UNIVERSAL MACHINING CENTRES FOR 5-SIDED / 5-AXIS MACHINING ...

DMGMORI.COM

DMU 60 P / FD duoBLOCK


DMU 90 P duoBLOCK

DMU 100 P duoBLOCK



DMC 60 U / FD duoBLOCK


DMC 100 U duoBLOCK



UNIVERSAL MACHINING CENTRES FOR 5-SIDED / 5-AXIS MACHINING

DMU | DMCduoBLOCK series

Applications and partsHighlights

Control technology

Overview

Technical data

DMU P / FD | DMC U / FD duoBLOCK SERIES

The benchmark in 5-axis machiningThe 5-axis machines in the highly stable duoBLOCK design with with maximum precision, performance and efficiency allow the highest machining performance and maximum precision with high dynamics. From hard-to-cut materials such as those found in the aerospace sector, to the highest requirements for surface quality such as in tool and mould making, the 4th Generation duoBLOCK machines provide optimal machining conditions.

AUTOMOTIVE

Steering knuckles for Infinity Red Bull Racing Formula 1 cars

02

AEROSPACE

Chassis components

DIE & MOLD

Tube mould

MACHINE CONSTRUCTION

Mould carrier for PET bottles

ENERGY TECHNOLOGY

Drill head for the oil and gas drilling sector

03

Applications and parts

HighlightsControl technology

Overview

Technical data

duoBLOCK – ADDED VALUE FOR YOU

Unique!With the new duoBLOCK series, every component becomes a masterpiece.

Comprehensive cooling and the high stiffness of the duoBLOCK concept are the basis for the highest possi-ble levels of precision and machining performance.

The new, innovative wheel magazine provides unbeatable flexibility with up to 453 tools and minimal space requirements.

PRECISION+ Full cooling of the axis drives with the

precision package

+ Comprehensive cooling measures

+ Significantly improved temperature response

+ SGS: Spindle Growth Sensor

+ µPrecision- volumetric accuracy of 13 μm

PERFORMANCE+ powerMASTER 1000 motor spindle

rated at 1,000 Nm and 77 kW

+ 5X torqueMASTER rated at 1,800 Nm and 52 kW

+ 50 % higher cutting power with the roughing package

+ Wide linear guides and large drives

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 P / FD | DMC U / FD duoBLOCK series

Unique

PR

ECIS

ION

PERFORMANCE

EFFICIENCY

CELOS

04

EFFICIENCY+ Lower space requirements, extremely compact wheel

magazine with short tool replenishment time

+ High machine availability

+ Optimal ease of maintenance and ideal ergonomics thanks to unrestricted accessibility

+ B-axis: improved interference contour, higher stiffness!

CELOS+ CELOS from DMG MORI enables consistent

administration, documentation and visual isation of order, process and machine data

+ CELOS can be extended with apps and is also compatible with your company’s existing infrastructures and programme

PR

ECIS

ION

PERFORMANCE

EFFICIENCY

CELOS

05

duoBLOCKPrecision Performance Efficiency CELOS


The masterpiece. Always precise!Comprehensive cooling measures achieve the highest long-term accuracy and precision. With the precision package, the entire feed drive is cooled and the machine bed is tempered, resulting in maximum higher component precision.

Standard cooling measures1 Headstock

Motor spindle B-axis planetary gear and motor A-axis gears and motor

2 NC rotary tableC-axis motor C-axis gears

3 Basic constructionY- / 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

Heat sinks on the machine bed

Y-axis measuring system is thermally decoupled from the machine bed (by carbon bearing)

Machine bed flushing (KSS)

Insulated switch cabinet at the rear

Precision package with coolant temperature control (optional)

4 X- / Y- / Z-ball screw nut

5 X-axis motor*

* As standard with the DMU 160 P / FP | DMC 160 U / FD

6 Heat sinks in the X axis (3 ×)

7 Thermoshield


Highlights› Precision

Control technology

Overview

Technical data

06 2

3

THE ENTIREFEED DRIVEIS COOLED

μPRECISION – HIGH PRECISION MACHINING ON STANDARD MACHINES (optional)

Volumetric accuracy of about 13 μm and positioning accuracy < 3 µm(available for DMU 80 / 125 / 160 P / FD | DMC 80 / 125 / 160 U / FD) ( Values on the example of the DMU 80 P duoBLOCK)

0707

1

5

3

4

6

7

PrecisionPerformanceEfficiencyCELOS


Maximum stiffness for the highest machining performance!The overall stiffness of the highly stable and extremely precise duoBLOCK concept has been further improved. The structure of the basic design has been optimised further using FEM calculations and the components have been strengthened. With the 5X torqueMASTER and the powerMASTER 1000 motor spindle, this results in maximum stiffness and machining performance with up to 1,800 Nm of torque.


Highlights› Performance

Control technology

Overview

Technical data

1 Optimised component structureHigher stiffness thanks to an elevated column with a wider support

2 Large drive systemsand internally cooled ball screws as standard

3 Wide linear guidesfor a high table load

4 Large YRT bearing in the B- and C-axisImproved stiffness thanks to the larger bearing diameter

5 Optimised three-point supportand a wider supporting area

08

3

A

4 B

4

PREMIUM CLASS!

STARK! – 5X-torqueMASTER*

5-axis universal milling head with gear-driven spindle. Significantly improved interference contour and higher stiffness!

HEAVY CUTTING WITH WITH 1,800 Nm*

1,800 Nm, 52 kW, SK 50 / HSK-A 100 tool taper and powerful 8,000 rpm* optional available for

DMU P 100 / 125 / 160 | DMC U 100 / 125 / 160

HEAVY DUTY MACHINING PACKAGE

+ 50 % higher power for cutting hard-to-machine materials+ Less tool wear+ Better surface quality

A Damper shoes in the Y-axis * two shoes with hydraulically operated sliding cover

B Hydraulic clamping of the NC rotary table

Heavy-duty machining ATC* for the NC rotary table *available for SIEMENS CNC control

092

1

5



Highlights› Efficiency

Control technology

Overview

Technical data


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 replenished during machining or idle time and thanks to its compact footprint. With rapid tool call-up times down to 5.6 seconds, despite the 453 tools, the preselected tool can be exchanged into the spindle within 0.5 second, even during short machining processes.

HIGHLIGHTS

+ Tool replenishment during machining and idle times (two wheels or more)

+ The most compact magazine on the market (41 % smaller machine width for the 123 pocket magazine)

+ Up to 453 tool pockets: call-up time down to 5.6 seconds

+ Patented design

+ Extremely short tool change time of just 0.5 second (0.8 second for HSK-A 100)

+ Safe tool retention thanks to the toolholder

+ No disassembly required to accommo date up to 123 (SK 50) or 183 (SK 40) tools of size 80 and up to 63 tools of size 100 / 125

10



Manufacture more efficiently!The duoBLOCK series enables highly efficient production in every respect, due to intelligent and demand-controlled accumulators, which contribute to a consid-erable energy saving. Optimal serviceability and unrestricted access to the work area from three sides allow fast and ergonomic set-up and adjustment.

OBVIOUS!

+ Optimal accessibility: from three sides completely open, large, cubic workspace

+ Large doors+ Quick and ergonomic set-up and adjustment+ Unrestricted crane access from above

to over the centre of the table

OPTIMAL WORKING AREA ACCESSIBILITY

E N E RGY S AV ING

0 KW

H

5

10

15

21

25 KWH

Energy required for complete machining of a component on the duoBLOCK

CHIP

CON

VEYO

R KS

S SY

STEM

COOLANT UNIT MAIN SPINDLE

MISCELLANEOUS

duoBLOCK 4th generation Previous generation

Save energy with efficient features 30

%

11



Highlights› CELOS

Control technology

Overview

Technical data

ERGOline CONTROL WITH 21.5″ MULTI- TOUCH SCREENAND SIEMENS

SimpleUser-friendly machine operation for all new high-tech machines from DMG MORI.

