DIXI 125 / DIXI 210 / DIXI 270
Transcription
DIXI 125 / DIXI 210 / DIXI 270
www.dmgmori.com High-precision universal milling machines for 5-sided / 5-axis machining DIXI 125 / DIXI 210 / DIXI 270 Applications and parts Machine and technology Control technology Technical data DIXI 125 / 210 / 270 Swiss precision – highly accurate and unique. DIXI high-precision machines are in a class of their own, with volumetric accuracy of 15 µm. The duoBLOCK® and portal design features three-point support with GGG60 cast components and provides the basis for an optimal machine geometry. Temperature control of the relevant heat-generating machine components guarantees thermal stability. Volumetric machine compensation at the installation site ensures final optimisation and provides the basis for ultimate dynamic finishing precision. 02 Aerospace Aerospace Helicopter gear Transmission housings ++ Material: Magnesium for turbine units ++ Large workpiece volumes with minimum wall thickness and weight ++ Material: Aluminium ++ Machining of negative angles ++ The component length and positional tolerances require high positioning accuracy and temperature stability ++ Machining is only allowed with an optional fire extinguishing system ++ Typical profile and positional tolerances in the range of 10 – 20 μm ++ The thin wall construction requires an absolutely stress-free set-up ++ Drill hole tolerances better than H5, positional tolerances: 12 – 15 μm Mechanical engineering Table console ++ Material: Grey cast iron ++ High-precision finishing, including turning and 5-sided milling in one set-up ++ Turning to H5 quality ++ Profile and positional tolerances in the range of 10 μm 03 Mechanical engineering Machine bed ++ Material: Grey cast iron ++ High-precision finishing on 5 sides ++ Squareness and parallelism in the 10 μm range Plant building Automotive Base frame for wafer production Mould for car bumper ++ Material: Aluminium ++ Material: Steel ++ High-precision part for the manufacture of wafer plates ++ Rough machining followed by high-precision finishing ++ Coaxial values in the 10 μm range ++ Internal bores that are difficult to reach require optimum accessibility to the workpiece ++ Form and positional tolerance in the 10 – 20 μm range ++ The large dimensions of the component require the highest temperature stability for the process ++ Shape and positional tolerances in the range of 30 μm Applications and parts Machine and technology êê Highlights Control technology Technical data DIXI 125 / 210 / 270 Maximum precision – unique. Maximum precision thanks to 500 hours of hand scraping the guideways Unbeatable dynamics up to 6 m/s2 and 60 m/min 04 Individual optimisation on the user’s premises Compensation of thermal expansion and volumetric compensation under individual on-site conditions Maximum rigidity for top milling performance (GGG60 cast components) Maximum workpiece dimensions mm ø 1,250 ø 1,700 ø 2,200 2,500 8,000 12,000 max. ø 3,000 max. ø 2,500 max. ø 1,250 Portal 1,860 1,600 kg DIXI 270 Table configuration 1,250 mm Maximum load DIXI 210 Table configuration 1,600 Table size DIXI 125 Table configuration Portal 2,500 80 % volumetric precision + down to < 15 μm compared with standard 5-axis machines of other manufacturers > 100 / 200 μm Travel ranges X / Y / Z DIXI 125: 1,250 / 1,250 / 1,000 mm DIXI 210: 1,800 / 2,100 / 1,250 mm DIXI 270: 2,700 / 2,700 / 1,600 mm Positioning accuracy down to 3 μm Workpiece weight up to 12,000 kg with diameters up to 3,000 mm and heights up to 1,600 mm Temperature control Powerful gear-driven spindle of all relevant heat-generating machine components (1,550 Nm – 6,300 rpm) 3-point support High-performance motor spindle no additional costs because no foundation is needed thanks to the inherently rigid machine bed