DMC 80 U / FD duoBLOCK DMU 100 P duoBLOCK Universal …€¦ · · 2018-05-15DMU 80 P / FD...

www.dmgmori.com

DMU 80 P / FD duoBLOCK®

DMC 80 U / FD duoBLOCK®

DMU 100 P duoBLOCK®

DMC 100 U duoBLOCK®



World Premieres

4th Generation duoBLOCK®

Universal milling machines for 5-sided / 5-axis machining

DMU / DMC duoBLOCK®

02

DMU / DMC P / U / FD duoBLOCK® Series

The new standard in 5-axis machining.

Applications and parts

Highlights

Control technology

Overview

Technical specifications

DMG MORI 5-axis machines with a highly stable duoBLOCK® design offer 30% greater precision, performance, dynamics and efficiency for unmatched parts quality. From challenging materials in aerospace to demanding surface quality in tool and mold making, the 4th Generation duoBLOCK® Series is optimized for manufacturing success.

MotorsportSteering knuckle for

Infinity Red Bull Formula 1 racecar

03

Tool and mold making Tube form

Energy technology Drill head for oil / gas drilling

AerospaceChassis component

Mechanical engineeringMold carrier for PET bottles

04

30%

30%

30%


Highlights

Control technology

Overview


4th Generation duoBLOCK® – your competitive advantage!

Unrivaled!

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more prec ise

m o re e f f i c i e n t

more powerful

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®


Unrivaled

Precision

+ 30% greater precision

+ Precision package with complete feed drive cooling

+ Comprehensive cooling features

+ Improved temperature response

+ Spindle Growth Sensor (SGS)

Performance

+ 30% greater rigidity

+ powerMASTER 1000 motor spindle with 737.6 ft. / lbs. & 103.3 hp.

+ 5X torqueMASTER® with 958.8 ft. / lbs. & 49.6 hp.

+ Table with 76% greater rigidity

+ Ball screw with 2.0 in. diameter

+ 2.2 in. diameter linear guides

With the new duoBLOCK® Series, every part can be a masterpiece. Comprehensive cooling features and the optimized rigidity of the redesigned duoBLOCK® frame provides impressive accuracy and performance. The more rigid duoBLOCK® body delivers 30% greater stability and precision while the innovative wheel magazine offers exceptional flexibility with capacity for 453 tools - all on a compact footprint.

Note: Machine performance data may vary due to environmental and operating conditions.

05

30%

30%

30%

m

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ov

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i ve

more prec ise

m o re e f f i c i e n t

more powerful

c

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®

Efficiency

+ 30% less energy use

+ Compact footprint, small wheel magazine, and fast setup

+ Maximum machine utilization

+ Low maintenance and impressive ergonomics with unrestricted accessibility

+ B-axis: improved interference contour & greater rigidity!

CELOS®

+ CELOS® from DMG MORI for comprehensive management, documentation and visualization of jobs, processes and machine data.

+ CELOS® offers an ever-growing portfolio of APPs and is compatible with your company’s existing programs and IT systems.

4th GenerationduoBLOCK®

PrecisionPerformance Efficiency CELOS®

06


Highlights

ê Precision

Control technology

Overview



A precision masterpiece every time!

Impressive long-term accuracy is achieved through comprehensive cooling features. The precision package also offers complete feed drive cooling and machine bed tempering for up to 30% greater parts precision.

Fully cooled feed drive

Standard cooling features

Headstock

Headstock housing Motor spindle Motor (B-axis)

NC rotary table

Motor (C-axis) Gears (C-axis)

Base unit

Motor (Y / Z-axis) Feed (X / Y / Z-axis)

Ball screw bearing Linear guides (X / Y / Z)

Symmetrical column cooling via column cooling bars

07

30%

Precision Performance Efficiency CELOS®


3rd Generation duoBLOCK®

Others

30% better temperature response

through efficient cooling features

Precision package with coolant

temperature control(optional)

Ball screw nut (X / Y / Z)

Motor (X-axis)

Cooling bars on the machine bed

Thermal shield

08

76%

12% 20%

3

4


Highlights

ê Rigidity / Performance

Control technology

Overview



Unmatched rigidity for maximum performance!


Industry leader!



Others

The overall stability of the precision duoBLOCK® design was improved by 30% through strengthened components and structural optimization (via FEM calculation).

And, the impressive powerMASTER 1000 motor spindle delivers maximum rigidity with 737.6 ft. / lbs. of torque for unbeatable cutting performance.

Rigidity increase:

B-axisnc rotary taBle Base assemBly

09

130%

1

2

4

5

powerMASTER 1000

powerMASTER 1000

130% increased torque



Others

Motor spindle:powerMASTER CAT50 Big Plus

9,000 rpm / 103.9 ** hp. / 737.6 ** ft. / lbs.

* Optional, ** 15% DC (2 min.)

1 Optimized components

12% greater rigidity through an elevated column and wider support structure

2 Size 50 ball screw in all axes

Large drive systems and inner-cooled ball screws (standard)

3 Size 55 linear guides in all axes

Wide linear guides for 5,511.6 lbs. maximum table loads

4 Larger YRT bearing on the B-axis and C-axis

Increased rigidity through larger bearing diameter

5 Optimal 3-point support

3.9 in. wider support base

60.3 hp. 100%

427.8 ft./lbs. 100%

72.4 hp. 40%

103.9 hp. 15%516.3 ft./lbs. 40%

737.6 ft./lbs. 15%107.3

67.1

53.6

20.1

737.6

516.3

442.5

73.8

Torque(ft./lbs.)

Spe

ed(r

pm.)

Power(hp.)

20 740

3,00

0

9,00

0

10

0 K

WH

5

10

15

21

25 KW

H

30%


Highlights

ê Efficiency

Control technology

Overview




Greater efficiency!

energy s av ings



Ch

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Co

ola

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supp

ly s

ystem

Cooling unit main spindle

other

The new duoBLOCK® Series reduces energy consumption by up to 30% through intelligent needs-based systems for greater machine availability and efficient machining. It also features a compact tool magazine and space-optimizing footprint with easy access for maintenance.

