DMU 210 / 270 / 340 P DMU 210 / 270 / 340 FD DMC 210 / 270 / 340 U DMC 210 / 270 / 340 FD 5-AXIS LARGE MACHINES DMU P / FD | DMC U / FD portal series DMGMORI.COM
Applications and Parts Machine and Technology Control Technology Technical Data 1 2 MECHANICAL ENGINEERING 1: Crossbeam 2: Machine bed DMU P / FD | DMC U / FD PORTAL SERIES The portal series from DECKEL MAHO – more than 1,333 machines installed 02 These 5-axis machines with a highly stable portal design offer maximum precision and highest dynamics. In addition to drilling and milling, the turn-mill machines can also carry out turning operations in the same set-up. Long travels up to 3,400 mm and high maximum table load capacities up to 16 tonnes provide exceptional machining flexibility. A pallet changer for the DMC machines facilitates set-up during machining for maximum productivity. 1: Landing gear support beam 2: V16 diesel engine crankcase 1 2
3 4 5 6 7 8 GEAR MANUFACTURING TOOL AND MOULD MAKING 3: Planetary gear carrier 4: Spiral bevel gear 5: Bumper press tool 6: Bumper mould insert ENERGY TECHNOLOGY 7: Pelton wheel 8: Bearing housing AEROSPACE 9: HP compressor housing 13: Integral component 9 10 03 DMU 213 / 273 / 343 P / FD DMC 213 / 273 / 343 U / FD Designed to efficiently manufacture workpieces weighing up to 16 t with travels of up to 3,400 mm. Image: Vehicle wing compression mould Note: The results of machining and performance trials listed in this catalogue are to be taken as examples. The results may vary slightly depending on the environment and cutting conditions.
Applications and Parts Machine and Technology › DMU P: 5-axis machines without a pallet changer › DMC U: 5-axis machines without a pallet changer Control Technology Technical Data DMU P PORTAL RANGE Large components weighing up to 16 t, large working area, minimal footprint Large travels ranging from 2,100 × 2,100 × 1,250 mm up to 3,400 × 3,400 × 1,600 mm, a high maximum table load of up to 16 tonnes and innovative machining options such as 5-sided / 5-axis milling and turning in one set-up are just some of the factors behind efficient operation. This concept is rounded off by the optimal accessibility of the working area, a wide range of spindle variants and other process-optimising options. 04 Travel X / Y / Z mm 2,100 / 2,100 / 1,250 2,700 / 2,700 / 1,600 3,400 / 3,400 / 1,600 (2,000)* DMU 210 P DMU 270 P DMU 340 P Maximum workpiece dimensions mm ø 1,700 Maximum load kg 8,000 (10,000)* Maximum workpiece dimensions mm max ø 2,500 0 6 4 , 1 ø 2,200 12,000 max ø 3,400 0 6 9 , 1 ø 2,600 × 2,200 16,000 max ø 3,900 0 6 9 , 1 * ) 0 6 3 , 2 ( Portal 1,860 Portal 2,500 Portal 3,050 * option
Even higher productivity with the automatic pallet changer, up to five pallets in the system with RS 5 rotary storage on the DMC 210 U / FD DMC U PORTAL RANGE For machining large components with maximum flexibility and productivity A rapid and compact pallet changer in combination with the high flexibility of 5-axis universal machines deliver efficient production. Additional features promoting cost-effectiveness include a maximum pallet load of 10,000 kg, set-up during machining, more extensive automation options, optimal accessibility to the working area, a set-up station and maintenance equipment. 05 Travel X / Y / Z mm 2,100 / 2,100 / 1,250 2,700 / 2,700 / 1,600 3,400 / 3,400 / 1,600 (2,000)* Maximum workpiece dimensions mm ø 1,600 × 1,400 ø 2,000 × 2,000 ø 2,500 × 2,000 DMC 210 U DMC 270 U DMC 340 U Maximum load kg 6,000 Maximum workpiece dimensions mm max ø 2,500 0 6 4 , 1 9,000 max ø 3,400 0 2 6 , 1 10,000 max ø 3,900 0 6 9 , 1 * ) 0 6 3 , 2 ( Portal 1,860 Portal 2,500 Portal 3,050 * option