made of GGG60 (1,000 Nm – 78 kW) Applications and parts Machine and technology êê Accuracy Control technology Technical data DIXI 125 / 210 / 270 Maximum precision: +80 % increase in geometrical accuracy. To achieve perfect machining results over the entire working area, high precision flatness, squareness and straightness of all axes is required. In order to achieve the required accuracy, the guideways of every DIXI 210 / DIXI 270 undergo over 500 hours of hand scraping. For the DIXI 125, this results in flatness and straightness of the linear axes of ≤ 3 µm. 08 DIXI 125 DIXI 210 Positioning accuracy of the linear axes X / Y / Z µm 4/3/4 4/4/4 6/6/6 Positioning accuracy of the rotational axes A / B / C ws 5/4/4 5/4/4 5/4/4 Straightness and flatness of the linear axes µm 3 4 6 Volumetric accuracy* µm 15 20 25 * Only the linear axes were considered after room compensation 500 hours of manual scraping Scraping process: Up to 80 % increase in precision DIXI 270 The scraping process 1 Measurement of the straightness of the surface to be scraped with an autocollimator. Autocollimator 2 First scraping after measuring has been carried out. (Figurative representation) 4 Repetition of this measuring and scraping process until the required flatness is achieved. Block size = 100 mm Mirror Pitch = every 100 mm 3 Measurement of the straightness of the scraped surface with an autocollimator to control the desired geometrical shape. 09 Error tolerance: Accuracy / straightness ≤ 3 μm +80 % increase in geometrical accuracy: Portal angle with tolerance of 7 µm over a length of 1,000 mm. Applications and parts Machine and technology êê Accuracy Control technology Technical data DIXI 125 / 210 / 270 Maximum volumetric precision. A perfect machine geometry and high positioning accuracy are an optimal basis for maximum volumetric precision of DIXI machines. Based on this, a laser measurement of the entire working area is performed at the customer’s premises after commissioning of the machine. Minimal deviations identified are compensated and subsequently the volumetric precision is established via a final validation measurement. The results down to < 15 µm confirm that machining with maximum precision is possible throughout the entire working area of DIXI machines, which is also confirmed in practice. 10 1,000 / 1,250 / 1,600 mm Volumetric precision DIXI 125 / 210 / 270 Working area 1,25 0/1 ,800 / 2,7 00 m m Positioning accuracy over the whole machining envelope that is valid regardless of the spindle position. 1,250 / 2,100 / 2,700 mm 15 – 25 µm 11 > 100 / 200 µm 5-axis machines from other manufacturers Volumetric accuracy* DIXI 125 DIXI 210 DIXI 270 15 20 25 µm * Only the linear axes were considered after room compensation Component selection Thanks to the use of high quality components plus the selection of components and modules from the standard series and manual refinement of them, DIXI manufactures its precision universal machining centres to meet the highest standards of the aerospace, mechanical engineering and plant construction sectors. Applications and parts Machine and technology êê Temperature Control technology Technical data 12 Long-term precision guaranteed for decades Machine construction: High-precision machining of a cast component with form and positional tolerances in the range of 10 μm DIXI 125 / 210 / 270 Thermal control to ensure maximum long-term precision. The temperature of heat-generating machine elements is controlled using a large cooling unit that has a high flow rate, effectively reducing heat transfer to the machine structure. Temperature curves of the cooling unit (°C ) 22 Environment 21.5 Spindle 21 Cooling water 20.5 Coolant 20 13 19.5 Heat transfer to the machine is prevented by the constant flow of coolant to the heat generating elements. 