Trimming and drilling of CFRP / GFRP / AFRP components for series production Scarfing by accurately exposing the individual laminate layers Mobile and stationary -machining of COMPOSITES for MRO and Production. mobileblock // 85 / 260 / 360 Your contact // High Performance Cutting of COMPOSITES. Mobile 5-axis Milling Unit Stationary 5-axis Machining ++ Universal use for production and MRO ++ Longterm stable machine concepts ++ Highest precision and reproducibility ++ High-performance exhaust system ++ Lightweight construction with CFRP components ++ Surface measurement through integrated laser scan ++ Flexible integration of technology components ++ Surface cleaning through integrated atmospheric pressure plama Technology Benefits ++ Trimming with optimum surface quality without chipping or chatter marks for the subsequent joining processes % reduced process forces: prevention of built-up edges ++ Double feeds due to ++ Excellent component quality without delamination FLY.D6418_0115UK Florian Feucht Head of R&D COMPOSITES Tel: Fax: Mobile: florian.feucht@dmgmori.com ++ Drilling holes e.g. rivet holes with the best possible roughness values in the channel, diameter tolerances in the μm-range and reduced outbreaks on the initial drilling surface as well as the through-pierce side ++ Feasibility of through drilling holes and tapped blind holes, threads, grooves, pockets and other geometric free forms ++ Machining in a full section without fibre tearing or delamination DMG MORI SEIKI Deutschland GmbH Riedwiesenstraße 19, D Leonberg Tel.: +49 (0) / , Fax: +49 (0) / info@dmgmori.com, ++ Scarfing in a full section without fibre tearing or delamination ++ Reverse engineering: Integrated laser scanner for surface recognition, feedback and re-measuring ++ Integrated atmospheric pressure plasma: Surface activation / cleaning for optimal preparation for the subsequent reconstruction process ++ Stationary and mobile