DMU 60 / 160 P / FD and DMC 60 / 160 U / FD duoBLOCK®

DMU 60 / 160 P / FD and DMC 60 / 160 U / FD duoBLOCK®

www.dmgmori.com
Universal milling machines for 5-sided / 5-axis machining
DMU 60 / 160 P duoBLOCK®
DMU 60 / 160 FD duoBLOCK®
DMC 60 / 160 U duoBLOCK®
DMC 60 / 160 FD duoBLOCK®
DMU 60 / 160 P / FD and
DMC 60 / 160 U / FD duoBLOCK®
Applications and Parts
Machine and Technology
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
3rd generation duoBLOCK®: 20 % more
­flexibility with 5-axis machining.
The 5-axis machines in the highly stable duoBLOCK® design allow maximum precision with highest
dynamics. In addition to drilling and milling, turning operations can be carried out with the FD
machines in the same setup. The duoBLOCK® of the 3rd generation, with larger traverse paths and a
higher table load, provides the foundation for this. The pallet changer of the DMC machines allows
setup during production for maximum productivity.
02
Aerospace
1: Compressor plate 2: Integral component
1
3
5
7
2
4
6
8
Tool and
mould making
Mechanical
engineering
Energy
­technology
3: Mould insert 4: Segment for a tyre mould
5: Pinion cage 6: Tool turret
7: Pelton blade 8: Impeller
Automotive / Fluid
9: Crank housing 10: Hydraulic component
9
10
03
Please note: The results of machining and
performance trials given in this catalogue are
examples. The results may vary slightly due
to the site conditions and cutting conditions.
DMU / DMC duoBLOCK®:
Simple and high-tech work pieces
­manufactured to the highest precision.
Workpiece illustrated:
HP compressor housing / Aerospace.
Applications and Parts
Machine and Technology
êê Concept
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
3rd generation compact duoBLOCK® –
high stability and consistent
long-term precision.
++ B-axis as standard equipment
++ Reduced dynamic mass means higher
dynamics and lower energy use
++ Longer Y-axis results in a larger
work space
04
++ Optimised machine design supports
heavier workpiece weights
++ Cooling in all 5 axes delivers the
greatest precision
Development of the duoBLOCK®: maximum rigidity for the highest, constant
precision with continuous further development of the machine design.
Classic travelling column
>> large leverage
Raised guideways
>> reduced leverage
Tiered guideways
>> optimised leverage
Highlights of the duoBLOCK® design
++ FEM-optimised, patented duoBLOCK® construction results in maximum rigidity
for consistent long-term precision
++ High static mass and low dynamic mass of the moving components in GGG60
mean high machine dynamics
++ Three X-axis guideways provide consistent rigidity over the entire travel
++ Larger cube-shaped work space facilitates use of large fixtures for multiple
component clamping or larger component machining
++ Inherently rigid machine bed allows 3-point support and crane hook machine
design enables simple installation
++ SK50 / HSK-A100
Cooling in all linear axes as
standard delivers consistent
long-term precision
++ Cooling of all ball screw drives
++ Cooling of Y-axis drives*
05
++ Cooling of the B-axis and of the spindle
++ Cooling via active cooling units
* 160: X / Y / Z
duoBLOCK®
++ 50 % less dynamic mass
++ 100 % more static mass
== High dynamics and stability
== Lower energy use
duoBLOCK®
>> no leverage
++ Consistent rigidity over the
entire travel
++ Thermosymmetrical design
== Consistent long-term precision
Applications and Parts
Machine and Technology
êê Work Area
Control Technology
duoBLOCK® – the standard for accessibility, large cube-shaped
working volume and unrestricted crane loading from above. 1: Crane loading from above for workpieces up to 4,000 kg 2 – 3: Pallet changer for workpieces up to 3,500 kg, large access door
allows optimal accessibility to the working area and setup station
Technical Data
06
1
2
3
DMU P / FD and DMC U / FD duoBLOCK® Series
3rd generation duoBLOCK® –
even larger working area with
better accessibility.
5
07
6
4: Large cube-shaped working envelope and
consistent precision even at the extremities of the
axis travels by virtue of 3 guideways in the X-axis 5: Steep (30 °) 1-piece covers for efficient chip
clearance 6: Fast chip removal to the rear
4
Highlights
++ Unrestricted crane loading from above the table centre for DMU machines
and over the pallet centre for DMC machines (setup station)
++ Optimal accessibility to the large working area and setup station via the
large access door allows fast and ergonomic setting and changeover
++ Larger working area facilitates use of large multi-clamps or large
component machining
++ Steep covers and cabin angles provide optimal chip flow
++ 1-piece cover in the area of chip clearance
++ Fast chip removal to the rear
Applications and Parts
Machine and Technology
êê DMU P: 5-axis machines
without pallet changer
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
DMU duoBLOCK® –
largest cube-shaped working volume
and smallest footprint.
08
++ Standard equipment includes B-axis for
5-axis simultaneous machining
++ Space-saving chip removal to the rear
++ Larger working area with Y-axis travel
up to 250 mm longer
++ Optimised duoBLOCK® construction
provides greater maximum load
The duoBLOCK® Series modular design
with B-axis as standard.
Smaller building blocks – two guideways
in the X-axis (Size: 60)
Larger building blocks – three guideways
in the X-axis (Size 160)
B-axis
A-axis
B-axis
5X torqueMASTER® – B-axis with a drive
Tables
09
Rotary table
Milling / Turning table
Pallet table
Pallet changer
DMU 60 P duoBLOCK®
DMU 160 P duoBLOCK®
Travel X / Y / Z
mm
600 / 700 / 600
1,600 / 1,250 / 1,100
Table size
mm
ø 630
1,500 × 1,250
Maximum table load
kg
700
4,000
Workpiece measurements
mm
1,530
1,675
850
850
Applications and Parts
Machine and Technology
êê DMC U: 5-axis machines
with pallet changer
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
DMC U duoBLOCK® –
fast pallet changer for
maximum productivity.
10
++ Optimised pallet changer location results in a smaller footprint
++ NC axis changer technology leads to shorter pallet change times
++ Sturdy construction and the inherently rigid machine bed allows
heavy workpiece weights
++ duoBLOCK® design provides optimal accessibility to the
working area and setup station
++ Tool magazine technology in high-volume serial production
allows short chip-to-chip times down to 3.7 sec.
1
2
1: Faster and more space-saving pallet changer for setup of workpieces up to 3,500 kg during production 2: Vertical chain magazine with a fast cam-controlled double gripper for short chip-to-chip-times of down
to 3.7 seconds (available for size 160)
11
DMC 60 U duoBLOCK®
DMC 160 U duoBLOCK®
Travel X / Y / Z
mm
600 / 700 / 600
1,600 / 1,400 / 1,100
Pallet size
mm
ø 630 × 500
1,250 × 1,000
Maximum table load
kg
600
3,500
Pallet change time
sec.
9.5
22
Workpiece measurements
mm
1,400
1,295
850
630
Applications and Parts
Machine and Technology
êê FD Technology:
DMU FD / DMC FD
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
DMU FD and DMC FD duoBLOCK® –
­maximum productivity with complete
­machining on one machine.
Over 16 years of FD
1,000 machines installed
worldwide – 80 %
with pallet changers
Travel X / Y / Z
DMU / DMC 60 FD
DMU / DMC 160 FD
600 / 700 / 600
1,600 / 1,400 / 1,100
mm
Milling / turning table
rpm
1,200
400
Table / pallet size
mm
ø 700 / 630
ø 1,500 / 1,400
600 / 500
4,000 / 3,000
9.5
22
kg
sec.
Max. workpiece measurements
mm
1,530 / 1,400
700 (630)
1,640 (1,240)
Maximum table load
Pallet change time
850
12
1
2
3
4
5
6
7
8
1: Vertical turning with A- and B-axis 2: Horizontal turning with A- and B-axis 3: Tilted turning with A- and B-axis* 4: Measurement of turning tools* 5: Measurement of milling tools* 6: Measuring cycles for in-process workpiece measurement* 7: Use of multi-station tools (up to nine cutting edges) 8: Grinding package
Mill-turn cycles for
all requirements
++ Exclusive mill-turn cycles, only at DECKEL MAHO
++ Measurement cycles for (laser) measuring sensors:
calibrate the measuring sensor in the working area,
measure recesses etc.*
Standard mill-turn cycles
++ Grooving, undercutting, chip removal, thread
cutting etc.