Save energy with efficiency features

* Energy savings from complete machining of a part on the new 4th Generation duoBLOCK®

27.8 in.

66.7

ft.

2

39.8

ft.

2

11

easy acces s t o t h e work area


The obvious choice!

Conventional chain magazine* New wheel magazine*

* DMU 80 P duoBLOCK®

Compact magazineThe most compact wheel magazine on the market, with a 41% smaller footprint (vs. prior machines).

Example: SK50 toolholder with 123 stations

Easy maintenanceThe fluid box has a large window for easy access and maintenance.

The duoBLOCK® has always set benchmarks with its spacious cubical work area that offers optimal accessibility from three sides. Large service doors make fast, ergonomic setup easy while crane loading from above to the table center is unrestricted.

27.8 in.

66.7

ft.

2

39.8

ft.

2

26.9 ft.2 savings

12

41%


Innovation in every detail!



Others

41% smaller footprint

with 123-station magazine

Highlights

+ Setup during machining (2 wheels required)

+ Smallest magazine on the market (41% narrower with 123 stations)

+ Up to 453 tool stations: max. 5.6 sec. setup

+ Patented design

+ Quick 0.5 sec. tool changes (0.8 sec. with the HSK-A100)

+ Reliable tool intake via protective holder

+ No disassembly for transport required – max. 123 (SK50) / 183 (SK40) tools for size 80 & max. 63 tools for size 100 / 125


Highlights

ê Innovation

Control technology

Overview


Unmatched flexibility and productivity – the innovative wheel magazine offers setup during machining on a 41% smaller footprint. It also features quick 5.6-second setup (453 tools) with 0.5-second tool switching, even for short machining processes.

13

–30°

+180°2

1



Powerful! 5X-torqueMASTER®

80% more torque

958.8 ft. / lbs., 49.6 hp. power, SK50 / HSK-A100 toolholder & max. 6,300 rpm.

B-axis with a motor spindleUniversal 5-axis milling head (gear-driven) for improved interference contour and greater rigidity!



Others

1 20% greater rigidity with large YRT bearing

Enhanced B-axis rigidity with a 45° swivel plane

2 Integrated cable carrier

Improved interference contour and quality through better housing seals as well as longer service life thanks to rail-guided cables

20%

20% greater

rigidity

14


Highlights

Control technology

ê CELOS®

Overview



Simplified machining. Seamlessmachine and IT systems integration.

ERGOline® panel with a 21.5˝ multi-touch display on a SIEMENS control.

Easy

User-friendly control interface for the latest high-tech machine tools from DMG MORI.

Familiar

Consistent management, documentation and visualization of jobs, procedures and technical data.

Compatible

Compatible with PPS / ERP systems, CAD / CAM products and all CELOS® APPs.

Just like a smartphone –direct access via the"APP MENU" to all available applications.

SMARTkey®

Personalized access to the machine and control.

15

CELOS® provides a consistent user interface for all high-tech DMG MORI machines. It also delivers comprehensive management, documentation, and visualization of job processes and machine data while the growing portfolio of APPs (16 currently) simplifies preparation and systematic job automation.

CELOS® APPs – 3 examples:


– From the idea to the finished product.

JOB MANAGERSystematic job planning, management, and preparation.

+ Machine-specific development and configuration of new orders

+ Clearly organized storage of all production-relevant data and documents

+ Simple visualization of orders, including the NC program, resources, etc.

JOB ASSISTANTJob-specific processing.

+ Menu-guided machine setup and interactive order processing

+ Reliable error prevention via notification windows and confirmation steps

TOOL HANDLINGFaster setup with post-machining magazine configuration analysis for subsequent jobs.

+ Display job-specific tool requirements with automatically generated loading list

+ Automatically generated tool unloading list, based on subsequent job requirements

16


Highlights

Control technology

ê Software and cycles

Overview


STANDARD

Machine Protection

Control (MPC)

Machine protection via quick shutoff function

Vibration sensor on the milling spindle

Quick shutoff function with learning capability

Process monitoring via bar graphs

Milling spindle bearing condition diagnosis

Grinding

Unbeatable surface quality

Grinding via universal milling machine

Inner, outer and face grinding

Grinding wheel dressing cycle

Spindle Growth

Sensor (SGS)

Greater precision by spindle displacement measuring

Axial displacement measuring of rotors versus stator in real time

Displacement compensation via the CNC control

Application Tuning

Cycle (ATC)

Process optimization with the push of a button

Process-specific feed drive tuning

Faster machining and unbeatable part quality (subject to workpiece weight)

Exclusive DMG MORI Technology Cycles

3D quickSET®

Quick and easy for unrivaled precision

Toolkit to check and correct the kinematic accuracy of 4- and 5-axis machine configurations

All head variants and table axis configurations

Interpolated turning

Face and recess machining (no milling / turning table)

Circular machining on the inner and outer part perimeter

Spindle situated perpendicular to direction of movement

L measuring sensor package

Expanded surveying capabilities with L measuring sensor

Web pocket and groove measuring

Inaccessible area measuring

Single-point measuring

Manual and automatic calibration packages

Multi-tool

Time savings with efficient tool use

Multiple “sister tools” on the standard toolholder

Faster tool changing and more available stations

17


Effective CNCs for reliableand precise machining.