ConsistentConsistent administration, docu mentation and visualisation of order, process and machine data.

CompatibleCompatible with PPS and ERP systems. Can be networked with CAD / CAM products. Open to trendsetting CELOS APP extensions.

Simplified machine operation. Seamless integration of machine and company.

SMARTkeyCustomised user authorisation. Individ ually adapted access privileges to the control system and the machine.

APP MENULike on a smartphone, the operator has direct access to all available applications through the APP MENU.

12

CELOS APPS – 3 EXAMPLES


– From the idea to the finished productCELOS features a standard user interface for all new high-tech machines from DMG MORI. CELOS APPs facilitate the consistent management, documentation and visualisation of order, process and machine data on a unique 21.5″ multi-touch monitor. They also simplify, standardise and automate the operation of the machine. 16 standard APPs help the machine operator prepare, optimise and systematically process production jobs.

JOB MANAGERSystematic planning, administration and preparation of work orders.

+ Machine related creation and configuration of new work orders

+ Structured storage of all production related data and documents

+ Easy visualisation of orders, including NC program, equipment, etc.

JOB ASSISTANTProcess-defined orders.

+ Menu guided set-up of the machine and conversational processing of production orders

+ Reliable error prevention thanks to windows- based assistance instructions with a mandatory acknowledgement function

TOOL HANDLINGShorter tool set-up times through assessments of the magazine configuration for subsequent orders.

+ Display of all tools required for a job, including the automatic generation of a loading list

+ Generation of an unloading list through the automatic detection of all tools not required for subsequent jobs

13



Highlights

Control technology› Software and cycles

Overview

Technical data

Exclusive, optionally available DMG MORI technology cycles

3D quickSETImproved precision by measu-ring spindle displacement

+ Toolkit for checking and correcting the kinematic precision of 5-axis machine configurations

+ The CNC system compensates for the actual displacement

MULTI-TOOLSave time by efficiently using tools

+ Several ”sister tools” on one tool holder

+ Save tool change times and magazine pockets

INTERPOLATION TURNINGMachining of faces and recesses without a turn-mill table

+ The machining process takes place in a circular movement around and inside the workpiece

+ The spindle is perpendicular to the direction of movement

L MEASURING SENSOR PACKAGEEnhanced measuring options with the L measuring sensor

+ Measurement of pockets and grooves

+ Measurement in hard-to-reach areas

+ Measurement of individual points

+ Package with manual and automatic calibration

gearSKIVINGManufacturing of spur and spline gears

+ Synchronised turning of workpiece and tool

+ Machining of gears close to shoulders without interference

+ Synchronisation and tool path controlled by the cycle

+ Reduced process costs due to manufacturing of gears on universal machines

MPC 2.0 – MACHINE PROTECTION CONTROLProtecting machines with an emergency shut-off function

+ Vibration monitoring in the process

+ Emergency shut-off with teach function

+ NEW: Troque monitoring

+ Milling spindle bearing diagnostics

GRINDINGMachining with the highest surface accuracy

+ Grinding on a universal milling machine

+ For internal, external and face grinding

+ Truing cycles for the grinding wheel

ATC – APPLICATION TUNING CYCLEProcess optimisation at the push of a button

+ Process-oriented feed drive tuning

+ Minimised machining time with maximised component quality, irrespective of workpiece weight

+ High surface quality during finishing

14

CELOS WITH SIEMENS 840D SL OPERATE

+ Highly simplified interactive programming with identical ”look and feel“ for turning and milling

+ SINUMERIK Operate new user interface

+ ATC*, 3D quickSET*

+ With new powerful features around setup, programming, tools and program management

+ Fast block processing time of approx. 0.6 ms

+ DECKEL MAHO package MDynamics for improved surface quality with shortened machining time for the smoothing of surfaces etc.*

* Option

CELOS WITHHEIDENHAIN TNC 640

+ Unique, highly detailed 3D simulation display

+ New optimised TNC user interface

+ HSCI – HEIDENHAIN Serial Controller Interface

+ Conversational or ISO programming

+ Rapid program generation with plain text programming

+ Graphical programming

+ Collision monitoring (DCM)

+ ATC*, 3D quickSET*

* Option


High-end CNCs for safe machining and maximum precisionThe new duoBLOCK generation can be optionally equipped with the SIEMENS 840D solutionline or the HEIDENHAIN TNC 640 (optional). Both contorls are available in combination with the new ERGOline Control with 21.5″ screen and CELOS. Alternatively, the HEIDENHAIN TNC 640 is also available with 19″ ERGOline panel. Optionally, various exclusive software cycles such as ATC, MPC, 3D quickSET and DMG MORI Virtual Machine are available, which directly influence either workpiece quality or process optimisation.

15


Highlights

Control technology

OverviewTechnical data

DMU 60 P duoBLOCK

DMU 80 P duoBLOCK

DMU 100 P duoBLOCK

DMU 125 P duoBLOCK

DMU 160 P duoBLOCK

DMC 60 U duoBLOCK

DMC 80 U duoBLOCK

DMC 100 U duoBLOCK

DMC 125 U duoBLOCK

DMC 160 U duoBLOCK

Travels X / Y / Z mm 600 / 700 / 600 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000 1,600 / 1,600 / 1,100 600 / 700 / 600 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000 1,600 / 1,600 / 1,100

Table size mm ø 630 ø 900 × 700 ø 1,100 × 900 1,250 × 1,150 ø 1,600 × 1,250 ø 630 × 500 ø 800 × 630 ø 1,000 × 800 ø 1,000 × 800 ø 1,250 × 1,000

Maximum table load kg 700 1,800 2,200 2,800 4,500 600 1,500 2,000 2,000 4,000

Workpiece measurements

mm

850950

1,100 1,250

850 1,45

0

1,60

0

1,60

0

1,67

5

1,600


duoBLOCK – Modular concept for individual requirementsThe duoBLOCK series offers many configuration possibilities due to its modular design. In addition to three milling head variants, the wheel magazine can be built up in stages for up to 453 tools. And the table technology also leaves nothing to be desired with milling, turning or palletised variants.

5X-torqueMASTER

torque up to 1,800 Nm

1616

DMU 60 P duoBLOCK

DMU 80 P duoBLOCK

DMU 100 P duoBLOCK

DMU 125 P duoBLOCK

DMU 160 P duoBLOCK

DMC 60 U duoBLOCK

DMC 80 U duoBLOCK

DMC 100 U duoBLOCK

DMC 125 U duoBLOCK

DMC 160 U duoBLOCK

Travels X / Y / Z mm 600 / 700 / 600 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000 1,600 / 1,600 / 1,100 600 / 700 / 600 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000 1,600 / 1,600 / 1,100

Table size mm ø 630 ø 900 × 700 ø 1,100 × 900 1,250 × 1,150 ø 1,600 × 1,250 ø 630 × 500 ø 800 × 630 ø 1,000 × 800 ø 1,000 × 800 ø 1,250 × 1,000


Workpiece measurements

mm

630

9001,000 1,250

1,600

850

1,45

0

1,60

0

1,60

0

1,35

0

Milling heads

Tables

Wheel magazine

Pallet changer

Machine bed and column

B-axis

5X torqueMASTER A-axis 1 to 5 wheels, up to 453 tools (DMC)

NC Rotary table (DMU) Milling / Turning table (DMU) Turn-mill pallet table (DMC) NC Pallet table (DMC) Pallet changer (DMC)

1717

THE duoBLOCK SERIES MODULAR DESIGN

WITH B-AXIS AS STANDARD

EQUIPMENT


Highlights

Control technology

Overview› DMU 90 P duoBLOCK

Technical data

DMU 90 P duoBLOCK

Top quality equipment at a competitive priceThe DMU 90 P duoBLOCK package machine is unbeatable in terms of price performance. The extensive standard equipment includes the speedMASTER motor spindle with SK 40 20,000 rpm and 60 pockets in the chain magazine. Intelligent software features such as the Machine Protection Control (MPC) and the Spindle Growth Sensor (SGS) ensure the highest level of machine safety and processing accuracy.