++ Milling and turning tool measurement
++ Detect, control and monitor imbalances
++ Store, display and transmit measurement data
++ Deployment of long tools into the workpiece*
++ Alternating speed to dampen vibration during machining*
++ Use of multi-station tools (up to nine cutters)*
* optional
Grinding technology
­integration*
++ Grinding cycles for internal, external and
face grinding
++ Universal dressing unit in the working area
++ Grinding package with machine modifications,
e. g. additional wipers for protecting ball screws
and scales from dust ingress
++ Sensors for assisting programmed wheel
approach and retraction
* optional
9
10
11
12
9: Box jaws 10: Manual integrated power chuck 11: Hydraulic integrated power chuck 12: Mill / turn machining of a compressor housing
Highlights mill-turning (FD)
++ Complete machining: milling and turning in
one operation on one machine
++ Elimination of a second setup means time savings
and higher precision
++ Multiple operations on a single machine mean lower
investment costs and smaller space requirements
++ Elimination of idle time and processing steps
mean faster machining with fewer logistical costs,
which translates into lower cost per part and
higher precision
Standard equipment: 5-axis milling
and turning in one operation
++ FD drives with Direct Drive technology –
up to 1,200 rpm, power to 69 kW, torque up to
7,300 Nm, max. table load 4,000 kg
++ Oil mist separator and laminated glass security
viewing window
Options
++ Box jaw arrangements provide a simple
and inexpensive solution for clamping parts
for turning on the DMU / DMC 160 FD;
pallet preparation on the DMU / DMC 160 FD
comes as standard
++ Integrated manual power chuck for simple
centric clamping and short setup times
starting with DMU / DMC 60 FD
++ Integrated hydraulic power chuck for efficient
and precise clamping (exterior and interior)
and programmable clamping pressure starting
with DMU / DMC 60 FD
Over 16 Years of Turn-Mill Technology
DMU FD- / DMC FD-machines – the complete machining process
Milling
Turning
Drilling
Tapping
Setup
Reclamping
Milling
Turning
Drilling
Tapping
Unclamping
Complete
machining process:
1 machine
4 processing steps
300 % greater productivity
Conventional
machining process:
3 machines
10 processing steps
Machine 1
Single-purpose machines – conventional machining process
Setup
Reclamping
Turning
Turning
Milling
Drilling
Tapping
Setup
Setup
Reclamping
Machine 1
1
2
Milling
Drilling
Tapping
Setup
Fine turning
Machine 2
3
4
5
6
Unclamping
Machine 3
7
8
9
10
Applications and Parts
Machine and Technology
êê 5-axis machining
Control Technology
Technical Data
1
The essence of 5-axis machining –
high stability by machining at the
intersection of multiple axes
Maximum rigidity via 45 °
B-axis kinematics
++ For 100 mm tool lengths, no torque
on the B-axis for any swivel angle
Encoder
Bearing
High precision through
100
++ High-resolution encoder directly
on the bearing
++ Little force exerted through the
45 ° B-axis kinematics
M = 0 Nm
100
2
DMU P / FD and DMC U / FD duoBLOCK® Series
DMU / DMC duoBLOCK® –
5-axis milling of the highest order.
++ Patented B-axis as standard, NC-controlled swivelling milling head with high
stability and precision by machining at the intersection of multiple axes
++ High-precision NC rotary table, with angle encoders
++ Space-saving and fast turning pallet changer off-line setup during machining
on DMC machines
5-axis simultaneous machining (options)
++ NC-controlled A-axis for machining negative angles up to –30 °
17
++ 5X torqueMASTER , NC-controlled B-axis with gear-driven spindle
for 5-axis simultaneous machining with up to 1,100 Nm
®
++ Customised solutions, such as an indexing head
A-axis
60
B-axis
Gear-driven B-axis
Milling / Turning
Pallet changer
–
–
160
3
1 – 2: NC-controlled B-axis swivelling milling head for simultaneous
5-axis milling with high precision by machining at the intersection
of multiple axes 3: Indexing head and B-axis as customised
solution in toolmaking, for example 4: NC-controlled A-axis –
for simultaneous 5-axis milling with negative angles up to –30 °
–30 / +100 °
4
Applications and Parts
Machine and Technology
êê 5-axis machining
Control Technology
Technical Data
1: 5X torqueMASTER® – B-axis with a drive of up to 1,100 Nm torque 2: Pump end housing
made from GGG60 3: Cylinder head for a ship’s diesel engine made from GGG50 4: Fan disc
made from Ti 6Al 4V (Titanium) 5: Landing gear beam made from Ti 6Al 4V (Titanium)
18
1
2
3
4
5
DMU P / FD and DMC U / FD duoBLOCK® Series
5X torqueMASTER® – B-axis with
a drive torque of up to 1,100 Nm.
The 5X torqueMASTER® is ideal for machining difficult to clamp materials,
large diameter drilling (solid material), and deployment of side milling cutters
and form tools.
19
5X torqueMASTER®
++ Patented B-Axis, NC-controlled swivelling milling head as a B-axis
for simultaneous 5-axis milling with the highest stability by machining
at the intersection of multiple axes
++ SK50 / HSK-A100 tool holders
++ B-axis drive using planetary gear
++ Continuous positioning over the entire swivel range
++ Very rigid milling head with good damping due to the swivel plane below 45 °
++ Maximum cutting data can be used in any direction and swivel position
++ Gear-driven spindle with up to 1,100 Nm of torque and max. 32 kW
5X torqueMASTER®
Speed
Power / Torque
6,300 rpm
32 kW / 1,100 Nm
available option
Machine
DMU 160 P / FD
DMC 160 U / FD
Applications and Parts
Machine and Technology
êê Innovation
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
Innovative down to
the smallest detail.
The new, innovative wheel magazine provides the highest
flexibility and productivity due to the fact that it can be
­retooled during machining and non-productive time and
thanks to its compactness and small footprint. With short
tool access times down to 5.6 seconds with 243 tools, the
preselected tool can be switched into the spindle within
0.5 seconds, even during short machining processes.
Highlights
++ Retooling during machining
and non-productive time
(two wheels or more)
++ The most compact magazine
on the market
++ Up to 243 tool pockets, maximum
access time of 5.6 seconds
++ Patented design
++ Extremely short tool-changing
time of just 0.5 second
++ Safe retention thanks
to the toolholder
++ No disassembly required
before transportation, up to
123 tools (SK40) for size 60
20
How the wheel magazine works
1
1
The selected tool is on wheel 2
2
Free path (three empty pockets) for the shuttle
on wheel 1 by turning the wheels
3
The shuttle (double gripper) travels to the
selected tool, lift to release the tool from the
holder, the shuttle travels to the spindle
4
The tool is exchanged / replaced and the
double gripper returns
SK40 / HSK-A63
Number of wheels
1
Number of tools
2
40
63
DMU 60 P / FD
DMC 60 U / FD
–
standard,
123
3
183
243
–
optional
21
2
Maximised tool dimensions and
tool magazine configurations for size 60
SK40 / CAT 40 / HSK-A63
Tool holder
SK40 (HSK-A63)*
Magazine type / max. pockets
3
mm
ø 80 //
length 450
Measurements
(free adjacent pockets)
mm
ø 120 //
length 450
Boring bar measurements
mm
ø 280 × 160 //
length 450
Max. tool weight
kg
15
Maximum torque
Nm
25
Chip-to-chip time (HSK)
sec.
4.0
* FD only with HSK-A tool holder
4
243 pockets
Measurements
(occupied adjacent pockets)
Applications and Parts
Machine and Technology
êê Tool Handling
Control Technology
Technical Data
1 – 2: Vertical chain magazine for up to 120 tools (SK40 / HSK-A63) and maximum tool length of 650 mm 3: Rapid cam-controlled double gripper for short chip-to-chip times (3.7 seconds with HSK-A63)
22
1
2
3
DMU 160 P / FD and DMC 160 U / FD duoBLOCK®
Tool handling: chain magazine.
