www.dmgmori.com DMU 80 P / FD duoBLOCK ® DMC 80 U / FD duoBLOCK ® DMU 100 P duoBLOCK ® DMC 100 U duoBLOCK ® DMU 125 P / FD duoBLOCK ® DMC 125 U / FD duoBLOCK ® World Premieres 4 th Generation duoBLOCK ® Universal milling machines for 5-sided / 5-axis machining DMU / DMC duoBLOCK ®
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DMC 80 U / FD duoBLOCK DMU 100 P duoBLOCK Universal …€¦ · · 2018-05-15DMU 80 P / FD duoBLOCK ... kinematic accuracy of 4- and 5-axis machine configurations All head variants
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DMU 80 P / FD duoBLOCK®
DMC 80 U / FD duoBLOCK®
DMU 100 P duoBLOCK®
DMC 100 U duoBLOCK®
DMU 125 P / FD duoBLOCK®
DMC 125 U / FD 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
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30%
30%
30%
Applications and parts
Highlights
Control technology
Overview
Technical specifications
4th Generation duoBLOCK® – your competitive advantage!
Unrivaled!
m
or
e i
nn
ov
at
i ve
more prec ise
m o re e f f i c i e n t
more powerful
c
el
os
®
DMU / DMC P / U / FD duoBLOCK® Series
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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e i
nn
ov
at
i ve
more prec ise
m o re e f f i c i e n t
more powerful
c
el
os
®
Efficiency
+ 30% less energy use
+ Compact footprint, small wheel magazine, and fast setup
+ Maximum machine utilization
+ Low maintenance and impressive ergonomics with unrestricted accessibility
+ 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
Applications and parts
Highlights
ê Precision
Control technology
Overview
Technical specifications
DMU / DMC P / U / FD duoBLOCK® Series
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
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30%
Precision Performance Efficiency CELOS®
4th Generation duoBLOCK®
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
Applications and parts
Highlights
ê Rigidity / Performance
Control technology
Overview
Technical specifications
DMU / DMC P / U / FD duoBLOCK® Series
Unmatched rigidity for maximum performance!
Precision Performance Efficiency CELOS®
Industry leader!
4th Generation duoBLOCK®
3rd Generation duoBLOCK®
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
4th Generation duoBLOCK®
3rd Generation duoBLOCK®
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%
Applications and parts
Highlights
ê Efficiency
Control technology
Overview
Technical specifications
Precision Performance Efficiency CELOS®
DMU / DMC P / U / FD duoBLOCK® Series
Greater efficiency!
energy s av ings
4th Generation duoBLOCK®
3rd Generation duoBLOCK®
Ch
ip C
on
ve
yo
r
Co
ola
nt
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
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easy acces s t o t h e work area
DMU / DMC P / U / FD duoBLOCK® Series
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%
DMU / DMC P / U / FD duoBLOCK® Series
Innovation in every detail!
4th Generation duoBLOCK®
3rd Generation duoBLOCK®
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
Applications and parts
Highlights
ê Innovation
Control technology
Overview
Technical specifications
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.
B-axis with a motor spindleUniversal 5-axis milling head (gear-driven) for improved interference contour and greater rigidity!
4th Generation duoBLOCK®
3rd Generation duoBLOCK®
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
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Applications and parts
Highlights
Control technology
ê CELOS®
Overview
Technical specifications
Precision Performance Efficiency CELOS®
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.
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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:
DMU / DMC P / U / FD duoBLOCK® Series
– 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
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Applications and parts
Highlights
Control technology
ê Software and cycles
Overview
Technical specifications
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
DMU / DMC P / U / FD duoBLOCK® Series
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.
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Applications and parts
Highlights
Control technology
Overview
Technical specifications
DMU / DMC P / U / FD duoBLOCK® Series
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®
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
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.
Tools 6 Power 69.7 hp.
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.
Tools 62 Power 69.7 hp.
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
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
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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)
Single-purpose machines – conventional machining process
24
1 2
3
Applications and parts
Highlights
Control technology
Overview
Technical specifications
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
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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
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Applications and parts
Highlights
Control technology
Overview
Technical specifications
ê Tool magazines
ê Milling heads
DMU / DMC P / U / FD duoBLOCK® Series
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
* FD only on HSK-A toolholder, ** DMU 80 P / FD duoBLOCK®
Standard, Optional, * Upon request
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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
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.
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
Interface for tool magazine loading station
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
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Applications and parts
Highlights
Control technology
Overview
Technical specifications
ê Floor plans
DMU 80 P / FD duoBLOCK®
Side view Top view (40-station wheel magazine)
DMU 100 P duoBLOCK®
Side view Top view (63-station wheel magazine)
DMU 125 P / FD duoBLOCK®
Side view Top view (63-station wheel magazine)
DMU / DMC P / U / FD duoBLOCK® Series
Floor plans
120.
4 Tr
ansp
ort
hei
gh
t
175.8
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9 O
il m
ist
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er (
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idth
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Chip conveyor
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ansp
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Hydraulic clamping
241.9
Chip conveyor
39
DMC 100 U duoBLOCK®
Side view Top view (63-station wheel magazine)
DMC 125 U / FD duoBLOCK®
Side view Top view (63-station wheel magazine)
DMC 80 U / FD duoBLOCK®
Side view Top view (63-station wheel magazine)
144
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ist
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er (
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120.
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Chip conveyor
R51.5
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idth
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171.
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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.