HIGH TECH AS STANDARD AT AN EXCELLENT PRICE

+ Motor spindle SK 40 20,000 pm, 130 Nm / 35 kW (40 % DC)

+ Chain magazine for 60 tools, SK 40

+ Control system: CELOS from DMG MORI with 21.5″ ERGOline Control with SIEMENS 840D solutionline

+ Machine Protection Control (MPC))

+ Spindle Growth Sensor (SGS)

+ Internal coolant supply 980 l / 40 bar / 23 l/min

DMU 90 P duoBLOCK

Travels X / Y / Z mm 900 / 1,050 / 850

Table size mm ø 900 × 700

Maximum table load kg 1,800

Workpiece dimensions mm 1,000

1,45

018

952

3,05

7Tr

ansp

ort h

eigh

tTr

ansp

ort h

eigh

t

Chip

con

veyo

rej

ectio

n he

ight

Chip

con

veyo

rej

ectio

n he

ight

Chip conveyor

5,535

4,03

9

TECHNICAL DATA OPTIONS

+ Control CELOS with HEIDENHAIN TNC 640 or 3D Control HEIDENHAIN TNC 640

+ Main drive speedMASTER motor spindle SK 40 15,000 rpm, 46 kW, 200 Nm Motor spindle SK 50 12,00 rpm, 52 kW, 430 Nm Motor spindle HSK-A 100 15,000 rpm, 52 kW, 404 Nm

+ Tool interface HSK-A 63, BT 40, CAT 40, HSK-A 100, BT 50, CAT 50

+ Automation / Measurement / Monitoring 3D quickSET, Infrared measuring senor: (HEIDENHAIN / RENISHAW), Tool measuring in working area, Signal light

+ Coolants / chip disponsal Internal coolant supply (80 bar) frequency-controlled, Coolant temperature control, Spray pistol with pump, Oil and emulsion mist separator, Minimum quantity lubrication, Air blast cooling

+ Options for CELOS with SIEMENS MDynamics package, OMATIVE Advanced Adaptive Control

+ Options for HEIDENHAIN control Active chatter Control (ACC)

+ General control options Electronic handwheel, Application Tuning Cycle (ATC), Safety package for power failure

+ Further options Laminated safety glass, Control console for tool magazine loading station, Operation mode 4, Precision package, Heavy duty machining package Tropical Package, DMG wake up

Chain magazine for 60 pockets

DMU 90 P duoBLOCK

Working areaX / Y / Z axes mm 900 / 1,050 / 850

NC rotary tableTable mm 900 × 700

Table load max. kg 1,800

Workpiece dimensions max. mm ø 1,000

Workpiece height max. mm 1,450

Main driveSpeed rpm 20,000

Tool interface SK 40

Torque (S6 40 %) Nm 35

Power (S6 40 %) kW 130

Tool magazineTool interface SK 40

Tool magazine pockets 60 / Chain

Diameter (free adjacent pockets) mm 160

Length max. mm 550

Weight kg 8

Chip-to-chip time sec. 7

Linear axes (X / Y / Z)Feed rate mm/min 60,000

Rapid traverse rate m/min 60

Acceleration m/s2 7

Feed force (X / Y / Z) kN 13 / 18 / 25

Pmax. (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 5

Psmax. (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 4

LAYOUT

With tool magazine 60 pockets and chip conveyor as standard; footprint: 22.4 m2

Side view Plan view

19


Highlights

Control technology

Overview› Technology integration

Technical data

DMU FD | DMC FD duoBLOCK SERIES

DMU FD and DMC FD duoBLOCK – Maximum productivity through complete machining on one machine

DMU | DMC 60 FD duoBLOCK




Travels X / Y / Z mm 600 / 700 / 600 800 / 1,050 / 850 1,250 / 1,250 / 1,000 1,600 / 1,600 / 1,100

Table size mm ø 900 × 700 ø 800 / ø 800 × 630 ø 1,250 / ø 1,100 ø 1,500 / ø 1,400

Maximum table load kg 600 / 500 1,400 / 1,200 2,600 / 2,000 4,500 / 3,500

Workpiece measurements mm

700 (630)

950 (900)1,250 1,600

850

1,45

0

1,60

0

1,77

5 (1

,350

)

20

19 YEARS OF MILL-TURNING

TECHNOLOGY

MORE THAN 1,000MACHINES SOLD

+ Heavy workpieces up to 4,500 kg and maximum workpiece diameter of 1,600 mm

+ Oil mist filter and shatterproof safety glass panels as standard

+ Less investment and lower space requirements with the use of just one machine

+ Less time needed and higher precision thanks to easy set-up

+ Lower unit production costs with the highest precision thanks to faster machining; lower handling costs due to reduced idle times and fewer process steps

Direct drive technology – The strongest mill-turn table in its class with up to 7,200 Nm

Complete machining process+ 1 machine+ 4 process steps+ 300 % higher productivity

Conventional machining process+ 3 machines+ 10 process steps

MillingTurningDrillingTapping

Set-upReposition

MillingTurningDrillingTapping

Unclamp

Machine 1

TurningSet-up

RepositionTurning Set-up

MillingDrillingTapping

Set-upReposition

MillingDrillingTapping

Set-upPrecision turning

Unclamp

Machine 1 Machine 2 Machine 3

DMU FD- | DMC FD – COMPLETE MACHINING PROCESS

SINGLE-PURPOSE MACHINES – CONVENTIONAL MACHINING PROCESS

1 2 3 4 5 6 7 8 9 10

STANDARDMILLING / TURNING CYCLES

+ Highest productivity - complete machining on one machine in one set-up

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

+ Milling and turning tool measurement

+ Imbalance determination, control and monitoring

+ Measurement data storage, distribution and transfer

EXCLUSIVE MILLING / TURNING CYCLES FOR EVERY REQUIREMENT

+ Exclusive DMG MORI FD cycles

+ Measuring cycles for the (L-) measuring probe: Calibrate measuring probe in the working area; measure undercuts, recesses, etc.*

+ Swivelling of long tools into the workpiece*

+ Alternating speed to dampen vibration during machining*

+ Use of multi-station tools (up to nine cutters)*

* optional

21


Highlights

Control technology

Overview› Technology integration

Technical data

1: Detection of components via spindle load 2: Acoustic emission sensor for dressing

DMU FD | DMC FD duoBLOCK SERIES

Grinding

HIGHLIGHTS

+ Milling, turning and grinding in one set-up

+ Unrivalled surface quality

+ Grinding cycles for internal cylindrical, external cylindrical and surface grinding as well as dressing cycles

+ NEW: Automatically replaceable nozzle unit for coolant supply targeted between grinding wheel and workpiece

+ NEW: AE-sensor (Acoustic Emission) integrated into the dressing unit, to detect the initial contact between the grinding wheel and the dressing unit

+ NEW: Detection of the initial contact between the grinding wheel and the work-piece via spindle load

Grinding package+ Motor spindle with integrated accoustic

emission sensor for process-reliable approaching to the work piece

+ Dressing unit with integrated accoustic emission sensor as well as chip flushing for a process-reliable dressing process with additional support through dressing cycles

+ Coolant unit with 1,300 l and centifugal filter for particle filtration up to 10 µm