DMU: maximum tool dimensions and tool magazine configurations for machines without a pallet changer
Tool holder
DMU 160 P / FD duoBLOCK®
DMU 160 P / FD duoBLOCK®
SK40 (HSK-A63)
SK50 (HSK-A100)
Magazine type / max. pockets
120 pockets
120 pockets
Measurements (occupied adjacent pockets)
mm
ø 80 / length 650
ø 110 / length 650
Measurements (free adjacent pockets)
mm
ø 120 / length 650
ø 160 / length 350 (400)
ø 200 / length 650
Boring bar measurements
mm
ø 280 × 160 / length 350 (400)
ø 400 × 280 / length 400 (470)
Max. tool weight
kg
15
30
Breakdown torque
Nm
25
70
Chip-to-chip time (HSK)
sec.
4.7
4.8
Tool holder
DMU 160 P
DMU 160 P
DMU 160 FD
SK40 / CAT 40 / HSK-A63
SK50 / CAT 50 / HSK-A100
HSK-A63
Vertical chain, 60 pockets
Vertical chain, 120 pockets
standard,
optional
DMC: maximum tool dimensions and tool magazine configurations for machines with a pallet changer
Tool holder
DMC 160 U / FD duoBLOCK®
DMC 160 U / FD duoBLOCK®
SK40 (HSK-A63)
SK50 (HSK-A100)
Magazine type / max. pockets
480 pockets
480 pockets
Measurements (occupied adjacent pockets)
mm
ø 80 / length 650
ø 80 / length 650
Measurements (free adjacent pockets)
mm
ø 120 / length 650
ø 160 / length 350 (400)
ø 120 / length 650
ø 160 / length 350 (400)
Boring bar measurements
mm
ø 280 × 160 / length 350 (400)
ø 400 × 200 / length 650
ø 400 × 280 / length 400 (470)
Max. tool weight
kg
15
30
Breakdown torque
Nm
25
70
Chip-to-chip time (HSK)
sec.
4.7
4.8
Tool holder
DMC 160 U
DMC 160 U
DMC 160 FD
SK40 / CAT 40 / HSK-A63
SK50 / CAT 50 / HSK-A100
HSK-A100
–
–
–
–
Vertical chain, 60 pockets
Vertical chain, 120 pockets
Vertical chain, 180 / 240 pockets
Vertical double chain, 180 / 240 pockets
Vertical double chain, 360 / 480 pockets
standard,
optional
–
23
Applications and Parts
Machine and Technology
êê Spindle Array
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
Largest and most modern spindle range.
Motor spindle SK40 / HSK-A63*
Motor spindle HSK-A63
Motor spindle SK40 / HSK-A63*
12,000 rpm / 28 kW / 121 Nm
12,000 rpm / 35 kW / 111 Nm
18,000 rpm / 35 kW / 119 Nm
19 kW 100%
121 Nm 40%
8
5
82 Nm 100%
35 kW 40%
24 kW 100%
160
111 Nm 40%
80
0.9
0.5
12,000
6,000
3,000
750
1,500
375
12
Motor spindle HSK-A63
Motor spindle SK40 / HSK-A63* / SK50* / HSK-A100*
24,000 rpm / 26 kW / 85 Nm
10,000 rpm / 44 kW / 288 Nm
400
1.6
1
10
85 Nm 40%
5
60 Nm 100%
18,000
24,000
12,000
6,300
2,500
1,000
400
1
160
8
63
2
Speed
(rpm)
20
25
200
160
187 Nm 100%
100
63
40
10
5
0.6
10,000
50
40
25
20
16
10
8
5
3.15
2
32 kW 100%
288 Nm 40%
1,600
19 kW 100%
125
44 kW 40%
630
1,000
20
5
10
Power
(kW)
40
26 kW 40%
315
Speed
(rpm)
20
680
Torque
(Nm)
4,000
Power
(kW)
8
85 Nm 100%
0.6
5
5
Speed
(rpm)
12,000
6,300
4,000
2,000
20
Speed
(rpm)
0.2
20
25 kW 100%
119 Nm 40%
20
24
Torque
(Nm)
35 kW 40%
1.9
20
0.6
125
80
3.8
10
5
15
7.5
77 Nm 100%
40
2.5
1.25
31.5
12.5
630
500
315
30
320
Power
(kW)
40
35
14,000
250
125
80
20
14
Torque
(Nm)
* optional
18,000
31.5
28 kW 40%
315
Power
(kW)
15,000
500
Torque
(Nm)
2,000
Power
(kW)
Speed
(rpm)
20
Torque
(Nm)
Motor spindle SK50 / HSK-A100*
Gear-driven spindle SK50 / HSK-A100*
12,000 rpm / 52 kW / 430 Nm
6,300 rpm / 32 kW / 1,100 Nm
Torque
(Nm)
Power
(kW)
1,000
500
430 Nm 40%
250
300 Nm 100%
52 kW 40%
50
42 kW 100%
20
10
100
Torque
(Nm)
1,000
630
400
250
160
Power
(kW)
1,100 Nm 40%
32 kW 40%
32
25
20
12.5
750 Nm 100%
25 kW 100%
5
5
6,300
3,150
2,000
0.6
800
Speed
(rpm)
6,300
12,000
2,500
1,000
500
200
100
50
Speed
(rpm)
20
0.9
1,250
1
5
500
10
3.15
25
250
2
50
25
20
50
Aerospace spindles
Motor spindle HSK-A100
Motor spindle HSK-A63
15,000 rpm / 100 kW / 179 Nm
30,000 rpm / 85 kW / 40 Nm
25 kW 100%
119 Nm 40%
125
85 Nm 100%
5
4
50
20
2
10
5
50
40 Nm 40%
20
32 Nm 100%
2
10
0.6
5
Speed
(rpm)
12,000
15,000
5,340
2,000
20
Speed
(rpm)
20
200
0.6
5
68 kW 100%
630
10
Power
(kW)
100
80
85 kW 40%
40
35 kW 40%
630
500
315
Torque
(Nm)
30,000
Power
(kW)
100
80
22,000
Torque
(Nm)
* optional
DMU P / FD and DMC U / FD duoBLOCK® Series
Largest and most modern spindle range.
DMU P / DMC U machines: spindle range
Speed // Toolholder
Power, torque (40 / 100 % DC) // Run-up time
12,000 rpm // SK40 / HSK-A63*
28 / 19 kW, 121 / 82 Nm // 0 – 12,000 rpm: 2.0 sec.
DMU 60 P
DMC 60 U
DMU 160 P
DMC 160 U
Standard
Standard
18,000 rpm // SK40 / HSK-A63*
35 / 25 kW, 119 / 85 Nm // 0 – 18,000 rpm: 2.2 sec.
24,000 rpm // HSK-A63
26 / 19 kW, 85 / 60 Nm // 0 – 24,000 rpm: 3.5 sec.
Special option
10,000 rpm // SK40 / HSK-A63* / SK50* / HSK-A100*
44 / 32 kW, 288 / 187 Nm // 0 – 10,000 rpm: 3.5 sec.
–
12,000 rpm // SK50 / HSK-A100*
44 / 32 kW, 288 / 187 Nm // 0 – 12,000 rpm: 6.0 sec.
–
12,000 rpm // SK40 / HSK-A100*
52 / 42 kW, 430 / 300 Nm // 0 – 12,000 rpm: 4.5 sec.
–
6,300 rpm // SK50 / HSK-A100*
32 / 25 kW, 1,100 / 750 Nm // 0 – 6,300 rpm: 3.0 sec.
–
Aerospace spindles
15,000 rpm // HSK-A100
100 / 80 kW, 179 / 143 Nm // 0 – 15,000 rpm: 1.3 sec.
–
Special option
30,000 rpm // HSK-A63
85 / 68 kW, 40 / 32 Nm // 0 – 30,000 rpm: 2.8 sec.