Applications and Parts Machine and Technology › Turn-mill technology: DMU FD | DMC FD Control Technology Technical Data DMU FD | DMC FD PORTAL SERIES Complete machining of large components 5-sided and / or 5-axis simultaneous machining, including turning, in one set-up. The combination of milling and turning guarantees maximum precision and shorter machining times. The innovative applications are supported by numerous helpful options and features in both the software and hardware. 06 18 years of mill-turn technology: 1,000 machines installed worldwide – 80 % with pallet changers. Travel X / Y / Z mm 2,100 / 2,100 / 1,250 2,700 / 2,700 / 1,600 3,400 / 3,400 / 1,600 (2,000)* DMU | DMC 210 FD DMU | DMC 270 FD DMU | DMC 340 FD Maximum workpiece dimensions mm Maximum load kg Maximum workpiece dimensions mm *option **DMC 270 U / FD ø 1,850 5,000 / 4,000 max ø 2,500 0 6 4 , 1 ø 2,200 7,000 / 6,000 max ø 3,400 0 6 9 , 1 * * ) 0 2 6 , 1 ( ø 2,500 7,000 / 6,000 max ø 3,900 (DMC: 3,400) 0 6 9 , 1 * ) 0 6 3 , 2 ( Portal 1,860 Portal 2,500 Portal 3,050
0707 MILL-TURN TABLES Torque Detent torque Maximum speed Mass moment of inertia *option DMC 210 U DMC 270 U DMC 340 U Nm Nm rpm kg/m2 8,600 13,500 250 6,000 11,000 15,000 200 9,000 10,200 20,000 120 10,000
Applications and Parts Machine and Technology › Turn-mill technology: DMU FD | DMC FD Control Technology Technical Data 1 2 3 1 – 2: Horizontal or vertical milling head positioning, even during turning 3: Easy electronic balancing with SIEMENS 840D solutionline FD 4: Mill-turn table with direct drive (image: DMU 340 FD) 08 4 DMU FD | DMC FD PORTAL SERIES Exclusive mill-turn cycles + Detect, control and monitor imbalances + Automatic speed adjustment based on component vibration + Measurement cycles for (laser) measuring sensors: Calibrate the measuring sensor in the working area, measure recesses etc.; store, display and transfer measurement data + Tilted turning with A- and B-axes + Pivoting of long tools into the workpiece + Grinding cycles, e. g. for calibrating the dressing station and dressing the grinding wheel + Standard mill-turn cycles such as grooving / undercutting, chip breaking and thread cutting, use of multi-edged tools (up to nine) and milling / turning tool measurement DMU FD- | DMC FD-MACHINES – COMPLETE MACHINING PROCESS Milling Turning Boring Tapping Set-up Reclamp Machine 1 Milling Turning Boring Tapping Unclamp Full machining process: 1 machine 4 machining steps 300 % higher productivity Conventional machining process: 3 machines 10 machining steps SINGLE-PURPOSE MACHINES – CONVENTIONAL MACHINING PROCESS Turning Set-up Reclamp Turning Set-up Milling Boring Tapping Set-up Reclamp Milling Boring Tapping Set-up Precision turning Unclamp Machine 1 Machine 2 Machine 3 1 2 3 4 5 6 7 8 9 10
1: Turning of a turbocharger housing for a ship’s engine on a DMU 340 FD 2 – 3: Combined tool measurement: Laser measurement of rotating milling tools, probe measurement of turning tools 4: Box jaws 1 4 09 2 3 UNIQUE TECHNOLOGY + Mill-turn drives featuring Direct Drive technology – for speeds up to 250 rpm, power up to 68 kW, torque up to 20,000 Nm and a maximum table load of 7,000 kg + NC-controlled swivelling milling head as a B-axis (speed up to 30 rpm) for 5-sided machining and simultaneous 5-axis milling + 5X torqueMASTER as a B-axis rated at 8,000 rpm, max. 52 kW and 1,800 Nm + Oil mist separator and shatter-proof safety glass ADVANTAGES OF MILL-TURN (FD) TECHNOLOGY + Complete machining with milling and turning on one machine in one set-up + Faster and more precise thanks to the absence of additional set-ups + Lower investment and smaller footprint by using only one machine + Quicker machining and lower logistics costs by eliminating idle times and process steps – lower unit production costs and higher precision *Option