+ Machine protection by linear guides and ball screws with additional wipers, sealing air for all linear measuring systems as well as shortened lubrication intervals

ACHIEVABLE TOLERANCES

+ Surface finish < 0.4 μm

+ Roundness < 5 μm

+ Quality 5 with diameter < 120 mm

+ Quality 4 with diameter > 120 mm

3: Turning 4: Milling 5: Grinding on a

DMC 125 FD duoBLOCK

2222

4

5

3

21

1: Turning 2: Tapping3: Gear milling with standard tools

Process chainDrawing

Calculation of the tooth geometry

Free modification of the profile, the flanks and the contact pattern

CAM Program ming

Simulation with a 3D machine model

Complete machining

Measuring (in-process)

Finished component

Measuring (external)


DMG MORI gearMILL

HIGHLIGHTS

+ Complete machining with turning, drilling and gear cutting

+ Highest flexibility due to machining with standard tools on a standard machine

+ Unrestricted modifications of profiles, flanks and contact patterns with verification

+ Flexible for different gear types

+ Soft and hard machining on one machine

+ Quality control on the process with output log

SPUR GEAR+ Complex profile and

flank modifications+ Straight spur gear+ Helical spur gear+ Double helical spur

gear with or without middle gap

BEVEL GEAR+ Straight bevel gear+ Helical bevel gear+ Hypoid+ Shaft angle ≠ 90˚+ Klingelnberg

Cyclo-Palloid®

+ Gleason type, FORMATE & SGT

WORM GEAR+ Free modification of

contact pattern+ Profile ZA+ Profile ZN+ Profile Zl

ACHIEVABLE GEAR QUALITIES

+ Bevel gear DIN ≤ 5

+ Spur gear DIN ≤ 6 (depending on the pitch circle diameter)

2323

1 2 3


Highlights

Control technology

Overview› μPrecision

Technical data

HIGHLIGHTS

+ Maximum precision thanks to 500 hours of hand scraping the guideways (flatness and straightness ≤ 3 µm)*

+ Positioning accuracy down to 3 μm

+ Volumetric precision down to ≤ 13 µm

+ Individual optimisation on the user’s premises Compensation of thermal expansion and volumetric compensation under individual on-site conditions

+ Unbeatable dynamics up to 6 m/s2 and 60 m/min

+ Temperature control of all relevant heat-generating machine components* Information on the example of the DMU 80 P duoBLOCK

μPRECISION

Maximum precision: + 80 % increase in volumetric accuracyThe high precision variant μPrecision of the DMU | DMC duoBLOCK with a volumetric accuracy of up to 13 μm is unique worldwide. In order to achieve the required accuracy, the guideways undergo over 500 hours of hand scraping. To achieve perfect machining results over the entire working area, high precision flatness, squareness and straightness of all axes is required.

2424

Package µPRECISION includes+ All features of the increased accuracy package

+ Hand scraped guideways

+ Coolant temperature control

+ Volumetric Compensation System – Compensation of thermal expansion and volumetric compensation under individual on-site conditions

+ Spindle Growth Sensor (SGS)

+ Machine Protection Control (MPC)

+ Tool measuring in machining area BLUM

+ Increased number of compensation points in all axes

+ Tolerance reduced by up to 80 % compared to standard

DMU 80 P/FD DMC 80 U/FD



Positioning accuracy of the linear axes X / Y / Z μm 3 / 3 / 3 4 / 3 / 4 4 / 4 / 4

Positioning accuracy of the rotational axes A / B / C as 5 / 4 / 4 5 / 4 / 4 5 / 4 / 4

Straightness and flatness of the linear axes μm 3 / 3 / 3 4 / 4 / 4 6 / 6 / 6

Volumetric accuracy* μm 13 15 20* Only the linear axes were considered for compensation

500 HOURS OF MANUAL SCRAPINGScraping process: Up to 80 % increase in precision

Accuracy throughout the machining area, regardless of the spindle position.

1,00

0 / 1,

250 /

1,60

0 mm

working envelope

13 – 20 µm

100 / 200 µm5-axis machines of other

manufactureres1,250 / 1,800 / 2,700 mm

2525

HIGHEST POSITIONING

ACCURACY Pmax ≤ 3 / 3 / 3 μm

(X / Y / Z)*


Highlights

Control technology

Overview

Technical data› Application example

BEST EQUIPPED FOR YOUR REQUIREMENTS IN DIE AND MOLD MAKING

+ Universally equipped with motor spindle 15,000 rpm, 404 Nm for roughing and finishing operations*

+ Fully automatic change of long tools up to 650 mm, e. g. for processing cooling channels (in combination with wheel magazine)

+ Der Application Tuning Cycle (ATC)* ermöglicht einfaches Anpassen der Parameter auf Ihren Prozess

+ The Application Tuning Cycle (ATC)* allows easy customization of the parameters according to your process* Option

2626


Application examples

Knuckle – dimensions (unfinished part): 270 × 210 × 320 mm Machining time: 24 hours, clamping operations: 3achining focus: Surfaces from 0.4 Ra up to 0.6 Ra, precise position and size tolerance, contains 3 + 2 axis machining and full 5-axis simultaneous machining

Sector Motor sport Spindle 18,000 rpm

Number of tools 77 Power 35 kW

Material Aluminium alloy Torque 130 Nm

Chassis component – dimensions: 1,080 × 610 × 210 mm Machining time: 23 hours, clamping operations: 3Machining focus: Reducing the machining time by 43 %, 5 µm positioning accuracy, high effectiveness of the heavy-duty machining package, very high surface finish of Ra 0.4 µm

Sector Aerospace Gear-driven spindle 6,300 rpm


Material Titanium 10-2-3 Torque 1,100 Nm

Tube mould – dimensions: 680 × 470 × 335 mm Machining time: 4 hours 56 min., clamping operations: 2Machining focus: High surface finish of up to Ra 0.35, 3 + 2 axis and 5-axis simultaneous machining, two components on the machine

Sector Mould making Spindle 12,000 rpm


Material Aluminium / C 45 Torque 430 Nm

Mould for manufacturing PET bottles – dimensions: 400 × 360 × 400 mmMachining time: 86 min., clamping operations: 3Machining focus: Complete machining including in-process automatic contour measurement and fully automatic series production by means of a pallet system (FMS) including workpiece loading by robot

Sector Mould making Spindle 12,000 rpm


Material GGG60 Torque 430 Nm

Drill head – dimensions: 330 × 40 × 400 mmMachining time: 18 hours, clamping operations: 1Machining focus: Reducing machining time by 75 % from 70 hours to 18 hours, machining negative angles with the angle head, surface quality of Ra 1 µm, complete machining in one clamping

Sector Oil / gas drilling sector Spindle 12,000 rpm


Material 21CrNiMo2 (1.6523) Torque 288 Nm

2727


Highlights

Control technology

Overview

Technical data› Tool magazines› Milling heads


Innovative milling heads and intelligent tool management

A-axisSK 40 / HSK-A 63 / BT 40 / CAT 40SK 50 / HSK-A 100 / BT 50 / CAT 50*

B-axisSK 40 / HSK-A 63 / BT 40 / CAT 40SK 50 / HSK-A 100 / BT 50 / CAT 50

B-AXIS

+ Swivel range − 30 ° to 180 °

+ Complete 5-axis milling performance

+ Integrated cable carrier – Improved interference contour, higher quality thanks to better sealed housing, longer life because of mechanically guided cables

+ 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 moments of force thanks to the swivel plane positioned at 45 °

+ Outstanding milling performance regardless of the direction of the machining forces

+ No axis clamping necessary

+ Also available as a 5X torqueMASTER gear- driven spindle with up to 1,800 Nm torque