Operate 4.5 on SIEMENS 840D solutionline control

+ Simple interactive program with identical "look & feel" for turning and milling machining

+ New SINUMERIK Operate user interface

+ ATC*, 3D quickSET®*

+ Powerful 32-bit multi-processor system with controller and 1 GB of RAM

+ Fast 0.6 ms block processing

+ Preview function for up to 150 NC blocks (parameterized)

+ Graphical simulation and overview of the machining process with 3D representation and live animation during machining

+ DECKEL MAHO MDynamics package for improved surface quality with faster machining during surface smoothing machining

* Optional

HEIDENHAIN TNC 640 control

+ Unique, highly detailed 3D simulation graphics

+ Newly optimized TNC user interface

+ HSCI – Heidenhain Serial Controller Interface

+ Shop floor or DIN / ISO programming

+ Fastest program generation via plain-text programming

+ Graphical programming

+ Dynamic Collision Monitoring (DCM)

+ ATC*, 3D quickSET®*

+ Powerful processing (Intel i7-3, dual-core)

+ Newly optimized ADP movement guidance for improved surface quality and faster machining (0.5 ms block processing)

+ Dynamic preview function (no block limitations)

+ Adaptive feed control (AFC) & trochoidal milling comes standard, optional: active chatter control (ACC)

* Optional

The new duoBLOCK® Series can be equipped with a Siemens 840D solutionline control (featuring the new ERGOline® panel, 21.5˝ monitor and CELOS®) or a Heidenhain TNC 640 control (featuring the 19˝ ERGOline® panel). Many exclusive software cycles for enhanced machining are also available: ATC, MPC, 3D quickSET® and DMG Virtual Machine.

18


Highlights

Control technology

Overview



4th Generation duoBLOCK® for 30% greater precision, performance & efficiency!

Highlights:

+ Precision: 30% greater parts precision with fully water-cooled feed drive

+ Performance: 30% greater rigidity for unmatched machining results

+ Efficiency: 30% energy savings with intelligent, needs-based systems

+ Impressive flexibility and fast machining with the new B-axis, featuring 20% greater rigidity and a 210º swivel range (with integrated cable carrier)

+ Fast, innovative wheel magazine with 0.5 second tool changing and up to 453 tools on a compact footprint

+ Quick rotary pallet changer for setup during machining (comes standard)

+ Milling & turning in on setup on a DirectDrive table (max. speed: 800 rpm.)

DMU 80 P duoBLOCK® DMU 100 P duoBLOCK® DMU 125 P duoBLOCK®

Travel (X / Y / Z) in. 31.5 / 41.3 / 33.5 39.4 / 49.2 / 39.4 49.2 / 49.2 / 39.4

Table size in. ø 35.4 × 27.6 ø 43.3 × 35.4 ø 49.2 × 43.3

Load weight lbs. 3,306.9 4,850.2 5,511.6

Workpiece dimensions in.

63.0

43.3

63.0

49.2

57.1

37.4

19

Wheel magazine

Tables Pallet changer

Machine bed and column

1 to 5 wheels, up to 453 tools (DMC)

Milling heads

5X-torqueMASTER®

A-axis B-axis

The duoBLOCK® Series modular design with standard-equipped B-axis.

NC Rotary table (DMU)

Milling / Turning table (DMU)

Milling / turning pallet table (DMC)

NC Pallet table (DMC)

Pallet changer (DMC)

DMC 80 U duoBLOCK® DMC 100 U duoBLOCK® DMC 125 U duoBLOCK®

Travel (X / Y / Z) in. 31.5 / 41.3 / 33.5 39.4 / 49.2 / 39.4 49.2 / 49.2 / 39.4

Table size in. ø 31.5 × 24.8 ø 39.4 × 31.5 ø 39.4 × 31.5

Load weight lbs. 3,086.5 4,409.2 4,409.2


63.0

39.4

63.0

49.2

57.1

35.4

20

DMU P / FD and DMC U / FD duoBLOCK® Series

DMU FD and DMC FD duoBLOCK® – maximum efficiency through complete machining on one machine.

DMU 80 FD duoBLOCK® DMC 80 FD duoBLOCK® DMU 125 FD duoBLOCK® DMC 125 FD duoBLOCK®

Travel (X / Y / Z) in. 31.5 / 41.3 / 33.5 31.5 / 41.3 / 33.5 49.2 / 49.2 / 39.4 49.2 / 49.2 / 39.4

Table size in. ø 31.5 ø 31.5 × 24.8 ø 49.2 ø 43.3

Load weight lbs. 2,866.0 2,645.5 5,070.6 4,409.2


57.1

35.4

57.1

35.4

63.0

49.2


Highlights

Control technology

Overview


63.0

49.2

21

Milling / turning cycles for every requirement

+ Exclusive DECKEL MAHO milling / turning cycles

+ Measuring cycles for the (L-) measuring sensor: calibrate in the work area and measure grooves, heels, etc.*

+ Long tool pivoting for the workpiece

+ Automatic speed adjustment to minimize viabration during machining*

+ Multi-station tools (up to 9 cuts)*

* Optional

Standard milling / turning cycles

+ Recessing, undercutting, metal removal, threading, etc.

+ Milling and turning tool measurement

+ Imbalance detection, control, and monitoring

+ Measuring data storage and secure transfer

Milling & milling / turning

Grinding + Inner, outer and surface grinding

Highlights

+ Measuring cycle: dressing station calibration

+ Dressing cycle: grinding wheel dressing

+ Surface grinding cycle: surface smoothing on round sections, centrally clamped workpieces

+ Longitudinal grinding cycle: cylindrical surface smoothing on centrally clamped workpieces

Grinding package features

+ Linear guides and ball screws with additional wipers

+ Sealing air for all linear measuring systems

+ Reduced lubrication intervals

+ Supplemental maintenance compliance

+ Dressing station

+ Centrifugal filter

+ Sensors for dressing, tool measurement and practical probing

22


Application examples


Highlights

Control technology

Overview


ê Application examples

ê Integrated technology

Knuckle – dimensions (unfinished part): 10.6 × 8.3 × 12.6 in. Machining time: 24 hrs., setups: 3

Industry Motorsport Spindle 18,000 rpm.

Tools 77 Power 46.9 hp.

Material Aluminum alloy Torque 95.9 ft. / lbs.