Applications and Parts Machine and Technology › Kit Control Technology Technical Data HIGHLIGHTS OF THE P / FD | DMC U / FD PORTAL SERIES Unrivalled rigidity and dynamics up to 6 m/s2 + Superior dynamics: up to 6 m/s2 and 63 m/min + Highest precision: P = 3.338 mm (210 series with precision package) + A high degree of stiffness for maximum milling power, EN-GJS-633-3 (GGG63) cast iron components + High-performance motor spindles (1,333 Nm or 133 kW) + Powerful gear-driven spindle (1,833 Nm – 8,333 min–1) + Three-point support with an inherently stiff machine bed made of EN-GJS-600-3 (GGG60), no foundation required Accuracy P = 0,008 mm Dynamics 6 m/s2 Stiffness EN-GJS-600-3 (GGG60) Gussbauteile MODULES OF THE 210, 270 AND 340 SERIES 10 Portal, crossbeam, X-slide Milling heads Pallet changer or rotary magazine B-axis A-axis Gear-driven B-axis Table 210 / 270 / 340 tool magazine NC rotary table NC rotary table Turn / mill table Wheel magazine with changer and up to 243 tools Chain magazine with up to 120 tools
DMU P / FD | DMC U / FD PORTAL SERIES Maximum precision with temperature stability Comprehensive cooling produces long-term precision. The entire feed drive is cooled, which guarantees higher component precision. HIGH TEMPERATURE STABILITY STANDARD POSITIONING ACCURACY DOWN TO 10 μm 1 Cooled drive motors 2 Cooled ball screw drives 3 Cooled linear guides 4 Cooled motors in the rotary axes 5 Isolation of the rear of the cabinet 6 Sensor based spindle compensation 7 Cooled machine bed POSITIONING ACCURACY DOWN TO 8 μm WITH ACCURACY PACK OPTION: + Coolant temperature control + Use of selected assemblies and components + Reduction of geometrical tolerances of up to 50 % 2 3 6 4 2 1 3 2 11 4 1 5 1 7
Applications and Parts Machine and Technology › μPRECISION Control Technology Technical Data μPRECISION Maximum precision: +83 % increase in volumetric accuracy The high precision variant µPRECISION of the DMU | DMC 210 / 270 with a volumetric accuracy of down to 20 μm (DMU | DMC 210 µPRECISION) 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. 1212 HIGHLIGHTS + Maximum precision thanks to 533 hours of hand scraping of the guideways (flatness and straightness ≤ 4 μm) + Positioning accuracy down to 4 μm + Volumetric precision down to ≤ 23 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
500 HOURS OF MANUAL SCRAPING Scraping process: Up to 80 % increase in precision DMU | DMC 210 µPRECISION DMU | DMC 270 µPRECISION DMU | DMC 340 µPRECISION Positioning accuracy of the linear axes X / Y / Z μm Positioning accuracy of the rotational axes A / B / C arcsec Straightness and flatness of the linear axes Volumetric accuracy* *Only the linear axes were considered for compensation μm μm 4 / 4 / 4 5 / 4 / 4 4 20 6 / 6 / 6 5 / 4 / 4 7 25 7 / 7 / 7 5 / 4 / 4 8 30 HIGHEST POSITIONING ACCURACY Pmax ≤ 4 / 4 / 4 μm (X / Y / Z) Package µPRECISION includes: + All features of the increased accuracy package + Hand scraped guideways + Coolant temperature control + Volumetric Compensation System (VCS) – Compensation of thermal expansion and volumetric compensation under individual on-site conditions 1313 + Spindle Growth Sensor (SGS) + Machine Protection Control (MPC) + Tool measuring in machining area BLUM + Increased number of compensation base points in all axes + Tolerance reduced up to 83 % compared to standard Travel ranges X / Y / Z Maximum table load Maximum table load FD Workpiece dimensions mm mm kg mm *option **DMC 270 µPRECISION DMU | DMC 210 µPRECISION DMU | DMC 270 µPRECISION DMU | DMC 340 µPRECISION 2,100 / 2,100 / 1,250 2,700 / 2,700 / 1,600 3,400 / 3,400 / 1,600 (2,000) 8,000 (10,000*) / 6,000 12,000 / 9,000 16,000 / 10,000 5,000 / 4,000 7,000 / 6,000 7,000 / 6,000 max ø 2,500 0 6 4 , 1 Portal 1,860 max ø 3,400 max ø 3,900 (3,400) 0 6 9 , 1 * * ) 0 2 6 , 1 ( 0 6 9 , 1 * ) 0 6 3 , 2 ( Portal ø 2,500 Portal ø 3,040
Applications and Parts Machine and Technology › Spindle Technology Control Technology Technical Data DMU P / FD | DMC U / FD PORTAL SERIES 5X torqueMASTER – B-axis with gear-driven spindle, 8,333 rpm, 52 kW and 1,833 Nm torque. 