–
Special option
DMU 60 FD
DMC 60 FD
DMU 160 FD
DMC 160 FD
Standard
–
optionally available, * optional
FD – mill-turn machines: spindle range
Speed // Toolholder
Power, torque (40 / 100 % DC) // Run-up time
12,000 rpm // HSK-A63
35 / 24 kW, 111 / 77 Nm // 0 – 12,000 rpm: 2.0 sec.
18,000 rpm // SK40 / HSK-A63*
35 / 24 kW, 111 / 77 Nm // 0 – 18,000 rpm: 2.2 sec.
–
10,000 rpm // HSK-A100
44 / 32 kW, 288 / 187 Nm // 0 – 10,000 rpm: 3.5 sec.
–
12,000 rpm // HSK-A100
52 / 42 kW, 430 / 300 Nm // 0 – 12,000 rpm: 4.5 sec.
–
6,300 rpm // HSK-A100
32 / 25 kW, 1,100 / 750 Nm // 0 – 8,000 rpm: 3.0 sec.
–
optionally available, * optional
Standard
1
2
3
1: Compact filtration system with 500 l, metal band filter and
internal coolant supply 40 bar 2: Tool breakage detection during
cutting (mechanical) 3: HSK tool taper cleaning (mechanical) 4: Control cabinet construction according to the Automotive
Standard 5: Maintenance-friendly Fluidbox
4
5
DMU P / FD and DMC U / FD duoBLOCK® Series
Safe and efficient production,
easy and fast maintenance.
Machines in the duoBLOCK® series allow safe and efficient production due to their comprehensive
process-optimising features. Specially optimised coolant and production packages as well as
­expansion options are available for automated production. With regard to maintenance and service,
the 3rd duoBLOCK® generation will impress you with easily accessible maintenance doors and control
cabinets, clear equipment identification and the service-friendly Fluidbox.
Optimal process safety
Chip removal and cooling units
++ Internal coolant supply at 40 bar through the spindle,
chip conveyor, Rotoclear in the standard version
DMU: Compact coolant tank 500 l, metal band filter
DMC: Coolant tank 980 l, paper band filter
++ Production package with internal coolant supply
up to 80 bar (option)
++ Coolant temperature control (option)
Measuring and testing (options)
++ Mechanical tool breakage control during cutting
++ Tool measurement and tool breakage detection
by laser
++ Infrared measuring probe
Maintenance and service
++ Large and easily accessible service
and control cabinet doors
++ Individual cable identification drawing
in the control cabinet
++ Maintenance-friendly Fluidbox
(lubrication, hydraulics and pneumatics)
++ Colour-coded cables of different types
Options for automation
++ Multi-channel clamping hydraulics through
the table centre up to 240 bar
++ Motor-driven fixturing area with automatic doors
++ Rotary magazine for up to 12 pallets in the system
++ Individual automation interfaces for workpiece
and pallet handling systems
Applications and Parts
Machine and Technology
êê Application Examples
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
High performance milling,
drilling and tapping.
1
2
3
Motor spindle 12,000 rpm / 28 kW / 121 Nm*
1
Performance
milling
2
Performance
drilling
3
Tapping
Steel (Ck45)
Material work piece
Steel (Ck45)
Steel (Ck45)
Material removal rate
224 cm3/min
205 cm3/min
–
Tool
Face mill D = 80 (6 cutting)
Indexable insert drill D = 44
Tap M20
Spindle speed
995 rpm (Vc = 250 m/min)
905 rpm (Vc = 125 m/min)
240 rpm (Vc = 15 m/min)
Feed
1,492 mm/min (Fz = 0.25 mm)
135 mm/min (Fz = 0.15 mm)
597 mm/min (Fz = 2.5 mm)
Depth / width of cut
2.5 / 60 mm
70 mm / –
–/–
Thread depth
–
–
20 mm
* comparable values for the 12,000 rpm (29 kW, 130 Nm) and 24,000 rpm (26 kW, 85 Nm) motor spindle
Motor spindle 18,000 rpm / 35 kW / 130 Nm
1
Performance
milling
2
Performance
drilling
3
Tapping
Material work piece
Steel (Ck45)
Steel (Ck45)
Steel (Ck45)
Material removal rate
242 cm³/min
214 cm3/min
–
Tool
Face mill D = 80 (6 cutting)
Indexable insert drill D = 44
Tap M24
Spindle speed
995 rpm (Vc = 250 m/min)
905 rpm (Vc = 125 m/min)
80 rpm (Vc = 6 m/min)
Feed
1,611 mm/min (Fz = 0.27 mm)
141 mm/min (Fz = 0.16 mm)
240 mm/min (Fz = 3.0 mm)
Depth / width of cut
2.5 / 60 mm
70 mm
–
Thread depth
–
–
20 mm
29
4
5
6
Motor spindle 10,000 rpm / 44 kW / 288 Nm
4
Performance
milling
5
Performance
drilling
6
Tapping
Steel (Ck45)
Material work piece
Steel (Ck45)
Steel (Ck45)
Material removal rate
812 cm3/min
708 cm3/min
–
Tool
Face mill D = 100 (7 cutting)
Indexable insert drill D = 70
Tap M30
Spindle speed
1,255 rpm (Vc = 394 m/min)
1,023 rpm (Vc = 225 m/min)
106 rpm (Vc = 10 m/min)
Feed
2,900 mm/min (Fz = 0.33 mm)
186 mm/min (Fz = 0.18 mm)
371 mm/min (Fz = 3.5 mm)
Depth / width of cut
3.5 / 80 mm
– / 100 mm
–/–
Thread depth
–
–
30 mm
Motor spindle 12,000 rpm / 52 kW / 430 Nm
4
Performance
milling
5
Performance
drilling
6
Tapping
Material work piece
Steel (Ck45)
Steel (Ck45)
Steel (Ck45)
Material removal rate
1,000 cm3/min
830 cm3/min
–
Tool
Face mill D = 160 (9 cutting)
Indexable insert drill D = 80
Tap M42
Spindle speed
1,000 rpm (Vc = 500 m/min)
900 rpm (Vc = 225 m/min)
46 rpm (Vc = 6 m/min)
Feed
1,800 mm/min (Fz = 0.2 mm)
165 mm/min (Fz = 0.183 mm)
207 mm/min (Fz = 4.5 mm)
Depth / width of cut
4.5 / 120 mm
120 mm / –
–/–
Thread depth
–
–
40 mm
Applications and Parts
Machine and Technology
êê Application Examples
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
High performance milling,
drilling and tapping.
30
1
2
3
Gear-driven spindle 8,000 rpm / 28 kW / 727 Nm
1
Performance
milling
2
Performance
drilling
3
Tapping
Steel (Ck45)
Material work piece
Steel (Ck45)
Steel (Ck45)
Material removal rate
570 cm3/min
422 cm3/min
–
Tool
Face mill D = 125 (10 cutting)
Indexable insert drill D = 80
Tap M42
Spindle speed
400 rpm (Vc = 160 m/min)
400 rpm (Vc = 100 m/min)
46 rpm (Vc = 6 m/min)
Feed
1,140 mm/min (Fz = 0.29 mm)
207 mm/min (Fz = 4.5 mm)
207 mm/min (Fz = 4.5 mm)
Depth / width of cut
5.0 / 100 mm
80 mm / –
–/–
Thread depth
–
–
40 mm
Gear-driven spindle 6,300 rpm / 32 kW / 1,100 Nm
1
Performance
milling
2
Performance
drilling
3
Tapping
Material work piece
Steel (Ck45)
Steel (Ck45)
Steel (Ck45)
Material removal rate
695 cm3/min
472 cm3/min
–
Tool
Face mill D = 160 (12 cutting)
Indexable insert drill D = 100
Tap M48
Spindle speed
268 rpm (Vc = 135 m/min)
400 rpm (Vc = 125 m/min)
100 rpm (Vc = 15 m/min)
Feed
965 mm/min (Fz = 0.3 mm)
60 mm/min (Fz = 0.15 mm)
500 mm/min (Fz = 5.0 mm)
Depth / width of cut
6.0 / 120 mm
100 mm
–
Thread depth
–
–
50 mm
DMU P / FD and DMC U / FD duoBLOCK® Series
Milling / turning: DMU / DMC 60 / 160 FD
duoBLOCK® performance turning.