Machining focus: surfaces of 0.4 Ra up to 0.6 Ra, exact position and measuring tolerance, includes 3 + 2 positions & complete simultaneous 5-axis machining

Chassis components – dimensions: 42.5 × 24.0 × 8.3 in. Machining time: 23 hrs., setups: 3

Industry Aerospace Gear spindle 6,300 rpm.


Material Titanium (10-2-3) Torque 811.3 ft. / lbs.

Machining focus: 43% faster machining, 0.0002 in. positioning precision, effective heavy-duty package, exceptional surface quality (Ra 0.00002 in.)

Tube form – dimensions: 26.8 × 18.5 × 13.2 in. Machining time: 4 hrs. & 56 min., setups: 2

Industry Mold making Spindle 12,000 rpm.


Material Aluminum (C45) Torque 317.2 ft. / lbs.

Machining focus: max. Ra 0.35 surface quality, 3 + 2 axis & simultaneous 5-axis machining, 2 workpieces on 1 machine

Mold for PET bottles – dimensions: 15.7 × 14.2 × 15.7 in.Machining time: 86 min., setups: 3

Industry Mechanical engineering Spindle 12,000 rpm.


Material GGG60 Torque 317.2 ft. / lbs.

Machining focus: complete machining, including in-process measuring with automatic contours, fully automated serial machining via a pallet system (FMS) with workpiece loading by robot

Drilling head – dimensions: 13.0 × 1.6 × 15.7 in.Machining time: 18 hrs., setups: 1

Industry Oil / gas drilling Spindle 12,000 rpm.


Material 21CrNiMo2 (1.6523) Torque 212.4 ft. / lbs.

Machining focus: machining time reduced from 70 hours to 18 hours (75% faster), negative angle machining with the angled head, Ra 0.00004 in. surface quality, complete machining in one setup

23

16 years of milling / turning experience and over 1,000 machines sold

+ Complete turning and milling on one machine and in one setup with Direct Drive technology for up to 800 rpm.

+ Powerful milling / turning table with 3,982.8 ft. / lbs.

+ Low per-part costs and the highest precision through fast machining and streamlined logistics with fewer steps and less downtime

+ Exclusive DMG MORI milling / turning cycles

+ Fast machining and greater precision by eliminating setup processes

+ Smaller investment cost and better floor space utilization by using only one machine

+ Oil mist filter and shatterproof glass panels (comes standard)

+ Combined tool measuring

+ Greater workpiece weights (5,070.6 lbs.) and dimensions (ø 49.2 in.)

+ Electronic balancing

Maximum productivity with complete machining on

duoBLOCK® FD Series machines

1 2 3 4 5 6 7 8 9 10

Complete machining process:1 machine4 machining steps300% productivity increase

Conventional machining process:3 machines10 machining steps

MillingTurningDrilling

Threading

SetupReclamping

MillingTurningDrilling

Threading

Unclamping

Machine 1

TurningSetup

ReclampingTurning Setup

MillingDrilling

Threading

SetupReclamping

MillingDrilling

ThreadingSetup

Precision turning

Unclamping

Machine 1 Machine 2 Machine 3

DMU / DMC 80 FD, DMU / DMC 125 FD – complete machining process

Single-purpose machines – conventional machining process

24

1 2

3


Highlights

Control technology

Overview


ê Application examples

ê Integrated technology

DMG MORI gearMILL®

Gear machining – complete machining.

Highlights

+ Complete machining on one machine for cost and space savings:

Turning Drilling Gear milling

+ Soft and hard machining

+ Gear quality Bevel gear: DIN ≤ 5 Spur gear: DIN ≤ 6 (depending on pitch circle diameter)

1: Turning 2: Threading 3: Gear milling with standard tools

DMG MORI gearMILL® software –

widest selection of gear machining machining

DMG MORI gearMILL® highlights

+ Tooth geometry calculation of spur gears, straight and angular gear teeth, double angular teeth (double helical gears), couplings

+ Tooth geometry calculation of bevel spur gears with straight and angular gear teeth, spiral teeth, shaft angle (equal to or not equal to 90º), with and without axial offset (hypoid)

+ Tooth geometry calculation of worm gears, and wheels, ZA flank profile, ZN flank profile, ZI flank profile

+ Create individual contact patterns

+ Custom flank and profile modifications

+ Create 4- / 5-axis milling paths

+ Create 3D measurements

+ Machine simulation

+ Quality control on the CNC milling machine via output protocol

+ Custom training with technology transfer

25

1 32

ULTRASONIC technology integration

Unparalleled range of materials withULTRASONIC & milling on one machine.

ULTRASONIC is a promising technology for complex for virtually any industry that requires geometry machining with advanced materials. Through kinematic overlap of the tool rotation with an additional oscillation, normally challenging materials can now be machined economically with high quality results. Minimal process forces enable thin filament machining and offer longer tool service life by significantly reducing material micro-cracks. Depending on the material, surface finishes of Ra <0.000004 in. are also possible.

ULTRASONIC advantages

+ Minimized process forces deliver Ra < 0.000008 in. surface quality, fewer material micro-cracks, and longer tool service life

+ Up to 2x higher removal rates vs. conventional grinding

+ Self sharpening tools via diamond micro-splinters

+ Efficient particle rinsing in the work area

ULTRASONIC integration via HSK: how it works

When changing to the HSK toolholder, the ULTRASONIC frequency is inductively transferred from the fixed transmitter segment at the spindle tip to the rotating coil on the HSK holder.

ULTRASONIC HSK-63 actuator system

ULTRASONIC HSK-100 actuator system

max. 18,000 rpm. max. 12,000 rpm.

1: Finish grinding of a chemically resistant Si-quartz pump housing on an ULTRASONIC 125 FD duoBLOCK® 2: ULTRASONIC 60 FD duoBLOCK®: thin-walled lightweight structures in a Zerodur mirror carrier 3: Silicon nitride camera housing

Receiver coil

Transmitter Segment

26


Highlights

Control technology

Overview


ê Tool magazines

ê Milling heads


Innovative milling heads and intelligent tool management.