A-AXIS

+ More flexible production of complex shapes thanks to negative angles up to −35 ° (Swivel range −125 / +35 °)

+ 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 positioned at 90 °* Available on the DMU 100 P4 upwards

28

Maximum workpiece dimensions and tool magazine configurations Sizes 60, 80, 100, 125 and 160

SK 40 / CAT 40 / HSK-A 63 SK 50 / CAT 50 / HSK-A 100

Tool holder SK 40 (HSK-A 63)* SK 50 (HSK-A 100)*

Magazine type / maximum 453 Pockets 303 Pockets

Measurements (adjacent pockets occupied) mm ø 80 | Length 650 (450 ** / 550 ***) ø 110 | Length 650 (550 ***)

Measurements (adjacent pockets free) mm ø 120 | Length 650 ** (450 **/ 550 ***) ø 200 | Length 650 (550 ***)

Boring bar measurements mm ø 280 × 160 | Length 350 ø 400 × 280 | Length 400 (470 *)

Weight kg 15 30

Maximum torque Nm 25 70

Chip-to-chip time (HSK) sec. 4.2 (applies to the 80 series) 4.6 (applies to the 80 series)* FD only with HSK-A tool holder ** DMU 60 P / FD duoBLOCK *** DMU 80 P / FD duoBLOCK

PRINCIPLE OFOPERATION

1 The selected tool is on wheel 22 Free path (three empty pockets)

for the shuttle on wheel 1 by turning the wheel3 The shuttle (double gripper)

travels to the selected tool; lift to release the tool from the holder, shuttle travels to the spindle4 Exchange / replacement of

the tool and retraction of the double gripper

SK 40 / HSK-A 63 SK 50 / HSK-A 100

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 60 P / FD • – – – – – – – – – –

DMC 60 U / FD – • – (243 Pl.) – – – – – – –

DMU 80 / 100 / 125 P | DMU 80 FD • * * * * * * *

DMC 80 / 100 / 125 U | DMC 80 FD – • * – *

DMU 125 FD – – – – – – – • * * *

DMC 125 FD – – – – – – – – • *

DMU 160 P – • * * * * – * * *

DMU 160 FD – – – – – – – – • * * *

DMC 160 U – • –

DMC 160 FD – – – – – – – – •

• standard optional * on request

292929

1 2

3 4


Highlights

Control technology

Overview

Technical data› Automation

FLEXIBLEMANUFACTURING CELL

+ 6 × DMC H duoBLOCK

with workpiece handling

+ Prioritised processing on the next available machine

+ Simultaneous machining of three different components

1: Manufacturing system with three machining centres, two-level linear storage with 52 workpiece positions and central tool magazine with 400 pockets

2: Manufacturing cell for hydraulic components

3: Fully automated production of gearboxes

4: DMC H duoBLOCK with RS 7/12

5: rotary storage RS 7

3030

1 2 3 4

5


duoBLOCK – the basis for custom automation solutions

Workpiece handlingMachines with and

without pallet changer

Pallet handlingMachines

without pallet changer

Pallet handlingMachines

with pallet changer

Automation solutions

Articulated robotic arms

Portal loader

RS 7: 5-pallet rotary storage (7 pallets in the system) – –

RS 12: 10-pallet rotary storage (12 pallets in the system) – –

Flexible pallet systems (linear storage) – –

Pallet handling PH 150* – –

Configuration levels / peripherals

Central tool magazines

Wash

Deburr

Measure

Workpiece marking

optional – not available *available for DMU 60 / 80 P duoBLOCK

ROTARY PALLET STORAGE RS 12

+ Machine integrated automation system

+ 12 pallets in the system

3131


Highlights

Control technology

Overview

Technical data› Machining examples


High-performance milling, drilling and tapping

speedMASTER 20,000 rpm / 35 kW / 130 Nm motor spindle

1 High-performance milling 2 High-performance milling 3 Tapping

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

Material removal rate 520 cm3/min 435 cm3/min –

Tool Face mill ø 63 mm Modular drill ø 54 mm Tap M24

Spindle speed 1,800 rpm 1,650 rpm 464 rpm (Vc = 35 m/min)

Feed 2,600 mm/min (Fz = 0.24 mm) 190 mm/min (Fu = 0.115 mm) 1,400 mm/min

Depth / width of cut 4 / 50 mm – –

speedMASTER 15,000 rpm / 46 kW / 200 Nm motor spindle



Material removal rate 500 cm³/min 794 cm³/min –

Tool Face mill ø 80 mm Modular drill ø 54 mm Tap M24

Spindle speed 1,800 rpm 1,6500 rpm 530 rpm (Vc = 40 m/min)

Feed 2,741 mm/min (Fz = 0.41 mm) 347 mm/min (Fu = 0.21 mm) 1,600 mm/min

Depth / width of cut 3.5 / 552 mm – –

323232

1 2 3

12,000 rpm / 44 kW / 288 Nm MOTOR SPINDLE




ToolIndexable insert cutter ø 100

(7 inserts)Modular drill ø 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 – –

12,000 rpm / 52 kW / 430 Nm TORQUE SPINDLE






Spindle speed 1,800 rpm 900 rpm (Vc = 225 m/min) 46 rpm (Vc = 6 m/min)



powerMASTER 9,000 rpm / 77.5 kW* / 1,000 Nm* TORQUE SPINDLE



Material removal rate 1,680 cm3/min 900 cm³/min –



Spindle speed 900 rpm (Vc = 280 m/min) 673 rpm (Vc = 200 m/min) 60 rpm (Vc = 8 m/min)



* 15 % DC (2 min), all other information is 40 % DC

3333

4 5 6

Torque(Nm)

Power(kW)

Spee

d(r

pm)

320

5

160

80

20

10

40

30157.53.8

1.90.90.5

0.20.1

130 Nm 40%

86 Nm 100%

35 kW 40%

25 kW 100%

20

1,25

01,

100

2,80

0

5,70

0

2,50

0

5,00

0

10,0

0015

,000

Torque(Nm)

Power(kW)

Spee

d(r

pm)

320

5

160

80

20

10

40

30157.53.8

1.90.90.5

0.20.1

130 Nm 40%

86 Nm 100%

35 kW 40%

25 kW 100%

20

1,25

01,

100

2,80

0

5,70

0

2,50

0

5,00

0

10,0

00

20,0

00

Torque(Nm)

Power(kW)

Spee

d(r

pm)

320

5

160

80

20

10

40

25157.53.7

1.90.90.5

0.20.1

200 Nm 40%

130 Nm 100%

46 kW 40%

30kW 100%

20

1,25

01,

100

2,20

02,

800

9,83

07,

760

4,30

0

2,50

0

5,00

0

10,0

0015

,000

Torque(Nm)

Power(kW)

Spee

d(r

pm)

500

5

315250125

31.512.5

80

31.5

201485

2.51.25

0.6

121 Nm 40%

82 Nm 100%

28 kW 40%

19 kW 100%

20

2,00

0

4,00

06,

300

12,0

00

35kW 40%501,000

1,10

0

2,80

04,

700

15,4

0018

,000

30

15

5172

120

221613

130Nm 40%86Nm 100%

25kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

35kW 40% 40800

20

3,00

0

6,00

0

18,0

00

25

1.61.25

3856

1913

111Nm 40%77Nm 100%

24kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

26 kW 40% 40680

20

2,50

063 160

400

1,00

0

6,30

0

18,0

00

12,0

00

24,0

00

20

10

5

2

1

25

50

315

125

8

85 Nm 40%

60 Nm 100%

19 kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)