DMU / DMC 60 FD – 37 kW power / 1,000 Nm torque
1,200* rpm max. speed / 3,300 Nm holding torque
Material
Ck45
Material removal rate
405 cm3/min
Depth of cut
4.5 mm
Feed
0.45 mm / revolution
Cutting diameter
500 mm
Cutting speed
200 m/min
Speed
127 rpm
31
DMU / DMC 160 FD – 69 kW power / 7,300 Nm torque
400* rpm max. speed / 13,500 Nm holding torque
Material
Ck45
Material removal rate
1,440 cm3/min
Depth of cut
12 mm
Feed
0.6 mm / revolution
Cutting diameter
900 mm
Cutting speed
200 m/min
Speed
71 rpm
* specification for DC 10 min, cooling of the bearing is required
Applications and Parts
Machine and Technology
êê Application Examples
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
Spindles for special materials and
applications // Example applications.
Aerospace spindle – cutting of aluminium up to 13 l/min
Power milling with a 15,000 rpm motor spindle (179 Nm, 100 kW)
Material workpiece
AlMgSi
Material removal rate
13,650 cm³/min
Tool
Face mill D = 80 (5 cutting edges)
Spindle speed
8,000 rpm (Vc = 2,009 m/min)
Feed
19,500 mm/min (Fz = 0.49 mm)
Depth / width of cut
10.0 / 70 mm
32
5X torqueMASTER® – cutting of titanium
Power milling with an 8,000 rpm gear-driven spindle (727 Nm, 28 kW)
Material workpiece
Titanium – Ti 6Al 4V
Material removal rate
349 cm³/min
Tool
Porcupine cutter D = 50 (4 cutting edges)
Spindle speed
363 rpm (Vc = 60 m/min)
Feed
203 mm/min (Fz = 0.14 mm)
Depth / width of cut
43.0 / 40 mm
Performance milling with 6,300 motor spindle
(1,100 Nm, 32 kW)
Material work piece
Titanium – Ti 6Al 4V
Material removal rate
516 cm³/min
Tool
Porcupine cutter D = 80 (4 cutting edges)
Spindle speed
239 rpm (Vc = 60 m/min)
Feed
172 mm/min (Fz = 0.18 mm)
Depth / width of cut
60.0 / 50 mm
Angle head for internal machining of notches, holes, etc.
++ Simple exchange directly via the standard tool magazine
++ Available for all tool interfaces, including SK40, HSK-A63, SK50, HSK-A100
++ Maximum stability provided by torque supports
++ Swivel range depends on whether tool is fixed or adjustable
++ Internal coolant supply is tool-dependent
U-axis for contouring and turning
++ Simple exchange directly via the standard tool magazine
++ Deployment of the U-axis via actuator system
++ Programming and control as full NC axis
++ Ideal for machining grooves, contours and deep reliefs
++ Max. 22 mm travel for SK40 / CAT 40 / HSK-A63
++ Max. 50 mm travel for SK50 / CAT 50 / HSK-A100
33
Finishing of a segment for a tyre mould
Complete machining on a DMU 60 P duoBLOCK®
Industry
Mould making
Material
40CrMnMo7
Tool
Ball nose mill ø 6 mm
Spindle / power / torque
18,000 rpm / 35 kW / 119 Nm
Machining focus: 5-axis simultaneous machining with an NC-controlled B-axis and NC rotary table;
surface finish Ra < 0.2 µm – use of a multiple fixture
Finishing of a titanium landing gear beam
Complete machining on DMC 160 FD duoBLOCK®
Industry
Aerospace
Material
Titanium – Ti 6Al 4V
Tool
Ball nose mill ø 12 mm
Spindle / power / torque
6,300 rpm / 32 kW / 1,100 Nm
Machining focus: heavy roughing with 1,100 Nm in 5-axis operation; finishing by 5-axis
simultaneous machining; complete machining in two operations
Applications and Parts
Machine and Technology
êê Automation
êê Customized Solutions
Control Technology
Technical Data
DMU P / FD and DMC U / FD duoBLOCK® Series
duoBLOCK® – the foundation for
individual automation solutions.
Workpiece handling
Machines with and
without pallet changers
Pallet handling
Machines without
pallet changers
RS5: 5-fold multi-pallet APC (7 pallets in the system)*
–
–
RS10: 10-fold multi-pallet APC (12 pallets in the system)*
–
–
Flexible pallet systems (linear multi-pallet)
–
–
–
–
Pallet handling
Machines with
pallet changers
Solutions for Automation
Articulating arm robot
Portal loaders
Upgrades / Peripheral equipment
Central tool magazine
Washing
34
Deburring
Measurement
Workpiece labelling
* DMC 160 U / FD with RS4 multi-pallet APC (6 pallets in the system)
1
1: Manufacturing system with three machining centres, dual-storey
linear storage with 52 pockets and central tool magazine with 400 pockets,
24,000 rpm HSC pick-up spindle 2: Manufacturing cell for hydraulic
components 3: RS5 rotary storage
3
2
1
2
3
4
1: Thin-walled lightweight Zerodur structures 2: Si-Quarz pump housing 3: Silicon nitride camera housing 4: Silicon carbide mounting plate
Working principle –
flexible ULTRASONIC integration via HSK
ULTRASONIC advantages
++ Reduced process forces for
excellent surface finishes
(Ra < 0.2 µm), minimised
­microcracks in the material,
longer tool life
++ Up to 2 times higher removal
rates compared to conventional
grinding
++ Self-sharpening of the cutting
edge with micro-fragments in
the diamond grains
++ Optimised particle flushing
in the active zone
max. 18,000 rpm
max. 8,000 rpm
HSK-A63
HSK-A100
Max. milling speed
rpm
24,000
10,000
Max. ULTRASONIC speed
rpm
18,000
8,000
ER
20 H7
shrink
ER
20 H7
shrink
Tool interface
easySONIC-Control
(automatic ULTRASONIC
frequency recognition)
option
DMU P / FD and DMC U / FD duoBLOCK® Series
ULTRASONIC – unrivalled material range
and milling on one machine.
The latest generation of ULTRASONIC HSK actuator systems combines ULTRASONIC hard machining
of advanced materials (example: lightweight structures made of Zerodur, stamping tools made of hard metal,
wear parts made of ceramic for the pump, textile and valve industries) with conventional 5-axis milling
based on a HSK-A63 / -A100 interface. Here, the conventional tool rotation is inductively overlaid with an
additional ULTRASONIC oscillation in the axial direction.
35
Applications and Parts
Machine and Technology
êê Technology Cycles
Control Technology
Technical Data
Exclusive, optionally available DMG MORI technology cycles
STANDARD
MPC – Machine
SGS – Spindle
Protection Control
Growth Sensor
Protecting machines with an
emergency shut-off function
Improved precision
by measuring spindle
­displacement
Vibration sensors on the
milling spindle
Emergency shut-off with
teach function
Process monitoring by
means of a bar graph
36
Milling spindle bearing
diagnostics
Measurement of the
axial displacement of
the rotor compared to
the stator in real time
The control system
­compensates for the
actual displacement
Grinding
Machining with the highest
surface precision
Grinding on a universal
milling machine
For internal, external and
face grinding
ATC – Application
Tuning Cycle
Process optimisation at
the push of a button
Process-oriented feeddrive tuning
Truing cycles for truing
the grinding wheel
Minimised machining time
with maximised component
quality, even taking into
account the workpiece weight
3D quickSET®
L measuring sensor package
Interpolation turning
Multi-tool
Quick and easy for the
highest precision
Enhanced measuring options
with the L measuring sensor
Save time by efficiently
using tools
Toolkit for checking and
correcting the kinematic
precision of four- and five-axis
machine configurations
Measurement of pockets
and grooves
Machining of faces and
recesses without a
turn-mill table
All head variants and all
table axes
Measurement in
hard-to-reach areas
Measurement of
individual points
Package with manual and
automatic calibration
The machining process
takes place in a circular
movement around and
inside the workpiece
The spindle is perpendicular
to the direction of movement
Several „sister tools” on
one toolholder
Save tool-change time and
magazine pockets
1
2
3
1: Turning 2: Tapping 3: Gear hobbing with standard tools
DMU P / FD and DMC U / FD duoBLOCK® Series
Gear production –
complete machining.