A-axis + Flexible complex mold machining with

up to -30º angles

+ Full use of the X-axis travel for every A-axis angle

+ Optimal interference contour when using angle heads in the work area

+ User-friendly axis kinematics with the 90º swivel plane position

B-axis + Complete 5-axis milling

+ Minimal work area loss thanks to the 45º swivel plane position

+ Short overhang / distance (from tool to X-slide guides)

+ Rigid milling head for good damping and limited leverage force with the 45º swivel plane position

+ Impressive milling characteristics regardless of applied machining force direction

+ No axis clamping required

+ Also available as a 5X torqueMASTER® gear spindle with up to 958.8 ft. / lbs. of torque

A-axis B-axis

SK40 / CAT 40 / HSK-A63 SK40 / CAT 40 / HSK-A63

– SK50 / CAT 50 / HSK-A100

NEW!

271

2

3

4

Maximum tool dimensions and tool magazine configurations for size 80, 100, & 125

SK40 / CAT 40 / HSK-A63

Toolholder SK40 (HSK-A63)*

Magazine type / Stations, max. 453 stations

Dimensions (occupied adjacent stations) in. ø 3.1 // length 21.7** / 25.6

Dimensions (unoccupied adjacent stations) in. ø 4.7 // length 21.7** / 25.6

Dimensions (drilling bar bridge) in. ø 11.0 × 6.3 // length 13.8 (15.7*)

Weight lbs. 33.1

Torque, max. ft. / lbs. 18.4

Chip-to-chip time (HSK) sec. 4.2 (for 80 Series)

SK50 / CAT 50 / HSK-A100

Toolholder SK50 (HSK-A100)*

Magazine type / Stations, max. 303 stations

Dimensions (occupied adjacent stations) in. ø 4.3 // length 21.7** / 25.6

Dimensions (unoccupied adjacent stations) in. ø 7.9 // length 21.7** / 25.6

Dimensions (drilling bar bridge) in. ø 15.7 × 11.0 // length 15.7 (18.5*)

Weight lbs. 66.1

Torque, max. ft. / lbs. 51.6

Chip-to-chip time (HSK) sec. 4.5 (for 80 Series)

Wheel magazine: how it works 1 Select tool on wheel 2

2 Free pathway (3 empty stations) for the shuttle on wheel 1 by rotating the wheels

3 Shuttle (double gripper) travels to selected tool, lifts tool from holder, and transfers tool to spindle

4 Switch tool and retract double gripper

SK40 / HSK-A63 SK50 / HSK-A100

Number of wheels 1 2 3 4 5 1 2 3 4 5

Number of tools 40 63 123 183 273 363 453 40 63 123 183 243 303

DMU 80 / 100 / 125 P, DMU 80 FD * * * * * * *DMC 80 / 100 / 125 U, DMC 80 FD – –

DMU 125 FD – – – – – – –

DMC 125 FD – – – – – – – –

* FD only on HSK-A toolholder, ** DMU 80 P / FD duoBLOCK®

Standard, Optional, * Upon request

28

41 2 3

5

1: Machining system with 3 machining centers, double-deck linear storage with 52 stations & central tool magazine with 400 stations 2: Manufacturing cell for hydraulic components 3: Fully automated machining of gearboxes 4: DMC H duoBLOCK® with RS7 / 12 5: RS7 rotary storage

Flexible manufacturing cells

+ 6x DMC H duoBLOCK®

with workpiece handling

+ Prioritized machining on the next available machine

+ Simultaneous machining of 3 different parts


Highlights

Control technology

Overview


ê Automation

29


duoBLOCK® – ideal for customautomation solutions.

Workpiece handlingMachines with / without

pallet changer

Pallet handlingMachines without

pallet changer

Pallet handlingMachines with pallet changer

Automation solutions

Articulating robotic arm

Gantry loader

RS7: 5-pallet rotary storage (7 pallets / system) – – –

RS12: 10-pallet rotary storage (12 pallets / system) – –

Container solution – –

Flexible pallet systems (linear storage) – –

Customization / peripherals

Central tool magazines

Washing

Deburring

Measuring

Workpiece marking

30


Highlights

Control technology

Overview


ê Performance diagrams

Motor spindle: SK50 / HSK-A100

12,000 rpm. // 59.0 hp. // 212.4 ft. / lbs.

Motor spindle: powerMASTER SK50 / HSK-A100

9,000 rpm. // 72.4 hp. // 516.3 ft. / lbs.


12,000 rpm. // 46.9 hp. // 95.9 ft. / lbs.


18,000 rpm. // 46.9 hp. // 95.9 ft. / lbs.


Performance diagrams

conditions reflect 40% DC

Motor spindle: HSK-A63

24,000 rpm. // 34.9 hp. // 62.7 ft. / lbs.

25.5 hp. 100%

34.9 hp. 40%

44.3 ft./lbs. 100%

62.7 ft./lbs. 40%

20 63 160

400

1,00

0

2,50

0

6,30

0

12,0

00

18,0

0024

,000

53.6

26.8

13.4

6.7

2.7

1.3

501.5

232.3

92.2

36.9

18.4

5.9

Spe

ed(r

pm.)

Power(hp.)

Torque(ft./lbs.)

33.5 hp. 100%

64.2 ft./lbs. 100%

46.9 hp. 40%

95.9 ft./lbs. 40%

20

2,20

0

4,00

0

6,30

0

12,0

00

53.6

26.818.8

10.7

6.7

3.41.7

0.8

368.8

232.3

184.492.259.0

23.29.2

3.7

Spe

ed(r

pm.)

Power(hp.)

Torque(ft./lbs.)