5-axis simultaneous machining and torque of up to 1,800 Nm – the 5X torqueMASTER combines all the advantages of a B-axis with the power and torque of a gear-driven spindle without any limitations. With the latest, most precise technology, the portal machines are setting new standards in 5-sided and 5-axis simultaneous machining. The patented and optimised 5-axis concepts have overcome every challenge and are in use in all sectors around the world. SPINDLE SELECTION 1414 Spindle, Speed Tool Carrier Peistung / Torque (40 % DC) DMU 210 P DMC 210 U DMU 210 FD DMC 210 FD DMU 270 P DMC 270 P DMU 270 FD DMC 270 FD DMU 340 P DMC 340 U DMU 340 FD DMC 340 FD Motor spindle rated at 12,000 rpm SK50 / HSK-A100 44 kW / 288 Nm Motor spindle rated at 12,000 rpm HSK-A100 52 kW / 430 Nm Motor spindle rated at 15,000 rpm HSK-A100 52 kW / 404 Nm Motor spindle rated at 20,000 rpm SK40 / HSK-A63 35 kW / 130 Nm powerMASTER 9,000 rpm HSK-A100 54 kW / 700 Nm Gear-driven spindle rated at 8,000 rpm SK50 / HSK-A100 52 kW / 1,800 Nm Pick-up motor spindle rated at 24,000 rpm HSK-A63 20 kW / 33 Nm • standard option – not available • • – – – – • • – – – – • – • – – – –
1: 5X torqueMASTER – gear-driven spindle with 1,800 Nm torque integrated into the B-axis 2: A axis – for simultaneous 5-axis milling of negative angles up to –40° 3: Finishing with exchangeable 24,000 rpm HSC pick-up spindle 4: NC-controlled swivelling B-axis milling head for simultaneous 5-axis milling with maximum stability due to machining at the centre of rotation 5: Roughing a mould for a dashboard with the 5X torqueMASTER 1 3 4 2 5 1515
Applications and Parts Machine and Technology › Tool Handling Control Technology Technical Data 16 1: Chain magazine for up to 180 tools 2: Pick-up spindle 24,000 rpm or 30,000 rpm 3: Rack magazine for up to 303 tools 1 2 3
DMU P / FD | DMC U / FD PORTAL SERIES Innovative Tool Handling Machine DMU 210 P DMU 210 FD DMC 210 U DMC 210 FD DMU 270 P DMU 270 FD DMC 270 U DMC 270 FD DMU 340 P DMU 340 FD DMC 340 U DMC 340 FD SK50 / HSK-A100 Chain magazine SK50 / HSK-A100 Wheel magazine 60 120 63 123 183 243 303 SK40 / HSK-A63 Wheel magazine 93 183 Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard • – • – • – • – • – • – • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • – – • • – – • • – – • • – – • • – – • • – – • • • – • – • – • – – – – – • – • – • – • – – – – – MAGAZINE TYPES Tool carrier Measurements (adjacent positions occupied), mm Measurements (adjacent positions free), mm Boring bar dimensions, mm Tool length, mm Weight, kg Chip-to-chip time (HSK), seconds PICK-UP SPINDLES* Tool carrier Dimensions, mm Tool length, mm Weight, kg * Tools are all stored in the same magazine 17 Chain magazine SK50 (HSK-A100) Wheel magazine SK40 (HSK-A63) / SK50 (HSK-A100) ø 110 ø 250 ø 250 × 400 650 15 / 30 from 10 ø 110 / ø 80 ø 280 / ø 160 ø 200 to ø 400 900 15 / 30 from 7,5 Pick-up-Spindel 24,000 rpm HSK-A63 50 200 4
Applications and Parts Machine and Technology › Special Solutions Control Technology Technical Data ADVANTAGES OF LASERTEC + 5-axis milling and laser structuring of freeform tool and mould surfaces in a single set-up on one machine + Moulds for automotive (e. g. armatures), electronics (e. g. mobile phone cases), lifestyle (e. g. shoe soles) and general tool and mould making + Can be integrated into all portal machines by adapting a fibre laser source via the HSK interface on the spindle head + SIEMENS 843D solutionline with special crossprocess LASERSOFT 3D texturing software for organic and technical surface structures 18 1 3 2 4 1: LASERSOFT 3D texturing software for generating the laser machining program 2: Geometrically defined honeycomb structure 3: Laser structuring of a steering wheel cover mould 4: Final injection-moulded steering wheel cover mould with honeycomb structure DMU P / FD | DMC U / FD PORTAL SERIES 5-axis milling and laser surface structuring – a design advantage in mould making. For the first time, flexible integration of a fibre laser in the spindle head via the HSK interface enables laser surface structuring as well as 5-axis milling of mould components on one machine in a single set-up. Moulds for automotive armatures, household appliances, mobile phone and camera casings, shoe soles and other plastic injection mould tools can be pre-milled and then tailored by laser structuring to customers’ specific requirements.