Highlights

Control technology

Overview

Technical data› Power diagrams


Power diagrams

34

SK 40 / HSK-A 63 motor spindle


HSK-A 63 motor spindle





12,000 rpm / 28 kW / 121 Nm

18,000 rpm / 35 kW / 130 Nm

24,000 rpm / 26 kW / 85 Nm

15,000 rpm / 35 kW / 130 Nm

18,000 rpm / 35 kW / 111 Nm

15,000 rpm / 46 kW / 200 Nm

20,000 rpm / 35 kW / 130 Nm

34

44 kW 40%40

630

20

1,00

01,

400

2,45

0

4,06

0

8,00

010

,000

12,0

00

25

10

53.152

100

160

400200

63

5

288Nm 40%

187Nm 100%

32 kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

52 kW 40% 501,000

20 50

1,00

0

2,50

0

6,30

0

12,0

00

20

10

0.9

5

1

2

50

100

10

500

250

25

5

430 Nm 40%

300 Nm 100%

42 kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

52 kW 40% 50400

100

1,00

01,

310

1,71

0

10,0

00

15,0

00

4540

5

353025

1510

20200

250

100

350

300

150

50

404 Nm 40%

280 Nm 100%

42 kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

37 kW 40%

642,048

20 190

400

1,40

0

8,00

0

32

16

8

2

432

128

512

1,300 Nm 40%

831 Nm 100%

27 kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

52kW 40%

8

32

2,0481,235

997

302244

20 400

195

233

1,40

01,

642

5,08

2

8,00

0

64

32

7999

1,800Nm 40%

1,564Nm 100%

42kW 100%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

54 kW 40%

45 kW 100%

801,000

20 740

3,00

0

9,00

0

50

40

15

600

700

100

1,000 Nm 15%

520 Nm 100%

700 Nm 40%

77,5 kW 15%

Torque(Nm)

Power(kW)

Spee

d(r

pm)

All data collected with 40 % DC* 15 % DC (2 min)


powerMASTER SK 50 / HSK-A 100 motor spindle


gear-driven spindle 5X-torqueMASTER SK 50 / HSK-A 100


gear-driven spindle 5X-torqueMASTER SK 50 / HSK-A 100

12,000 rpm / 44 kW / 288 Nm

9,000 rpm / 77.5 kW* / 1,000 Nm*

12,000 rpm / 52 kW / 430 Nm

8,000 rpm / 37 kW / 1,300 Nm

15,000 rpm / 52 kW / 404 Nm

8,000 rpm / 52 kW / 1,800 Nm

3535


Highlights

Control technology

Overview

Technical data› Power diagrams› Floor plans

Speed | Tool carrierPower (40 % DC), torque (40 % DC)Speed range: Spindle run-up time

DMU | DMC 60 P / U

duoBLOCK

DMU | DMC 80 P / U

duoBLOCK

DMU | DMC 100 P/U

duoBLOCK

DMU | DMC 125 P/U

duoBLOCK

DMU | DMC 160 P/ U

duoBLOCK

12,000 rpm | SK 40 / HSK-A 63*

28 kW | 121 Nm | 0 – 12,000 rpm: 2.0 sec.• – – – –

18,000 rpm | SK 40 / HSK-A 63*

35 kW | 119 Nm | 0 – 18,000 rpm: 2.2 sec.– – – –

15,000 rpm | SK 40 / HSK-A 63*

35 kW, 130 Nm | 0 – 15,000 rpm: 1.65 sec. –

• • • •

20,000 rpm | SK 40 / HSK-A 63*

35 kW, 130 Nm | 0 – 20,000 rpm: 2.6 sec.–

15,000 rpm | SK 40 / HSK-A 63*

46 kW, 200 Nm | 0 – 15,000 rpm: on request–

24,000 rpm | HSK-A 6326 kW, 85 Nm | 0 – 24,000 rpm: 3.5 sec.

–

12,000 rpm | SK 50 / HSK-A 100*

44 kW, 288 Nm | 0 – 12,000 rpm: 3.5 sec.–

12,000 rpm | SK 50 / HSK-A 100*

52 kW, 430 Nm | 0 – 12,000 rpm: 4.5 sec.–

9,000 rpm | SK 50 / HSK-A 100* / ***

77.5** / 54 kW, 1,000** / 700 Nm0 – 9,000 rpm: 1.9 sec.

–

15,000 rpm | HSK-A 100*

52 kW, 404 Nm | 0 – 15,000 rpm: 4.7 sec.–

8,000 rpm | SK 50 / HSK-A 100*

37 kW, 1,300 Nm | 0 – 6,300 rpm: on request– –

8,000 rpm | SK 50 / HSK-A 100*


• standard optional – not available * optional ** 15 % ED (2 min) *** only in connection with shoulder / face contact

SPINDLE RANGE

SPINDLE RANGE MILL-TURNSpeed | Tool carrierPower (40 % DC), torque (40 % DC)Speed range: Spindle run-up time

DMU | DMC 60 FD

duoBLOCK

DMU | DMC 80 FD

duoBLOCK

DMU | DMC 125 FD

duoBLOCK

DMU | DMC 160 FD

duoBLOCK

12,000 rpm | HSK-A 63*

35 kW, 111 Nm | 0 – 12,000 rpm: 2.0 sec.• – – –

18,000 rpm | HSK-A 63*

35 kW, 111 Nm | 0 – 18,000 rpm: 2.2 sec.– – –


– • – –


– – –


– • •


–

8,000 rpm | HSK-A 100*


8,000 rpm | SK 50 / HSK-A 100*


• standard optional – not available * optional ** 15 % ED (2 min) *** only in connection with shoulder / face contact

3636

3,65

5 Op

tiona

l oil

mis

t filt

er3,

059

Tran

spor

t hei

ght

4,465

975

3,42

7 2,74

8

5,534

2,43

4 Tr

ansp

ort w

idth

with

out m

agaz

ine

4,964

9523,85

5.5

Optio

nal o

il m

ist f

ilter

3,29

2.5

Tran

spor

t hei

ght w

ithou

t mag

azin

e

6,144

R1,308.5

4,22

3 3,25

3.5

Tran

spor

t w

idth

Chipconveyer

3,05

8

2,76

8 Tr

ansp

ort h

eigh

t

3,759

2,43

0 Tr

ansp

ort w

idth

4,653

3,76

2

Chipconveyer


Floor plans

DMU P / FDFloor plan DMU 60 P / FD duoBLOCKSide view Plan view with wheel magazine, 63 pockets

Floor plan DMU 100 P duoBLOCKSide view Plan view with wheel magazine, 63 pockets

Floor plan DMU 80 P / FD duoBLOCKSide view Plan view with wheel magazine, 63 pockets

3737

975

4,999

3,65

8 Op

tiona

l oil

mis

t filt

er

3,05

9 Tr

ansp

ort h

eigh

t

2,74

9 Tr

ansp

ort w

idth

2,43

4

Chipconveyer

6,068

R1,309

5,031

3,37

22,

430

Tran

spor

t wid

th

Optio

nal o

il m

ist f

ilter

3,09

9

2,34

6

4,111

2,61

0 Tr

ansp

ort h

eigh

tw

ithou

t mag

azin

e2,

240

470

952

3,85

5

4,964

3,46

2M

ax. c

law

hei

ght (

stee

l cov

er)

3,29

2,5

Tran

spor

t hei

ght w

ithou

t mag

azin

e

Chipconveyer

6,144

3,57

8 Tr

ansp

ort w

idth

Hydraulicclamping unit R1.308,5

3,71

5 Tr

ansp

ort h

eigt

h4,

109

7,5036,100 8,683

6,06

2

3,80

8 Tr

ansp

ort w

idth


Highlights

Control technology

Overview

Technical data› Floor plans

DMC U / FD

DMU P / FD (Continued)



Floor plan DMC 60 U / FD duoBLOCKSide view Plan view with wheel magazine, 63 pockets