DMG MORI gearMILL® software – the software
package for various gear production operations
37
Highlights of the DMG MORI gearMILL®
gearing software
Highlights
++ Complete machining on one machine for reduced
overall investment and floor space requirements:
++ Calculation of the tooth geometry of spur gears
straight and helical gear teeth, double helical
gears (herringbone), couplings
++ Calculation of the tooth geometry of bevel
spur gears with straight or helical gear teeth,
spiral gears, shaft angle equal to or not equal
to 90 °, with and without offset (hypoid gear)
1
Turning
2
Drilling
3
Gear hobbing
++ Calculation of the tooth geometry of worms
and worm wheels, ZA flank profile, ZN flank
profile, ZI flank profile
++ Soft and hard machining
++ Generation of individual contact patterns
++ Attainable gear quality
Bevel spur gear DIN ≤ 5
Spur gear DIN ≤ 6
(depending on the pitch circle diameter)
++ Individual tooth flank and profile modifications
++ Generation of four- and five-axis milling paths
++ Generator for 3D measurement data
++ Machine simulation
++ Quality control on the CNC milling machine
with output protocol
++ Custom training concept with technology transfer
Applications and Parts
Machine and Technology
Control Technology
Technical Data
38
DMG MORI Energy Saving
DMG MORI Virtual Machine
DMG MORI Netservice
Intelligent technology saves up to
20 % of energy costs over the entire life
cycle of your DMG MORI machine tool.
Unique – your DMG MORI machine
1 : 1 with the PC
Green light for your machine
as standard equipment
++ Efficient production start-up
following optimal preparation
++ Immediate analysis and technical
support for your DMG MORI machine
++ Real-time display of cycle time
using PLC integration
++ Considerable increase in
machine availability
++ Complete availability of all cycles
and NC functions
++ Reduced service, personnel
and travel costs
++ High reliability using collision
detection and working area
verification
++ Faster, bidirectional data exchange
DMG MORI AUTOshutdown:
Intelligent standby control system
to avoid unnecessary energy use
during idle times.
DMG MORI GREENmode:
Increased process speed and
energy savings using intelligent
feed control.
++ Authentic machine model with
exact working area representation
++ Up to 80 % reduction of set-up
and retooling times
++ High data security using ISDN
or Internet VPN access
Operate 4.5 on
SIEMENS 840D solutionline
++ Highly simplified interactive programming with
identical “look and feel” for turning and milling
++ SINUMERIK Operate new user interface
++ ATC, 3D quickSET®
++ Powerful processor (1.85 GHz) and controller, 1 GB RAM
++ Short block processing time of approx. 2.5 ms
++ Look-ahead function for 99 blocks
++ Graphical simulation of the machining process with
plan view, triple-window display and 3D display;
synchronised display during the machining process
HEIDENHAIN TNC 640
++ Unique, highly detailed 3D simulation display
++ New optimised TNC user interface
++ HSCI – HEIDENHAIN Serial Controller Interface
++ Rapid program generation with plain-text programming
++ CollisionMonitoring (DCM)
++ ATC, 3D quickSET®
++ Powerful processor (Intel i7-3, two cores)
++ New optimised ADP movement guide for improved
surface quality and quicker machining (block
processing time of just 0.5 ms)
++ 3D machining, optional 3D tool correction via
the surface normal vector
++ MDynamics, optional optimisation of surface quality
and speed for smoothing surface transitions
Control Technology
DMG MORI ERGOline® Control –
high-end CNCs for reliable processes
and maximum precision.
Intelligent control systems are indispensable when it comes to converting engineering performance
into maximum process efficiency, applying the highest precision to the component and providing
optimal user-friendliness. DECKEL MAHO relies on the quality of the global market leaders SIEMENS
and HEIDENHAIN and improves their output holistically with its own software solutions such as
DMG MORI Virtual Machine and the DMG MORI process chain.
39
Applications and Parts
Machine and Technology
Control Technology
Technical Data
êê Floor Plans
DMU P / FD and DMC U / FD duoBLOCK® Series
Floor Plans
DMU 60 P / FD duoBLOCK®
DMU 160 P / FD duoBLOCK®
Side view
Side view
3,809
3,554 transport height
3,058
2,768 transport height
2,200
5,683
3,759
6,654
DMU 160 P duoBLOCK®
Top view with a chain magazine 60 pockets
6,134
5,802
3,984
transport width
without magazine
Footprint 47.7 m2
7,774
DMU 160 FD duoBLOCK®
Top view with a chain magazine 60 pockets
7,774
605
1,150
6,356
3,948
transport width
without magazine
Footprint 49.4 m2
5,802
40
DMC 60 U / FD duoBLOCK®
DMC 160 U / FD duoBLOCK®
Side view
Side view
2,200
3,969
3,714 transport height
2,908
3,056
2,715
2,610 transport height
1,600
4,111
DMC 160 U duoBLOCK®
41
Top view with a chain magazine 60 pockets
6,134
5,346
3,949
transport width
without magazine
Footprint 56.2 m2
9,170
DMC 160 FD duoBLOCK®
Top view with a chain magazine 60 pockets
9,170
605
1,150
6,356
5,802
3,949
transport width
without magazine
Footprint 58.2 m2
Applications and Parts
Machine and Technology
Control Technology
Technical Data
êê DMU P / FD duoBLOCK®
DMU P / FD duoBLOCK® Series
Technical Data
Machine type
DMU 60 P duoBLOCK®
Work area
X / Y / Z-axis travels
mm
600 × 700 × 600
Spindle centre to pallet clearance
Milling head horizontal
mm
50 – 650
Milling head vertical
mm
150 – 750
Milling head horizontal
mm
–150 up to 550
Milling head vertical
mm
–250 up to 450
NC rotary table
rpm
40
Milling / turning table (milling / turning)
rpm
–
Table size
mm
ø 630
Max. table load
kg
Spindle nose to pallet clearance
Table / clamping surface / workpieces
NC-controlled swivelling milling head (B-axis)
42
700
standard
Swivel range (0 = vert. / 180 = horiz.)
degrees
Rapid traverse and feed rate
rpm
–30 / +180
30
5-axis options
–
NC-controlled swivelling milling head (A-axis)
Swivel range (0 = vert. / –90 = horiz.)
degrees
Rapid traverse and feed rate
rpm
–
5X torqueMASTER® – NC-controlled B-axis with a gear-driven spindle
Swivel range (0 = vert. / 180 = horiz.)