1 2 3 1: Machining a diffuser case from Inconel 718 with an ULTRASONIC 125 FD 2: ULTRASONIC 60 FD duoBLOCK: Thin-walled, lightweight structures of a Zerodur mirror carrier 3: External / internal cylindrical grinding of a mineral cast pump housing on an ULTRASONIC 125 FD ULTRASONIC TECHNOLOGY INTEGRATION Unbeatable range of materials thanks to ULTRASONIC and milling on one machine ULTRASONIC machining is a pioneering technology for the production of complex geometries in high-tech materials which is finding its way into almost every sector with unbelievable speed. Thanks to the kinematic overlapping of tool rotation with additional axial oscillation, high-performance materials which are normally difficult to machine can be economically processed to the highest quality. The low process forces allow the production of thin walls and result in longer tool service life and significantly reduced micro-cracks in the material. Depending on the material properties, outstanding surface finishes of Ra < 0.1 μm can be achieved. NEW: ULTRASONIC 2ND GENERATION 2 3 4 1 FUNCTIONAL PRINCIPLE 19 The tool rotation is superimposed via the HSK-E32 / HSK-E40 / HSK-E50 / HSK-A63 / HSK-A100 interface of the ULTRASONIC actuator tool holder with an additional oscillation in the axial direction (piezoelectric effect). > 10 µm HIGHLIGHTS 1 Powerful ULTRASONIC with optimised inductive transmission 2 Stronger ULTRASONIC booster for up to 3 times higher amplitudes 3 Shorter actuator for higher stiffness 4 Tools with undefined and defined cutting edge + Economical grinding, milling and drilling of hard and brittle as well as hard-tomachine advanced materials + New, stiffer ULTRASONIC HSK actuating tool holder with increased amplitude power for a powerful ULTRASONIC performance + Up to 40 % reduced process forces for high productivity, excellent surface quality and precision and longer tool life + Automatic detection and tracking of ULTRASONIC frequency and amplitude
Applications and Parts Machine and Technology › Technology integration Control Technology Technical Data DMU P / FD | DMC U / FD PORTAL SERIES Grinding 2020 ACHIEVABLE TOLERANCES + Surface finish < 0.4 μm + Roundness < 5 μm + Quality 5 with diameter < 120 mm + Quality 4 with diameter > 120 mm Grinding package 1 2 1: Detecting of components via spindle load 2: Acoustic emission sensor for dressing 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: External, automatically inter- changeable nozzle unit to deliver coolant directly between the grinding wheel and the 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 workpiece via spindle load + Linear guideways and ball screws with additional wipers + Sealing air for all linear encoders + Extended lubrication intervals + Observation of additional maintenance notes + Coolant supply 1,300 l incl. centrifugal filter for particles down to 10 μm
3 4 5 1: Turning 2: Tapping 3: Gear milling with standard tools DMU P / FD | DMC U / FD PORTAL SERIES DMG MORI gearMILL ACHIEVABLE GEAR QUALITIES + Bevel gear DIN ≤ 5 + Spur gear DIN ≤ 6 (depending on the pitch circle diameter HIGHLIGHTS + Gears up to ø 5,000 mm or gear segments + 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 2121 SPUR GEAR BEVEL GEAR WORM GEAR + Complex profile and flank modifications + Straight spur gear + Helical spur gear + Double helical spur gear with or without middle gap + Straight bevel gear + Helical bevel gear + Hypoid + Shaft angle ≠ 90 ° + Klingelnberg Cyclo-Palloid® + Gleason type, + FORMATE & SGT + Free modification of contact pattern + Profile ZA + Profile ZN + Profile Zl Process chain Drawing Calculation of the tooth geometry Free modification of the profile, the flanks and the contact pattern CAM programming Simulation with a 3D machine model Complete machining Measuring (in-process) Finished component Measuring (external)