Floor plan DMC 80 U / FD duoBLOCKSeitenansicht Plan view with wheel magazine, 63 pockets

3838

3,85

6 Op

tiona

l oil

mis

t filt

er3,

320

Tran

spor

t hei

ght w

ithou

t mag

azin

e

5,702

952

4,14

8 3,17

9Tr

ansp

ort w

idth

Chipconveyer

6,822

R1,309

3,85

5.5

optio

nal o

il m

ist f

ilter

3,31

9.5

Tran

spor

t hei

gth

with

out m

agaz

ine

952

5,822

4,34

8 3,49

8.5

Tran

spor

t wid

th

Chipconveyer

7,002

R1,300

3,71

5 Tr

ansp

ort h

eigh

t

952 3,

704

Tran

spor

t wid

th la

nd tr

avel

5,68

0

Chipconveyer

10,088

4,27

7 Tr

ansp

ort w

idth

sea

trav

el

Layouts without coolant system and cooling units are shown. Subject to change, details on request

Floor plan DMC 100 U duoBLOCKSide view Plan view with wheel magazine, 63 pockets



3939


Highlights

Control technology

Overview

Technical data


Technical dataDMU 60 P / FD dB DMU 80 P / FD dB DMU 100 P dB DMU 125 P / FD dB DMU 160 P / FD dB DMC 60 U / FD dB DMC 80 U / FD dB DMC 100 U dB DMC 125 U / FD dB DMC 160 U / FD dB

Working area

X-, Y- and Z-axes mm 600 × 700 × 600 800 × 1,050 × 850 1,000 × 1,250 × 1,000 1,250 × 1,250 × 1,000 1,600 × 1,600 × 1,100 600 × 700 × 600 800 × 1,050 × 850 1,000 × 1,250 × 1,000 1,250 × 1,250 × 1,000 1,600 × 1,600 × 1,100

Table / Workpiece mounting surface / Workpieces

NC rotary table rpm 40 40 35 35 15 40 40 35 35 15

Table size mm ø 630 ø 900 × 700 ø 1,100 × 900 ø 1,250 × 1,100 ø 1,600 × 1,250 630 × 500 800 × 630 1,000 × 800 1,000 × 800 1,250 × 1,000


Turn-mill table (FD) rpm 1,200 800 – 500 400 1,200 800 – 500 400

Table size mm ø 700 ø 900 – ø 1,250 ø 1,600 ø 630 ø 800 × 630 – ø 1,100 ø 1,400

Maximum table load kg 600 1,400 – 2,600 4,500 500 1,400 – 2,000 3,500

NC-controlled swivelling milling head (B-axis) • • • • • • • • • •

Swivel range (0 = vertical / 180 = horizontal) Degrees −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180

Rapid traverse and feed rpm 30 30 30 30 30 30 30 30 30 30

5-axis options

5X torqueMASTER – NC-controlled B-axis with gear-driven spindle – –

Swivel range (0 = vertical / 180 = horizontal) Degrees 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180

Rapid traverse and feed rpm 30 30 30 30 30 30 30 30

NC-controlled swivelling milling head (A-axis) – –

Swivel range (0 = vertical / −90 = horizontal) Degrees −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35


Main drive

Integrated motor spindle rpm 12,000 15,000 15,000 15,000 (12,000) 15,000 (12,000) 12,000 15,000 (12,000) 15,000 (12,000) 15,000 (12,000) 15,000

Tool holder SK 40 / HSK-A 63* SK 40 / HSK-A 63* SK 40 / HSK-A 63SK 40

(FD: HSK-A 100) SK 40

(FD: HSK-A 100)SK 40 / HSK-A 63* SK 40 / HSK-A 63* SK 40 / HSK-A 63

SK 40 (FD: HSK-A 100)

SK 40 (FD: HSK-A 100)

Power (40 / 100 % DC) kW 28 / 19 (35 / 24) 35 / 25 35 / 25 35 / 25 (44 / 32) 35 / 25 (FD: 44 / 32) 28 / 19 (35 / 24) 35 / 25 35 / 25 35 / 25 (44 / 32) 35 / 25

Torque (40 / 100 % DC) Nm 121 / 82 (FD: 111 / 77) 130 / 86 130 / 86 130 / 86 (FD: 288 / 187) 130 / 86 (FD: 288 / 187) 121 / 82 (FD: 111 / 77) 130 / 86 130 / 86 130 / 86 (FD: 288 / 187) 130 / 86

Tool changer

Tool holder SK 40 SK 40 SK 40 SK 40 SK 40

(FD: HSK-A 100)SK 40 SK 40 SK 40 SK 40 SK 40

Tool magazine wheel Pockets 40 (63, 123) 40 (63, 123) 40 (63, 123) 40, 63 (123) 63 (123) 60 (123 / 183 / 243) 63 (123 / 183 / 273 / 363) 63 (123 / 183 / 273 / 363) 63 (123 / 183 / 273 / 363) 63 (123 / 183 / 273 / 363 / 453)

Linear axis (X / Y / Z)

Feed speed, rapid traverse speed m/min 60 60 60 60 60 60 60 60 60 60

Acceleration m/s2 6 / 6 / 5 7 6 / 5 / 6 6 / 5 / 6 6 / 4 / 5 6 / 6 / 5 7 6 / 5 / 6 6 / 5 / 6 6 / 4 / 5

Feed force kN 10 13 / 18 / 25 15 / 20 / 28 15 / 20 / 28 20 / 30 / 35 12 / 12 / 8 13 / 18 / 25 15 / 20 / 28 15 / 20 / 28 20 / 30 / 35

Pmax (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 6 5 6 6 7 6 5 6 6 7

Psmax (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 4 4 5 5 5 4 4 5 5 5

Machine dataSpace requirements of base machine plus chip conveyor, without internal coolant supply

m2 18.9 26 27 37.6 21.4 28.5 30.4 45.7

Machine height (standard machine) m 2.8 3.1 3.3 3.4 3.7 2.715 3.1 3.3 3.3 3.7

Machine weight kg 11,300 17,500 24,500 26,000 35,000 12,000 20,500 26,500 28,500 41,000

• standard optional – not available * HSK-A tool holder included as standard with mill / turn machines

40

DMU 60 P / FD dB DMU 80 P / FD dB DMU 100 P dB DMU 125 P / FD dB DMU 160 P / FD dB DMC 60 U / FD dB DMC 80 U / FD dB DMC 100 U dB DMC 125 U / FD dB DMC 160 U / FD dB

Working area

X-, Y- and Z-axes mm 600 × 700 × 600 800 × 1,050 × 850 1,000 × 1,250 × 1,000 1,250 × 1,250 × 1,000 1,600 × 1,600 × 1,100 600 × 700 × 600 800 × 1,050 × 850 1,000 × 1,250 × 1,000 1,250 × 1,250 × 1,000 1,600 × 1,600 × 1,100

Table / Workpiece mounting surface / Workpieces

NC rotary table rpm 40 40 35 35 15 40 40 35 35 15

Table size mm ø 630 ø 900 × 700 ø 1,100 × 900 ø 1,250 × 1,100 ø 1,600 × 1,250 630 × 500 800 × 630 1,000 × 800 1,000 × 800 1,250 × 1,000


Turn-mill table (FD) rpm 1,200 800 – 500 400 1,200 800 – 500 400

Table size mm ø 700 ø 900 – ø 1,250 ø 1,600 ø 630 ø 800 × 630 – ø 1,100 ø 1,400

Maximum table load kg 600 1,400 – 2,600 4,500 500 1,400 – 2,000 3,500

NC-controlled swivelling milling head (B-axis) • • • • • • • • • •

Swivel range (0 = vertical / 180 = horizontal) Degrees −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180 −30 bis 180