14,0

00

25 kW 100%

46.9 hp. 40%

63.4 ft./lbs. 100%

95.9 ft./lbs. 40%

20

2,00

0

15,0

00

18,0

00

46.9

26.8

10.7

6.7

2.1

1.3

0.8

368.8

232.3

92.259.0

14.8

7.4

3.7

Spe

ed(r

pm.)

Power(hp.)

Torque(ft./lbs.)

42.9 hp. 100%

59.0 hp. 40%

137.9 ft./lbs. 100%

212.4 ft./lbs. 40%

20

1,00

01,

400

2,45

0

4,06

0

8,00

0

10,0

00

12,0

0053.6

33.5

13.4

6.74.22.7

464.7

295.0

147.5

118.0

73.846.5

3.7

Spe

ed(r

pm.)

Power(hp.)

Torque(ft./lbs.)

60.3 hp. 100%

427.8 ft./lbs. 100%

72.4 hp. 40%

103.9 hp. 15%516.3 ft./lbs. 40%

737.6 ft./lbs. 15%

20 740

3,00

0

9,00

0

107.3

67.1

53.6

20.1

737.6

516.3

442.5

73.8

Power(hp.)

Tourqe(ft./lbs.)

Spe

ed(r

pm.)

56.3 hp. 100%

221.3 ft./lbs. 100%

69.7 hp. 40%

317.2 ft./lbs. 40%

20 50

1,00

0

2,50

0

6,30

0

12,0

00

67.1

26.8

13.4

6.7

2.7

1.3

1.2

737.6

368.8

184.4

73.8

36.9

18.4

7.4

3.7

Spe

ed(r

pm.)

Power(hp.)

Torque(ft./lbs.)


12,000 rpm. // 69.7 hp. // 317.2 ft. / lbs.

31

Gear spindle: 5X torqueMASTER® SK50 / HSK-A100

6,300 rpm. // 49.6 hp. // 958.8 ft. / lbs. (optional 8,000 rpm.)

Universal Many spindle options, including an 18,000 rpm. motor spindle with 95.9 ft. / lbs. or the new high- performance 9,000 rpm. powerMASTER motor spindle with max. 737.5 ft. / lbs. and 103.3 hp.

Spindle selection

Speed // ToolholderPower (40 / 100% DC), torque (40 / 100% DC)Spindle run-up time

12,000 rpm. // SK40 / HSK-A63*46.9 / 33.5 hp., 95.9 // 63.4 ft. / lbs.0 – 12,000 rpm.: 1.4 sec.


24,000 rpm. // HSK-A6334.9 / 25.5 hp., 62.7 // 44.3 ft. / lbs.0 – 24,000 rpm.: 3,5 sec.

6,300 rpm. (optional 8,000 rpm.) // SK50 / HSK-A100*49.6 / 36.2 hp., 958.8 // 599.6 ft. / lbs.

9,000 rpm. // SK50 / HSK-A100*103.9** / 72.4 / 60.3 hp., 737.6** // 516.3 // 427.8 ft. / lbs.0 – 9,000 rpm.: 2.2 sec.



15,000 rpm. // HSK-A100*69.7 hp., 298.0 ft. / lbs.0 – 12,000 rpm., 4.7 sec.

* Optional, ** 15% DC (2 min.)

Only clockwise spindle rotation data shown. Counterclockwise spindle data available by request.

Motor spindle: HSK-A100

15,000 rpm. // 69.7 hp. // 295.0 ft. / lbs.

36.2 hp. 100%

612.9 ft./lbs. 100% 49.6 hp. 40%

958.8 ft./lbs. 40%

20 190

400

1,40

0

8,00

0

85.8

42.9

21.5

10.7

5.4

2.7

1,510.5

377.6

94.4

23.6

Spe

ed(r

pm.)

Power(hp.)

Torque(Nm)

69.7 hp. 40%

56.3 hp. 100%

206.5 ft./lbs. 100%

298.0 ft./lbs. 40%

15,0

00

1,00

0

1,31

01,

710

100

10,0

00

67.1

60.3

53.6

46.9

40.2

33.5

295.0

258.1

221.3

184.4

Spe

ed(r

pm.)

Power(hp.)

Torque(Nm)

147.5

110.6

73.8

36.9

26.8

20.1

13.4

6.7

32

1 2 3


Highlights

Control technology

Overview


ê Machining examples

Motor spindle: 12,000 rpm. // 46.9 hp. // 95.9 ft. / lbs.

High-performance milling High-performance drilling Tapping

Workpiece material Steel (Ck45) Steel (Ck45) Steel (Ck45)

Material removal rate 13.7 in.3 / min. 12.5 in.3 / min. –

Tool Milling head D = 80 (6 inserts) Insert drill D = 44 Tap M20

Speed 995 rpm. (Vc = 9,842.5 ipm.) 905 rpm. (Vc = 4,921.3 ipm.) 240 rpm. (Vc = 590.6 ipm.)

Feed rate 58.7 ipm. (Fz = 0.01 in.) 5.3 ipm. (Fz = 0.006 in.) 23.5 ipm. (Fz = 0.1 in.)

Cutting width / depth 0.1 / 2.4 in. – / – – / –

1 2 3

Motor spindle: 18,000 rpm. // 46.9 hp. // 95.9 ft. / lbs.






Feed rate 63.4 ipm. (Fz = 0.01 in.) 5.6 in. (Fz = 0.006 in.) 9.4 ipm. (Fz = 0.1 in.)


1 2 3


High-performance milling, drilling and tapping.

33

4 5 6

Torque spindle: powerMASTER 9,000 rpm. // 103.9* hp. // 737.6* ft. / lbs.








* 15% DC (2 min.)

4 5 6

Motor spindle: 12,000 rpm. // 59.0 hp. / 212.4 ft. / lbs.





Speed 1,255 rpm. (Vc = 15,511.8 ipm.) 1,023 rpm. (Vc = 8,858.3 ipm.) 106 rpm. (Vc = 393.7 ipm.)