19 18.5 18 11.5 12.5 13.5 14.5 15.5 16.5 17.5 18.5 19.5 20.5 21.5 (H) Temperature control points The components relevant for the long-term precision of the machine are kept at an optimum temperature by means of adaptive cooling. Headstock Headstock housing Motor spindle B-axis motor NC rotary table C-axis motor C-axis gearbox Basic construction Y- / Z-axis motor X / Y / Z feed axes: Ball screw bearing X / Y / Z linear guideways Symmetrical column cooling with cooling bars on the column X- / Y- / Z-ball screw X-axis nut X-axis motor Cooling bars on the machine bed Thermal shield Applications and parts Machine and technology êê Modular concept Control technology Technical data DIXI 125 / 210 / 270 The DIXI modular concept – the right components for every application. The modular duoBLOCK® concept of the 125 series with B-axis as standard 14 Milling heads A-axis Wheel magazine Machine bed and column B-axis Horizontal milling head 1 to 5 wheels, up to 453 tools Tables NC rotary table Pallet changer Turn / mill table Turn / mill pallet table NC pallet table Pallet changer State-of-the-art spindle technology Speed / tool interface / power / torque (40 % DC) DIXI 125 Motor spindle rated at 10,000 rpm // SK50 / HSK-A100 / 44 kW / 288 Nm DIXI 210 DIXI 270 – – Motor spindle rated at 12,000 rpm // SK50 / HSK-A100 / 44 kW / 288 Nm Motor spindle rated at 12,000 rpm // SK50 / HSK-A100 / 52 kW / 430 Nm Motor spindle rated at 12,000 rpm // SK40 / HSK-A63 / 35 kW / 130 Nm – – Motor spindle rated at 18,000 rpm // SK40 / HSK-A63 / 35 kW / 119 Nm Motor spindle rated at 15,000 rpm // HSK-A100, 52 kW / 404 Nm Motor spindle rated at 9,000 rpm // SK50 / HSK-A100 / 54 kW / 700 Nm Gear-driven spindle rated at 6,300 rpm // SK50 / HSK-A100 / 44 KW / 1,550 Nm Standard, – Optional The modular portal concept of the 210 and 270 series Portal, cross beam, X-axis slideway 15 Milling heads Pallet changer or rotary storage A-axis B-axis B-axis with gears Multi-level magazine (DIXI 210) up to 240 tools Chain magazine (DIXI 210) up to 180 tools Tool magazines Tables NC rotary table Turn / mill table Wheel magazine (DIXI 270) up to 183 tools Applications and parts Machine and technology êê Milling heads & special solutions Control technology Technical data DIXI 125 / 210 / 270 Innovative milling heads and intelligent tool management. 16 A-axis B-axis SK40 / BT40 / CAT40 / HSK-A63 SK40 / BT40 / CAT40 / HSK-A63 SK50 / BT50 / CAT50 / HSK-A100 SK50 / BT50 / CAT50 / HSK-A100 A-axis ++ More flexible production of complex shapes thanks to negative angles to –30° ++ Full use of the X-axis travel for every A-axis angle ++ Optimal interference contour when using angle heads ++ User-friendly axis kinematics thanks to the swivel plane under 90° B-axis ++ Full 5-axis milling ++ The 45° swivel plane results in minimal loss of working area ++ Very short overhang / distance from the tool to the guideways in the X-axis ++ Very stiff milling head with good damping and low leverage forces thanks to the swivel plane positioned under 45° ++ Outstanding milling behaviour regardless of the direction of the active machining forces ++ No axis clamping necessary ++ Also available as gear-driven spindle 5X torqueMASTER® with up to 1,550 Nm torque NEW! DIXI 125 / 210 / 270 Grinding ++ For internal, external and surface grinding Grinding package measures ++ Linear guideways and ball screws with additional wipers ++ Sealing air for all linear scales ++ Reduction of lubrication intervals Highlights ++ Observation of additional maintenance notes ++ Positioning cycle: Positioning of dressing station ++ Dressing station ++ Dressing cycle: Dressing the grinding wheel ++ Centrifugal filter ++ Surface grinding cycle: Re-grinding of flat surfaces of round, centrically clamped workpieces ++ Sensors for dressing, tool measurement and process-oriented probing ++ Longitudinal grinding cycle: Re-grinding of cylindrical surfaces on centrically clamped workpieces 17 For internal, external and surface grinding Applications and parts Machine and technology Control technology Technical data DIXI 125 / 210 / 270 – From the idea to the finished product. CELOS® features a standard user interface for all new high-tech machines from DMG MORI. CELOS® APPs enable the consistent administration, documentation and visualisation of order, process and machine data. They also simplify, standardise and automate the operation of the machine. 16 standard apps help the machine operator prepare, optimise and system atically process production jobs. Optionally, various exclusive software cycles such as ATC, MPC, 3D quickSET® and DMG MORI Virtual Machine are available, which are able to directly influence either workpiece quality or process optimisation. 18 Simplified machine operation. The holistic integration of machines within a manufacturing organisation. ERGOline® Control with 21.5" multitouch screen and SIEMENS. Simple User-friendly operation for all new high-tech machines from DMG MORI. Continuous Consistent administration, documentation and visualisation of order, process and machine data. Compatible Like on a smart phone, the operator has direct access to all available applications through the APP MENU. Compatible with PPS and ERP systems. Can be networked with CAD / CAM products. Open to trendsetting CELOS® APP extensions. Exclusive DMG MORI technology cycles STANDARD Mill / turn cycles for MPC – SGS – ATC – all requirements Machine protection control Spindle Growth Sensor Application Tuning Cycle* Exclusive mill / turn cycles only at DMG MORI Protecting machines with an emergency shut-off function Process optimisation at the push of a button Pivoting of long tools into the workpiece* Vibration sensors on the milling spindle Improved precision by measuring and compensating for spindle displacement Alternating speed for vibrationcritical set-ups* Emergency shut-off with teach function Process monitoring by means of a bar graph Measurement of the axial displacement of the rotor compared to the stator in real time Process-oriented feed drive tuning Minimised machining time with maximised component quality, regardless of workpiece weight The CNC system compensates for the actual displacement Milling spindle bearing diagnostics 19 3D quickSET®* L measuring sensor package* Interpolation turning* Multi-tool* Quick and easy for maximum precision Enhanced measuring options with the L measuring sensor Save time by efficiently using tools Tool kit for checking and correcting the kinematic precision of 4- and 5-axis machine configurations Measurement of slots and grooves Production of seal faces and recesses without a turn-mill table All head variants and every table axis Measurement in hard-toreach areas Measurement of individual points The machining process takes place in a circular movement around or within the workpiece Several sister tools on one tool carrier Save tool change time and magazine positions The spindle is perpendicular to the direction of movement Package with manual and automatic calibration * optional Applications and parts Machine and technology Control technology Technical data êê Floor plans DIXI 125 Technical data Table configuration Pallet configuration HBZ (4-axis configuration) 1,250 × 1,250 × 1,000 1,250 × 1,250 × 1,000 1,250 × 1,000 × 1,250 Working area X- / Y- / Z-axis mm Distance from spindle centre to table Horizontal milling head mm 50 to 1,050 20 to 1,020 150 to 1,150 Vertical milling head mm –300 to 950 –300 to 950 – Horizontal milling head mm –200 to 1,050 –200 to 1,050 100 to 1,350 Vertical milling head mm 150 to 1,150 