Rapid traverse and feed rpm 30 30 30 30 30 30 30 30 30 30

5-axis options

5X torqueMASTER – NC-controlled B-axis with gear-driven spindle – –

Swivel range (0 = vertical / 180 = horizontal) Degrees 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180 0 bis 180


NC-controlled swivelling milling head (A-axis) – –

Swivel range (0 = vertical / −90 = horizontal) Degrees −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35 −125 / +35


Main drive

Integrated motor spindle rpm 12,000 15,000 15,000 15,000 (12,000) 15,000 (12,000) 12,000 15,000 (12,000) 15,000 (12,000) 15,000 (12,000) 15,000

Tool holder SK 40 / HSK-A 63* SK 40 / HSK-A 63* SK 40 / HSK-A 63SK 40

(FD: HSK-A 100) SK 40

(FD: HSK-A 100)SK 40 / HSK-A 63* SK 40 / HSK-A 63* SK 40 / HSK-A 63

SK 40 (FD: HSK-A 100)

SK 40 (FD: HSK-A 100)

Power (40 / 100 % DC) kW 28 / 19 (35 / 24) 35 / 25 35 / 25 35 / 25 (44 / 32) 35 / 25 (FD: 44 / 32) 28 / 19 (35 / 24) 35 / 25 35 / 25 35 / 25 (44 / 32) 35 / 25

Torque (40 / 100 % DC) Nm 121 / 82 (FD: 111 / 77) 130 / 86 130 / 86 130 / 86 (FD: 288 / 187) 130 / 86 (FD: 288 / 187) 121 / 82 (FD: 111 / 77) 130 / 86 130 / 86 130 / 86 (FD: 288 / 187) 130 / 86

Tool changer

Tool holder SK 40 SK 40 SK 40 SK 40 SK 40

(FD: HSK-A 100)SK 40 SK 40 SK 40 SK 40 SK 40

Tool magazine wheel Pockets 40 (63, 123) 40 (63, 123) 40 (63, 123) 40, 63 (123) 63 (123) 60 (123 / 183 / 243) 63 (123 / 183 / 273 / 363) 63 (123 / 183 / 273 / 363) 63 (123 / 183 / 273 / 363) 63 (123 / 183 / 273 / 363 / 453)

Linear axis (X / Y / Z)

Feed speed, rapid traverse speed m/min 60 60 60 60 60 60 60 60 60 60

Acceleration m/s2 6 / 6 / 5 7 6 / 5 / 6 6 / 5 / 6 6 / 4 / 5 6 / 6 / 5 7 6 / 5 / 6 6 / 5 / 6 6 / 4 / 5

Feed force kN 10 13 / 18 / 25 15 / 20 / 28 15 / 20 / 28 20 / 30 / 35 12 / 12 / 8 13 / 18 / 25 15 / 20 / 28 15 / 20 / 28 20 / 30 / 35

Pmax (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 6 5 6 6 7 6 5 6 6 7

Psmax (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 4 4 5 5 5 4 4 5 5 5

Machine dataSpace requirements of base machine plus chip conveyor, without internal coolant supply

m2 18.9 26 27 37.6 21.4 28.5 30.4 45.7

Machine height (standard machine) m 2.8 3.1 3.3 3.4 3.7 2.715 3.1 3.3 3.3 3.7

Machine weight kg 11,300 17,500 24,500 26,000 35,000 12,000 20,500 26,500 28,500 41,000

• standard optional – not available * HSK-A tool holder included as standard with mill / turn machines

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Highlights

Control technology

Overview

Technical data› Options


OptionsDMU 60 P / FD dB DMU 80 P / FD dB DMU 100 P dB DMU 125 P / FD dB DMU 160 P / FD dB DMC 60 U / FD dB DMC 80 U / FD dB DMC 100 U dB DMC 125 U / FD dB DMC 160 U / FD dB

Manual table options

Hydraulic clamping for table

Tool holder

HSK-A 63 / BT 40 / CAT 40 – HSK-A for turn-mill machines as standard

HSK-A 100 / BT 50 / CAT 50 – HSK-A for turn-mill machines as standard – –

Automation / Measurement / Monitoring

3D quickSET

Infrared measuring sensor: HEIDENHAIN TS649 / Renishaw PP60 (OMP 60)

Tool measurement in the working area, Blum Laser NT hybrid

Mechanical tool breakage detection in the tool magazine

Combined tool measurement in the working area, laser system for milling tools, 3D scanner for turning tools

(FD) (FD) – (FD) (FD) (FD) (FD) – (FD) (FD)

Four-colour signal lights

Coolant / Chip disposalProduction package with 980 litre coolant unit, paper band filter, 40 bar internal coolant supply

• • • • • • • • • •

80 bar internal coolant supply frequency-controlled

Temperature control for the 600 / 980 litre internal coolant supply system

Coolant gun with 13-bar pump, 40 litres per minute

Minimum quantity lubrication through the spindle and through external nozzles

Oil and emulsion mist filter (included as standard with turn-mill machines)

Air cooling through the spindle

Optional HEIDENHAIN TNC 640 control systems

Application Tuning Cycle ATC

Electronic TNC 640 hand wheel

Control console for tool magazine loading station

Active Chatter Control ACC

Options SIEMENS 840D solutionline Operate

Electronic SIEMENS 840D hand wheel


DECKEL MAHO Paket MDynamics

General options

Shatterproof safety glass viewing panels (Standard with FD)

Operating mode 4 ”Process monitoring in production”

Package for increased precision

Heavy-duty machining package – –

Grinding package (only in combination with FD) – – – –

µPRECISION – – – –

• standard optional – not available

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DMU 60 P / FD dB DMU 80 P / FD dB DMU 100 P dB DMU 125 P / FD dB DMU 160 P / FD dB DMC 60 U / FD dB DMC 80 U / FD dB DMC 100 U dB DMC 125 U / FD dB DMC 160 U / FD dB

Manual table options

Hydraulic clamping for table

Tool holder

HSK-A 63 / BT 40 / CAT 40 – HSK-A for turn-mill machines as standard

HSK-A 100 / BT 50 / CAT 50 – HSK-A for turn-mill machines as standard – –

Automation / Measurement / Monitoring

3D quickSET

Infrared measuring sensor: HEIDENHAIN TS649 / Renishaw PP60 (OMP 60)

Tool measurement in the working area, Blum Laser NT hybrid

Mechanical tool breakage detection in the tool magazine

Combined tool measurement in the working area, laser system for milling tools, 3D scanner for turning tools

(FD) (FD) – (FD) (FD) (FD) (FD) – (FD) (FD)

Four-colour signal lights

Coolant / Chip disposalProduction package with 980 litre coolant unit, paper band filter, 40 bar internal coolant supply

• • • • • • • • • •

80 bar internal coolant supply frequency-controlled

Temperature control for the 600 / 980 litre internal coolant supply system

Coolant gun with 13-bar pump, 40 litres per minute

Minimum quantity lubrication through the spindle and through external nozzles

Oil and emulsion mist filter (included as standard with turn-mill machines)

Air cooling through the spindle

Optional HEIDENHAIN TNC 640 control systems

Application Tuning Cycle ATC

Electronic TNC 640 hand wheel


Active Chatter Control ACC

Options SIEMENS 840D solutionline Operate

Electronic SIEMENS 840D hand wheel


DECKEL MAHO Paket MDynamics

General options

Shatterproof safety glass viewing panels (Standard with FD)

Operating mode 4 ”Process monitoring in production”

Package for increased precision

Heavy-duty machining package – –

Grinding package (only in combination with FD) – – – –

µPRECISION – – – –

• standard optional – not available

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UNIVERSAL MACHINING CENTRES FOR 5-SIDED / 5-AXIS MACHINING ...

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