4 5 6

Torque spindle: 12,000 rpm. // 69.7 hp. // 317.2 ft. / lbs.





Speed 1,000 rpm. (Vc = 19,685.0 ipm.) 900 rpm. (Vc = 8,858.3 ipm.) 46 rpm. (Vc = 236.2 ipm.)



4 5 6

34


Highlights

Control technology

Overview



Technical specificationsDMU 80 P / FD dB® DMU 100 P dB® DMU 125 P / FD dB®

Work area

X- / Y- / Z-axis in. 31.5 × 41.3 × 33.5 39.4 × 49.2 × 39.4 49.2 × 49.2 × 39.4

Distance (spindle center - table)

Milling head (horizontal) in. 2.0 to 35.4 2.0 to 41.3 2.0 to 41.3

Milling head (vertical) in. –11.8 to 29.5 –11.8 to 37.4 –11.8 to 37.4

Distance (spindle nose - table)

Milling head (horizontal) in. –7.9 to 33.5 –7.9 to 41.3 –7.9 to 41.3

Milling head (vertical) in. 5.9 to 39.4 5.9 to 45.3 5.9 to 45.3

Table / Clamping area / Workpiece

NC rotary table rpm. 40 35 35

Table size in. Ø 35.4 × 27.6 Ø 43.3 x 35.4 Ø 49.2 × 43.3

Table load, max. lbs. 3,306.9 4,850.2 5,511.6

Milling / turning table (FD) rpm. 800 – 500

Table size in. Ø 31.5 – Ø 49.2

Table load, max. lbs. 2,866.0 – 5,070.6

NC controlled swivel milling head (B-axis) Standard Standard Standard

Swivel range (0 = vertical / 180 = horizontal) degrees –30 to 180 –30 to 180 –30 to 180

Rapid traverse and feed rate rpm. 30 30 30

5-axis options

5X torque MASTER® (NC controlled B-axis with gear spindle)

Swivel range (0 = vertical / 180 = horizontal) degrees 0 to +180 0 to +180 0 to +180


NC controlled swivel milling head (A-axis)

Swivel range (0 = vertical / 180 = horizontal) degrees –120 / +10 –120 / +10 –120 / +10


Main spindle

Integrated motor spindle rpm. 12,000 12,000 12,000

Toolholder SK 40 / HSK-A63* SK 40 / HSK-A63 SK 40 / HSK-A100*

Power (40 / 100% DC) hp. 46.9 / 33.5 46.9 / 33.5 46.9 / 33.5

Torque (40 / 100% DC) ft. / lbs. 95.9 / 63.4 (FD: 81.9 / 56.8)

95.9 / 63.4 95.9 / 63.4(FD: 212.4 / 130.5)

Tool changer

Toolholder SK40 SK40 SK40

Tool magazine, wheel stations 40 (63, 123) 40 (63, 123) 40, 63 (123)

Linear axes (X / Y / Z)

Feed / rapid traverse speed ipm. 2,362.2 2,362.2 2,362.2

Acceleration ft. / sec.2 23.0 19.7 / 16.4 / 19.7 19.7 / 16.4 / 19.7

Feed force lbf. 2,922.5 / 2,922.5 / 2,023.3 3,372.1 / 4,046.6 / 4,046.6 3,372.1 / 4,046.6 / 4,046.6

P max. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 in. 0.0002 0.00023 0.00023

P smax. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 in. 0.00015 0.0002 0.0002

Machine specifications

Footprint, base machine (incl. chip conveyor without internal coolant supply) ft.2 201.3 279.9 290.6

Machine height (standard machine) in. 122.0 133.9 133.9

Machine weight lbs. 34,171.7 54,013.3 57,320.2

*HSK-A toolholder comes standard on FD machines

35

DMC 80 U / FD dB® DMC 100 U dB® DMC 125 U / FD dB®

Work area

X- / Y- / Z-axis in. 31.5 × 41.3 × 33.5 39.4 × 49.2 × 39.4 49.2 × 49.2 × 39.4

Distance (spindle center - table)

Milling head (horizontal) in. 2.0 to 35.4 0.8 to 40.2 0.8 to 40.2

Milling head (vertical) in. –11.8 to 29.5 –11.8 to 37.4 –11.8 to 37.4

Distance (spindle nose - table)

Milling head (horizontal) in. –7.9 to 33.5 –7.9 to 41.3 –7.9 to 41.3

Milling head (vertical) in. 5.9 to 39.4 4.7 to 44.1 4.7 to 44.1

Table / Clamping area / Workpiece

NC rotary table rpm. 40 35 35

Table size in. Ø 31.5 × 24.8 Ø 39.4 × 31.5 Ø 39.4 × 31.5

Table load, max. lbs. 3,086.5 4,409.2 4,409.2

Milling / turning table (FD) rpm. 800 – 500

Table size in. Ø 31.5 – Ø 43.3

Table load, max. lbs. 2,645.5 – 4,409.2

NC controlled swivel milling head (B-axis) Standard Standard Standard

Swivel range (0 = vertical / 180 = horizontal) degrees –30 to 180 –30 to 180 –30 to 180


5-axis options

5X torque MASTER® (NC controlled B-axis with gear spindle)

Swivel range (0 = vertical / 180 = horizontal) degrees 0 to +180 0 to +180 0 to +180


NC controlled swivel milling head (A-axis)

Swivel range (0 = vertical / 180 = horizontal) degrees –120 / +10 –120 / +10 –120 / +10


Main spindle

Integrated spindle motor rpm. 12,000 12,000 12,000

Toolholder SK 40 / HSK-A63* SK40 / HSK-A63 SK40 / HSK-A 100*

Power (40 / 100% DC) hp. 46.9 / 33.5 46.9 / 33.5 46.9 / 33.5

Torque (40 / 100% DC) ft. / lbs. 95.9 / 63.4 (FD: 81.9 / 56.8)