Applications and Parts Machine and Technology › Example Applications Control Technology Technical Data DMU P / FD | DMC U / FD PORTAL SERIES Spindles for special materials and applications 2222 Machining of tool steel Motor spindle rated at 15,000 rpm (52 kW, 404 Nm) – for high-performance milling Workpiece material 50CrV4 Material removal rate 460 cm3/min Tool D = 80 mm (7 cutting edges) Spindle speed 477 min–1 (Vc = 120 m/min) Feed 1,282 mm/min (Fz = 0,385 mm) Cutting depth / width 6 / 60 mm 5X torqueMASTER – Machining of tool steel Gear-driven spindle rated at 8,000 rpm (52 kW, 1,800 Nm) – for high-performance milling Workpiece material 50CrV4 Material removal rate 792 cm3/min Tool Milling head D = 160 mm (12 cutting edges) Spindle speed 238 min–1 (Vc = 120 m/min) Feed 1,100 mm/min (Fz = 0,385 mm) Cutting depth / width 6 / 120 mm powerMASTER – Machining steel Motor spindle rated at 9,000 rpm (77,5 kW*, 1,000 Nm*) – for high-performance milling Workpiece material Stahl (Ck45) Material removal rate 1,680 cm3/min Tool Milling head D = 100 (11 cutting edges) Spindle speed 900 min–1 (Vc = 280 m/min) Feed 14,000 mm/min (Fz = 1,42 mm) Cutting depth / width 2 / 60 mm *15 % DC (2 min)
DMU P / FD | DMC U / FD PORTAL SERIES Example applications Hard machining of a bevel spur gear (60 HRC) – ø 1,320 mm Complete machining on a DMU 210 FD 5-axis simultaneous finishing of the tooth flanks; Machining with standard tools; soft milling and hard turning on the same machine Sector Tool Material Mechanical engineering Solid carbid end mill ø 12 mm 18CrNiMo-6 Spindle Power Torque 12,000 rpm 43 kW 288 Nm Finishing of a Pelton wheel from a single piece – ø 1,600 mm Complete machining on a DMU 210 FD Machining focus: Turning of the outer contour; 5-axis simultaneous roughing and finishing of the buckets; no post-processing required Sector Tool Material Energy technology Ball nose end mill ø 16 mm 1.4317 steel casting Spindle Power Torque 12,000 rpm 44 kW 288 Nm Pre-finishing of a bumper mould Complete machining on a DMU 340 P Machining focus: 5-axis simultaneous machining with 5X torqueMASTER – NC-controlled B-axis with counter spindle; finishing with an exchangeable pick-up motor spindle rated at 24,000 rpm; complete machining in one set-up Sector Tool Material Automotive Spindle Indexable insert end mill ø 100 mm Power 40CrMnNiMo8-6-4 Torque 8,000 rpm 52 kW 1,800 Nm Roughing of a machine column Complete finish machining on a DMC 340 U 5-axis simultaneous machining with 5X torqueMASTER –NC-controlled B-axis with gear-driven spindle; minimally attended production with integrated rotary storage Sector Tool Material Mechanical engineering Spindle Indexable insert end mill ø 280 mm Power GGG60 Torque 8,000 rpm 52 kW 1,800 Nm Turning of a bearing housing (wind energy) Complete machining on a DMC 340 FD Machining focus: Turning of the inner contour; machining of the horizontal recess with spindle tools (540 mm length); complete machining in two set-ups Sector Tool Material Energy technology Turning tool GGG40 Spindle Power Torque 8,000 rpm 52 kW 1,800 Nm 2323
Applications and Parts Machine and Technology Control Technology › CELOS Technical Data Simplified machine operation. Seamless integration of machine and company. APP MENU Like on a smartphone, the operator has direct access to all available applications through the APP MENU. 24 ERGOline CONTROL WITH 21,5″ MULTI- TOUCH SCREEN AND SIEMENS Simple User-friendly machine operation for all new high-tech machines from DMG MORI. Consistent Consistent administration, docu mentation and visualisation of order, process and machine data. Compatible Compatible with PPS and ERP systems. Can be networked with CAD / CAM products. Open to trendsetting CELOS APP extensions. SMARTkey Customised user authorisation. Individ ually adapted access privileges to the control system and the machine.