120 to 1,120 – Distance from spindle nose to table Table / set-up area / workpieces NC rotary table rpm 35 35 35 Table size / pallet size mm Ø 1,250 × 1,100 Ø 1,000 × 800 800 x 800 Maximum table load kg 2,500 2,000 2,000 Mill-turn table (FD) rpm 500 500 – Table size mm Ø 1,250 Ø 1,100 – Maximum table load kg 2,300 2,000 – Standard Standard – –30 to 180 –30 to 180 – 30 30 NC-controlled swivelling milling head (B-axis) 20 Swivel range (0 = vertical / 180 = horizontal) Degrees Rapid traverse and feed rpm NC-controlled swivelling milling head (A-axis) – – Swivel range (0 = vertical / –90 = horizontal) Degrees Rapid traverse and feed rpm –120 / +10 –120 / +10 – 30 30 – Main drive Integrated motor spindle rpm Tool interface 12,000 12,000 12,000 SK 40 / HSK-A100* SK40 / HSK-A 100* SK40 / HSK-A 100* Power (40 / 100 % DC) kW 35 / 25 35 / 25 44 / 32 Torque (40 / 100 % DC) Nm 130 / 86 (FD: 288 / 177) 130 / 86 (FD: 288 / 177) 288 / 187 40, 63 (123) 63 (123 / 183 / 273 / 363 / 453) 63 / 123 / 183 / 243 / 303* SK40 (HSK-A63) / SK50 (HSK-A100) SK40 (HSK-A63) / SK50 (HSK-A100) SK40 (HSK-A63) / SK50 (HSK-A100) Tool magazine Tool magazine wheel Positions Tools Tool interface (FD only HSK-A) Tool diameter (filled adjacent positions) mm 80 / 110 80 / 110 80 / 110 Tool diameter (free adjacent positions) mm 160 / 280 160 / 280 160 / 280 Diameter of boring bar mm 280 × 160 / 400 × 280 280 × 160 / 400 × 280 280 × 160 / 400 × 280 Tool length mm 650 / 650 650 / 650 650 / 650 Weight kg 15 / 30 15 / 30 15 / 30 Linear axes (X / Y / Z) Feed speed, rapid traverse speed m/min Acceleration m/s2 60 60 60 6/5/6 6/5/6 6/6/5 Feed force kN 15 / 18 / 18 15 / 18 / 18 15 / 18 / 18 Pmax (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 µm 4/3/4 4/3/4 4/4/3 Machine weight kg 26,000 28,500 28,000 * HSK-A tool carrier included as standard with mill / turn machines Control system CELOS® from DMG MORI with 21.5" ERGOline® Operates on SIEMENS 840D solutionline DIXI 125 Floor plans DIXI 125 (table configuration) DMC 125 (table configuration) with wheel magazine, 63 positions Side view Plan view 3,578 Transport width Clamping hydraulics 952 Discharge height 3,292.5 Transport height without magazine 3,855 3,462 Maximum shear height 470 4,964 Chip conveyor .5 08 ,3 R1 6,144 21 4,348 3,498.5 Transport width Plan view 3,319.5 Transport height without magazine DIXI 125 (pallet configuration) with wheel magazine, 63 positions Side view Chip conveyor 0 0 ,3 952 3,855.5 Option Oil mist separator DIXI 125 (pallet configuration) 5,822 R1 7,002 Applications and parts Machine and technology Control technology Technical data êê Floor plans DIXI 210 Technical data Table configuration Pallet configuration 1,800 / 2,100 / 1,250 1,800 / 2,100 / 1,250 Working area X- / Y- / Z-axis mm Distance from spindle to table surface Horizontal milling head mm 130 to 1,380 130 to 1,380 Vertical milling head mm 230 to 1.480 230 to 1,480 Distance from spindle to table centre Horizontal milling head mm –750 to 1,350 –750 to 1,350 Vertical milling head mm –850 to 1,250 –850 to 1,250 Tables NC rotary table Speed rpm 12 12 Table size / pallet size mm ø 1,700 1,600 x 1,400 Maximum table load kg 8,000 5,000 Mill-turn table (FD) 22 Milling speed rpm 20 20 Turning speed rpm 250 250 Table size / pallet size mm ø 1,850 ø 1,850 Maximum table load kg 5,000 4,000 –30 / +180 –30 / +180 30 30 –120 / +10 –120 / +10 25 25 (not for FD) (not for FD) –10 / +180 –10 / +180 23 23 SK40 (HSK-A63) / SK50 (HSK-A100) SK40 (HSK-A63) / SK50 (HSK-A100) 110 5-axis options NC-controlled swivelling milling head (B-axis) Swivel range (0 = vertical / 180 = horizontal) Degrees Rapid traverse and feed rpm NC-controlled swivelling milling head (A-axis) Swivel range (0 = vertical / –90 = horizontal) Degrees Rapid traverse and feed rpm 5X