95.9 / 63.4 95.9 / 63.4(FD: 212.4 / 130.5)

Tool changer

Toolholder SK40 SK40 SK40

Tool magazine, wheel stations 63 (123 / 183 / 273 / 363 / 453)

63 (123 / 183 / 273 / 363 / 453)

63 (123 / 183 / 273 / 363 / 453)

Linear axes (X / Y / Z)

Feed / rapid traverse speed ipm. 2,362.2 2,362.2 2,362.2

Acceleration ft. / sec.2 23.0 19.7 / 16.4 / 19.7 19.7 / 16.4 / 19.7

Feed force lbf. 4,046.6 / 4,046.6 / 2,023.3 3,372.1 / 4,046.6 / 4,046.6 3,372.1 / 4,046.6 / 4,046.6

P max. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 in. 0.00019 0.00023 0.00023

P smax. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 in. 0.00015 0.00019 0.00019

Machine specifications

Footprint, base machine (incl. chip conveyor without internal coolant supply) ft.2 230.3 300.3 321.8

Machine height (standard machine) in. 133.9 153.5 153.5

Machine weight lbs. 45,194.8 58,422.5 62,831.7

36


Highlights

Control technology

Overview


ê Options

DMU 80 P / FD dB® DMU 100 P dB® DMU 125 P / FD dB®

Table options (manual)

Clamping hydraulics for working table

Toolholder

HSK-A63 / BT40 / CAT40 HSK-A for milling / turning machines (standard)


Automation / Measurement / Monitoring

3D quickSET®

Infrared measuring sensor: Heidenhain TS640 / Renishaw PP60 (OMP 60)

Tool measuring in the work area via a NT hybrid Blum laser

Tool break control (mechanical) in the tool magazine

Combined tool measuring in the work area, laser system for milling tools, 3D sensor for turning tools (FD)

– (FD)

Status light (4-color)

Coolants / Chip disposal

Machining package: coolant unit (158.5 gal.) paper band filter, internal coolant supply (580.1 psi.)

Standard

Standard

Standard


Internal coolant supply (1,160.3 psi.), frequency-controlled

Coolant temperature control for internal coolant supply system (158.5 / 258.9 gal.)

Rinsing gun, with pump (14.5 psi. // 10.6 gal. / min.)

Minimal lubrication, internally through the spindle center & externally via nozzles

Oil and emulsion mist filter system (standard for FD)

Air cooling through spindle center

Heidenhain TNC 640 control (optional)

Application Tuning Cycle (ATC)

TNC 640 electronic hand wheel

Interface for tool magazine loading station

Active Chatter Control (ACC)

SIEMENS 840D solutionline Operate control (optional)

SIEMENS 840D electronic hand wheel


DECKEL MAHO MDynamics package

Additional options

Shatterproof glass viewing panes (standard for FD)

Machining mode 4 “process monitoring during machining”

Precision package

Heavy-duty package

Optional


Options

37

DMC 80 U / FD dB® DMC 100 U dB® DMC 125 U / FD dB®

Table options (manual)

Clamping hydraulics for working table

Toolholder



Automation / Measurement / Monitoring

3D quickSET®

Infrared measuring sensor: Heidenhain TS640 / Renishaw PP60 (OMP 60)

Tool measuring in the work area via a NT hybrid Blum laser

Tool break control (mechanical) in the tool magazine

Combined tool measuring in the work area, laser system for milling tools, 3D sensor for turning tools (FD)

– (FD)

Status light (4-color)

Coolants / Chip disposal


–

–

–


Standard

Standard

Standard

Internal coolant supply (1,160.3 psi.), frequency-controlled

Coolant temperature control for internal coolant supply system (158.5 / 258.9 gal.)

Rinsing gun, with pump (14.5 psi. // 10.6 gal. / min.)

Minimal lubrication, internally through the spindle center & externally via nozzles

Oil and emulsion mist filter system (standard for FD)

Air cooling through spindle center

Heidenhain TNC 640 control (optional)

Application Tuning Cycle (ATC)

TNC 640 electronic hand wheel


Active Chatter Control (ACC)

SIEMENS 840D solutionline Operate control (optional)

SIEMENS 840D electronic hand wheel


DECKEL MAHO MDynamics package

Additional options

Shaterproof glass viewing panes (standard for FD)

Machining mode 4 “process monitoring during machining”

Precision package

Heavy-duty package

38


Highlights

Control technology

Overview


ê Floor plans


Side view Top view (40-station wheel magazine)

DMU 100 P duoBLOCK®





Floor plans

120.

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39

DMC 100 U duoBLOCK®






144

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DMG MORI USA2400 Huntington Blvd, Hoffman Estates, IL 60192Tel: (847) 593-5400, Fax: (847) [email protected], www.dmgmori.com

DMG MORI Lifecycle Services

24 / 7 Hotline & Service Network The combined worldwide resources of DMG MORI benefit customers through a broad range of solutions designed to maximize performance - training, software, servicing, retrofitting, and pre-owned machine sourcing.

DMG MORI Manufacturing USA, Inc.

Our Davis, California location offers North American customers numerous benefits:

+ Reduced delivery times

+ Customized and price-competitive solutions

+ Access to engineers and developers

+ Direct factory support for machines and software

+ Assembled in the USA

+ Efficient logistics and freight

DMG MORI USA Headquarters2400 Huntington Blvd, Hoffman Estates, IL 60192Tel: (847) 593-5400, Fax: (847) 593-5433

To locate your nearest DMG MORI Technology Center, please visit:www.dmgmori.com

Spare Parts Service – always available through our global network.

Fast delivery: All orders are processed centrally and parts are shipped from the nearest global DMG MORI Spare Parts Center – for quick and dependable delivery.

+ $140 million spare parts inventory

+ Over 95% shipping within 24 hours

+ Original spare parts direct from the factory

+ Spare parts availability for many early models

1-855-364-6674

Support around the clock!

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