degrees
Rapid traverse and feed rate
rpm
Main drive
Integrated motor spindle SK40
rpm
12,000
Integrated motor spindle HSK-A63
rpm
–
Integrated motor spindle HSK-A100
rpm
Power (40 / 100 % DC)
kW
28 / 19
Torque (40 / 100 % DC)
Nm
121 / 82
–
Tool changer
SK40
Tool interface
Tool magazine
pockets
40 / wheel
Linear axes (X / Y / Z)
Feed / rapid traverse
m/min
Acceleration
m/s2
Feed force
kN
60
6/6/5
10
Machine data
Space requirement of the basic machine incl. a chip conveyor without internal coolant supply
approx. m2
Machine height (standard machine)
mm
Machine weight
kg
Controls
DMG MORI ERGOline® Control with a 19" screen
optional, – not available
–
2,768
10,600
DMU 160 P duoBLOCK®
DMU 60 FD duoBLOCK®
DMU 160 FD duoBLOCK®
1,600 × 1,250 × 1,100
600 × 700 × 600
1,600 × 1,250 × 1,100
50 – 1,150
20 – 620
15 – 1,115
150 – 1,250
120 – 720
115 – 1,215
–200 up to 1,050
–150 up to 550
–200 up to 1,050
–300 up to 950
–250 up to 450
–300 up to 950
15
–
–
–
50 / 1,200
20 / 400
ø 1,500 × 1,250
ø 700
ø 1,500
4,000
600
4,000
standard
standard
standard
–30 / +180
–30 / +180
–30 / +180
30
30
30
–
–120 / +10
–120 / +10
25
25
–
–30 / +180
–30 / +180
23
23
12,000
–
–
12,000
–
–
–
–
10,000
28 / 19
29 / 19
44 / 32
121 / 82
130 / 87
288 / 187
SK40
SK40
HSK-A100
60 / chain
40 / wheel
60 / chain
60
60
60
5/4/5
6/6/5
6/4/5
15 / 15 / 10
10
15 / 15 / 10
46.9
–
46.9
3,782
3,058
3,782
35,000
12,000
35,000
DMU P: SIEMENS 840D solutionline, HEIDENHAIN TNC 640
DMU FD: SIEMENS 840D solutionline FD
43
Applications and Parts
Machine and Technology
Control Technology
Technical Data
êê DMC U / FD duoBLOCK®
DMC U / FD duoBLOCK® Series
Technical Data
Machine type
DMC 60 U duoBLOCK®
Work area
X / Y / Z-axis travels
mm
600 × 700 × 600
Spindle centre to pallet clearance
Milling head horizontal
mm
20 – 620
Milling head vertical
mm
120 – 720
Milling head horizontal
mm
–150 up to 550
Milling head vertical
mm
–250 up to 450
NC rotary table
rpm
40
Milling / turning table (milling / turning)
rpm
–
Table size
mm
ø 630 × 500
Max. table load
kg
Spindle nose to pallet clearance
Table / clamping surface / workpieces
NC-controlled swivelling milling head (B-axis)
44
600
standard
Swivel range (0 = vert. / 180 = horiz.)
degrees
Rapid traverse and feed rate
rpm
–30 / +180
30
5-axis options
NC-controlled swivelling milling head (A-axis)
–
Swivel range (0 = vert. / –90 = horiz.)
degrees
Rapid traverse and feed rate
rpm
5X torqueMASTER® – NC-controlled B-axis with a gear-driven spindle
–
Swivel range (0 = vert. / 180 = horiz.)
degrees
Rapid traverse and feed rate
rpm
Main drive
Integrated motor spindle SK40
rpm
12,000
Integrated motor spindle HSK-A63
rpm
–
Integrated motor spindle HSK-A100
rpm
Power (40 / 100 % DC)
kW
28 / 19
Torque (40 / 100 % DC)
Nm
121 / 82
–
Tool changer
Tool interface
Tool magazine
SK40
pockets
63 / wheel
Linear axes (X / Y / Z)
Feed / rapid traverse
m/min
Acceleration
m/s2
Feed force
kN
60
6/6/5
10
Machine data
Space requirement of the basic machine incl. a chip conveyor without internal coolant supply
approx. m2
Machine height (standard machine)
mm
Machine weight
kg
Controls
DMG MORI ERGOline® Control with a 19" screen
optional, – not available
–
2,715
12,000
DMC 160 U duoBLOCK®
DMC 60 FD duoBLOCK®
DMC 160 FD duoBLOCK®
1,600 × 1,400 × 1,100
600 × 700 × 600
1,600 × 1,400 × 1,100
50 – 1,150
20 – 620
10 – 1,110
150 – 1,250
120 – 720
110 – 1,210
–200 up to 1,050
–150 up to 550
–200 up to 1,050
–300 up to 950
–250 up to 450
–300 up to 950
15
–
–
–
50 / 1,200
20 / 400
ø 1,250 × 1,000
ø 630
ø 1,400
3,000
500
3,000
standard
standard
standard
–30 / +180
–30 / +180
–30 / +180
30
30
30
–
–120 / +10
–120 / +10
25
25
–
–30 / +180
–30 / +180
23
23
12,000
–
–
–
12,000
–
–
–
10,000
28 / 19
29 / 19
44 / 32
121 / 82
130 / 87
288 / 187
SK40
SK40
HSK-A100
60 / chain
63 / wheel
60 / chain
60
60
60
5/4/5
6/6/5
6/4/5
15 / 15 / 10
10
15 / 15 / 10
55.3
–
55.3
3,942
3,056
3,942
43,000
12,000
43,000
DMC U: SIEMENS 840D solutionline, HEIDENHAIN TNC 640
DMC FD: SIEMENS 840D solutionline FD
45
Applications and Parts
Machine and Technology
Control Technology
Technical Data
êê Options
DMU P / FD and DMC U / FD duoBLOCK® Series
Options
Machine Type
Options
Table options
Clamping hydraulics 2 / 4 for the work table and set-up area
RS7 / RS12 multi-pallet APC, incl. 5 / 10 additional pallets (only for DMC machines)
Toolholder
HSK-A63 / BT 40 / CAT 40 (HSK with the milling / turning machines, FD, standard version)
HSK-A100 / BT 50 / CAT 50 (HSK with the milling / turning machines, FD, standard version)
Automation / measuring / monitoring
3D quickSET®
Infrared measuring probe: HEIDENHAIN TS 640 / Renishaw PP60 (OMP 60)
Tool measurement in the working area Mfg. Blum Laser NT-Hybrid
Tool magazine has built-in mechanical tool breakage monitor
Combination tool measuring in the working area, laser system for milling tools, 3D-caliper for turning tools
4-colour signal lamp
Coolant / chip removal
46
Production package cooling unit 500 litres, fabric tape filter, internal coolant supply 40 bar
Production package cooling unit 600 litres, paper band filter, internal coolant supply 40 bar
Production package cooling unit 980 litres, paper band filter, internal coolant supply 40 bar
(standard equipment with DMC machines / for DMU only with 80 bar through-spindle coolant)
Prod. package cooling unit 980 litres, paper band filter, int. coolant supply 40 / 80 bar, (2 pressure stages)
Temperature control for the internal coolant supply unit 980 litres
Spray gun with a pump 1 bar / 40 l/min
External minimum quantity lubrication with the spindle centre positioned over the jets
Oil and emulsion-mist separator
Cooling unit air-blast through the spindle centre
Options controls TNC 640
Application Tuning Cycle ATC
Electronic hand wheel TNC 640
Control cabinet for the load station tool magazine
2. processor card with Windows 2000
Options SIEMENS 840D solutionline
Electronic hand wheel SIEMENS 840D
Control panel for tool magazine loading station
3D-operation, 3D-tool correction with the surface-normal vector
TRANSMIT Lateral surface transformation (milling of cylindrical paths)
CompCad compressor function for high-speed machining
General options
Shatterproof safety glass for the viewing window
Operating mode 4 (process supervision in production)
Package for increased precision
optional, – not available
DMU 60 P dB
(DMC 60 U dB)
DMU 160 P dB
(DMC 160 U dB)
DMU 60 FD dB
(DMC 60 FD dB)
DMU 160 FD dB
(DMC 160 FD dB)
(DMU on request)
(RS6)
–
(RS6)
standard
–
–
standard
–
–
–
–
standard
–
–
–
–
standard
–
standard
–
standard
standard
standard
–
–
–
–
–
–
–
–
standard
standard
–
47
www.dmgmori.com
Headquarters
Europe
Germany:
DMG MORI Deutschland
Riedwiesenstraße 19
D-71229 Leonberg
Tel.: +49 (0) 71 52 / 90 90 - 0
Fax: +49 (0) 71 52 / 90 90 - 20 00
Service Hotline: +49 (0) 180 5 49 00 22
DMG MORI Austria
Oberes Ried 11
A-6833 Klaus
Tel.: +43 (0) 55 23 / 69 141 - 0
Fax: +43 (0) 55 23 / 69 141 - 100
Service Hotline: +43 (0) 17 95 / 76 109
DMG MORI Hungary
Vegyész u. 17 – 25 · B. Building
H-1116 Budapest
Tel.: +36 1 430 16 14
Fax: +36 1 430 16 15
Service Hotline: +36 1 777 90 57
_ Stockerau
Josef-Jessernigg-Straße 16
A-2000 Stockerau
Tel.: +43 (0) 55 23 / 69 141 - 0
Fax: +43 (0) 55 23 / 69 141 - 100
DMG MORI Ibérica
Pol. Ind. Els Pinetons
Avda. Torre Mateu 2 – 8 · Nave 1
E-08291 Ripollet · Barcelona
Tel.: +34 93 586 30 86
Fax: +34 93 586 30 91
Service Hotline: +34 91 - 2 75 43 22
Europe:
DMG MORI Europe
Sulzer-Allee 70
CH-8404 Winterthur
Tel.: +41 (0) 58 / 611 5000
Fax: +41 (0) 58 / 611 5001
Service Hotline: +41 (0) 446 545 670
Asia:
DMG MORI Japan
2-3-23 Shiomi Koto-ku, Tokyo
JP-135-0052, Japan
Tel.: +81 3 - 6758 - 5900
Fax: +81 3 - 6758 - 5919
America:
DMG MORI USA
2400 Huntington Blvd.
Hoffman Estates, IL 60192
Tel.: +1 (847) 593 - 5400
Fax: +1 (847) 593 - 5433
DMG MORI Benelux
_ Netherlands
Wageningselaan 48
NL-3903 LA Veenendaal
Tel.: +31 (0) 318 - 55 76 - 11
Fax: +31 (0) 318 - 52 44 - 29
Service Hotline: +31 (0) 202 00 81 83
_ Belgium
Hermesstraat 4B
B-1930 Zaventem
Tel.: +32 (0) 2 / 7 12 10 - 90
Fax: +32 (0) 2 / 7 12 10 - 99
Service Hotline: +32 (0) 2 / 2 200 62 - 52
DMG MORI Czech
Kaštanová 8 · CZ-620 00 Brno
Tel.: +420 545 426 311
Fax: +420 545 426 310
Service Hotline: +420 239 000 561
_ Planá
Chýnovská 535
CZ-39111 Planá nad Lužnicí
Tel.: +420 381 406 914
Fax: +420 381 406 915
_ Slovakia
Brnianska 2
SK-91105 Trenčín
Tel.: +421 326 494 824
DMG MORI France
Parc du Moulin · 1 Rue du Noyer
B.P. 19326 Roissy-en-France
F-95705 Roissy CDG Cedex
Tel.: +33 (0) 1 / 39 94 68 00
Fax: +33 (0) 1 / 39 94 68 58
Service Hotline: +33 (0) 8 10 90 20 20
_ Lyon
Parc des Lumières
1205 Rue Nicéphore Niepce
F-69800 Saint-Priest
Tel.: +33 (0) 4 / 78 90 95 95
Fax: +33 (0) 4 / 78 90 60 00
_ Toulouse
Futuropolis Bat. 2 · 2 Rue Maryse Hilsz
F-31500 Toulouse
Tel.: +33 (0) 5 / 34 25 29 95
Fax: +33 (0) 5 / 61 20 89 19
_ Haute-Savoie
Espace Scionzier · 520 avenue des Lacs
F-74950 Scionzier
Tel.: +33 (0) 4 / 50 96 41 62
Fax: +33 (0) 4 / 50 96 41 30
_ Madrid
C / Alcañiz 23 · E-28042 Madrid
Tel.: +34 91 66 99 865
Fax: +34 91 66 93 834
_ San Sebastián
Edificio Igaraburu
Pokopandegi 11, Oficina 014
E-20018 San Sebastián
Tel.: +34 943 100 233
Fax: +34 943 226 929
Service Hotline: +34 91 - 2 75 43 22
DMG MORI Italia
Via G. Donizetti 138
I-24030 Brembate di Sopra (BG)
Tel.: +39 035 62 28 201
Fax: +39 035 62 28 210
Service Hotline: 199 177 811
_ Milano
Via Riccardo Lombardi 10
I-20153 Milano (MI)
Tel.: +39 02 48 94 921
Fax: +39 02 48 91 44 48
_ Padova
Via E. Fermi 7 · I-35030 Veggiano (PD)
Tel.: +39 049 900 66 11
Fax: +39 049 900 66 99
DMG MORI Middle East
Jebel Ali Free Zone · JAFZA Towers
Lob 18, Office 2403, P.O. Box 262 607
Dubai, U.A.E.
Tel.: +971 - 4 - 88 65 740
Fax: +971 - 4 - 88 65 741
DMG MORI Polska
ul. Fabryczna 7 · PL-63-300 Pleszew
Tel.: +48 (0) 62 / 7428 000
Fax: +48 (0) 62 / 7428 114
Service Hotline: +48 (0) 62 / 7428 285
DMG MORI Romania
DN 65B, KM. 4 + 471
RO-110180 Pitesti
Tel.: +40 248 610 408
Fax: +40 248 610 409
DMG MORI Russia
ul. Novohohlovskaya 23 / 1
RU-109 052 Moscow
Tel.: +7 495 225 49 60
Fax: +7 495 225 49 61
Service Hotline: +7 495 912 50 09
_ Jekaterinburg
ul. Sofi Kowalewskoj 4, litera Z
RUS-620049 Jekaterinburg
Tel.: +7 343 379 04 73
Fax: +7 343 379 04 74
DMG MORI Europe AG
Sulzer-Allee 70, CH-8404 Winterthur
Tel.: +41 (0) 58 / 611 5000, Fax: +41 (0) 58 / 611 5001
[email protected], www.dmgmori.com
_ St. Petersburg
pr. Obuhovskoy Oborony 271, litera A
RUS-192012 St. Petersburg
Tel.: +7 812 313 80 71
Fax: +7 812 313 80 71
DMG MORI Scandinavia
_ DMG MORI Finland & Baltics
Jasperintie 310
FI-33960 Pirkkala
Tel.: +358 10 271 4450
Service Hotline: +358 10 271 4460
_ DMG MORI Sweden
E A Rosengrens gata 5
SE-421 31 Västra Frölunda
Tel.: +46 (0) 771 364 6674
Fax: +46 (0) 31 476 351
Service Hotline: +46 (0) 771 365 724
_ DMG MORI Denmark
Robert Jacobsens Vej 60, 2.tv
DK-2300 København S
Tel.: +45 70 21 11 11
Fax: +45 49 17 77 00
Service Hotline: +45 70 21 11 12
_ Norway
Bergsli Metallmaskiner AS
Bedriftsveien 64
NO-3735 Skien
Tel.: +47 35 50 35 00
Fax: +47 35 50 35 70
DMG MORI Schweiz
Sulzer-Allee 70
CH-8404 Winterthur
Tel.: +41 (0) 58 / 611 5000
Fax: +41 (0) 58 / 611 5001
Service Direct Line: +41 (0) 58 / 611 5555
Service Hotline: +41 (0) 446 545 670
DMG MORI South East Europe
Ag. Georgiou 5 – Patriarchiko
Pylaias, Cosmos Offices, PO 60233
GR-57001 Thessaloniki
Tel.: +30 2310 474486
Fax: +30 2310 474487
DMG MORI Turkey
Ferhatpaşa Mah. Gazipaşa Cad. No: 11
TR-34885 Ataşehir · İstanbul
Tel.: +90 216 471 66 36
Fax: +90 216 471 80 30
Service Hotline: +90 216 47 16 636
DMG MORI UK
4030 Siskin Parkway East
Middlemarch Business Park
Coventry CV3 4PE · GB
Tel.: +44 (0) 2476 516 120
Fax: +44 (0) 2476 516 136
Service Direct Line: +44 (0) 2476 516 130
Service Hotline: +44 (0) 20 30241514
DMG MORI Africa
Representative
WIN-TECH Machinery & Tooling
90 El Thawra Street
El Golf Area Heliopolise
11341 Cairo, Egypt
Tel.: +202 2 690 36 08
Fax: +202 2 690 36 09
PRO.D6653_0715UK PRO.Dxxxx_xxxxUK Subject
Subjecttotomodification.
modification.Technical
Technicalupdate
updaterights
rightsreserved.
reserved.The
Themachines
machinesdepicted
depictedhere
heremay
mayinclude
includesome
someoptions,
options,equipment
equipmentand
andCNC
CNCalternatives.
alternatives.
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