torqueMASTER® – NC-controlled B-axis with gear-driven spindle Swivel range (0 = vertical / 180 = horizontal) Degrees Rapid traverse and feed rpm Tools Tool interface (FD only HSK-A) Tool diameter (filled adjacent positions) mm 110 Tool diameter (free adjacent positions) mm 250 250 Diameter of boring bar mm 400 x 250 400 x 250 Tool length mm Weight kg Chip-to-chip time (HSK) Seconds Number of pockets 650 650 15 / 30 15 / 30 10 10 60 / 120 / 180 60 / 120 / 180 / 240 Further magazine options and tool dimensions on request. Main drive Integrated SK50 motor spindle rpm 10,000 10,000 Power (40 / 100 % DC) kW 44 / 32 44 / 32 Torque (40 / 100 % DC) Nm Linear axes (X / Y / Z) m/min Machine weight kg 288 / 187 288 / 187 60 / 40 / 40 60 / 40 / 40 41,000 45,000 Control system DMG MORI ERGOline® Control with 19" monitor and 3D control system Standard, Optional SIEMENS 840D solutionline DIXI 210 Floor plans DIXI 210 (table configuration) DIXI 210 (table configuration) with chain magazine, 60 positions Side view Plan view 5,844 4,900 with oil mist separator 1,396 4,773 Footprint of 51.1 m² 8,743 8,743 23 DIXI 210 (pallet configuration) DIXI 210 (pallet configuration) with chain magazine, 60 positions Side view Plan view Footprint of 102.2 m² 10,939 5,100 with oil mist separator 1,596 4,973 9,339 5,840 Transport length without floor 10,939 Applications and parts Machine and technology Control technology Technical data êê Floor plans DIXI 270 Technical data Table configuration Pallet configuration 2,700 / 2,700 / 1,600 2,700 / 2,700 / 1,600 Working area X- / Y- / Z-axis mm Distance from spindle to table surface Horizontal milling head mm 130 to 1,730 130 to 1,730 Vertical milling head mm 230 to 1,830 230 to 1,830 Horizontal milling head mm –1,050 to 1,650 –1,050 to 1,650 Vertical milling head mm –1,150 to 1,550 –1,150 to 1,550 Distance from spindle to table centre Tables NC rotary table Speed rpm 9 9 Table size / pallet size mm ø 2,200 2,000 x 2,000 Maximum table load kg 12,000 9,000 –70 / +180 –70 / +180 30 30 –120 / +10 –120 / +10 25 25 SK40 (HSK-A63) / SK50 (HSK-A100) SK40 (HSK-A63) / SK50 (HSK-A100) 5-axis options NC-controlled swivelling milling head (B-axis) 24 Swivel range (0 = vertical / 180 = horizontal) Degrees Rapid traverse and feed rpm NC-controlled swivelling milling head (A-axis) Swivel range (0 = vertical / –90 = horizontal) Degrees Rapid traverse and feed rpm Tools Tool interface (FD only HSK-A) Tool diameter (filled adjacent positions) mm 80 / 110 80 / 110 Tool diameter (free adjacent positions) mm 160 / 280 160 / 280 280 × 160 / 400 × 280 Diameter of boring bar mm 280 × 160 / 400 × 280 Tool length mm 650 650 Weight kg 15 / 30 15 / 30 Chip-to-chip time (HSK) Seconds Number of pockets 13 13 63 / 123 / 183 63 / 123 / 183 Further magazine options and tool dimensions on request. Main drive Integrated SK50 motor spindle rpm 12,000 12,000 Power (40 / 100 % DC) kW 44 / 32 44 / 32 Torque (40 / 100 % DC) Nm Linear axes (X / Y / Z) m/min Machine weight kg 288 / 187 288 / 187 60 / 30 / 40 60 / 30 / 40 79,000 83,000 Control system CELOS® from DMG MORI with 21.5" ERGOline® Standard, Optional Operates on SIEMENS 840D solutionline DIXI 270 Floor plans DIXI 270 (table configuration) DIXI 270 (table configuration) Side view Plan view BFA 2500 l 9,205 7,885 2,220 1,860 4,600 6,200 9,753 (Wheel 63 tools) Coolant unit 9,900 DIXI 270 (pallet configuration) Side view Plan view 4,888 1,260 3,463 3,662.5 5,963 3,840 Rolling shutter opening 12,421 6,439 154 Z travel 1,600 130 100 11,585 a 1,830 1,730 2,670 Motor spindle 1,066 1,550 2,161 3,315 4,619 1,620 Rolling shutter opening DIXI 270 (pallet configuration) 0 Y travel 2,700 1,922 2,860 3,612.5 13,045 2,772 25 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. 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