DMU P / FD | DMC U / FD duoBLOCK SERIES – From the idea to the finished product CELOS 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 MANAGER Systematic 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 ASSISTANT Process-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 HANDLING Shorter 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 CELOS APPS – 3 EXAMPLES 25
Applications and Parts Machine and Technology Control Technology › Technology integration Technical Data Exclusive, optionally available DMG MORI technology cycles MPC 2.0 – MACHINE PROTECTION CONTROL Protecting machines with an emergency shut-off function 3D quickSET Quick and easy for maximum precision ATC – APPLICATION TUNING CYCLE Process optimisation at the push of a button + Vibration sensors on the milling + Tool kit for checking and correcting + Process-oriented feed drive tuning spindle + Emergency shut-off function with teach function + Process monitoring by means of a bar graph + Milling spindle bearing diagnostics 26 the kinematic precision of 5-axis machine configurations + All head variants and all table axes + Minimised machining time with maximised component quality, regardless of workpiece weight GRINDING Machining with the highest surface precision + Grinding on a universal milling machine MULTI-TOOL Save time by efficiently using tools LASER MEASURING SENSOR PACKAGE Enhanced measuring options with a laser measuring sensor + Several “sister tools” on one + Measurement of slots and grooves tool holder + For internal, external and + Save tool change times and surface grinding + Cycles for dressing the grinding wheel magazine pockets + Measurement in hard-to-reach areas + Measurement of individual points + Package with manual and automatic calibratio
CELOS WITH SIEMENS 840D SL OPERATE CELOS WITH HEIDENHAIN TNC 640 + Highly simplified interactive programming with identical “look and feel” for turning and milling + SINUMERIK Operate new user interface + ATC*, 3D quickSET* + Powerful 32-bit multiprocessor system and controller, 1 GB RAM + Fast block processing time of approx. 0.6 ms + Look-ahead function for up to 150 NC blocks (capable of parameterisation) + Graphical simulation of the machining process with overhead view, triple-plane display and 3D display; synchronised display during the machining process + 3D machining, optional 3D tool correction via the surface normal vector + 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* + Powerful dual-core processor (Intel i7-3) + New optimised ADP (Advanced Dynamic Prediction) movement guide for improved surfaces and quicker machining (block processing time of just 0.5 ms) + DECKEL MAHO Package MDynamics, optional + Dynamic look-ahead function with no path optimisation of surface finish and speed for smoothing surface transitions *option restrictions + Dynamic Efficiency with adaptive feed control AFC and trochoidal milling as standard (Active Chatter Control ACC optional) *option 27 DMU P / FD | DMC U / FD PORTAL SERIES High-end CNCs for reliable processes and maximum precision Together with SIEMENS 840D solutionline, the portal series is equipped with the ERGOline Control th a 21.5″ monitor and CELOS. The 19″ ERGOline panel is available for the HEIDENHAIN TNC 640. Optionally, various exclusive software cycles such as ATC, MPC or 3D quickSET are available, which are able to optimise workpiece quality and productivity.
Applications and Parts Machine and Technology Control Technology Technical Data › Floor plans DMU P / FD | DMC U / FD PORTAL SERIES Floor plans DMU 210 P / FD Side view DMU 210 P / FD with chain magazine with 60 positions Plan view Footprint 67.7 m2 1,250 0 8 4 , 1 0 8 3 , 1 100 0 3 1 6 9 3 , 1 Y travel 2,100 r e t l i f t s i m l i o h t i w 5 7 7 , 4 0 4 5 , 2 i g n n e p o r o o D 4 7 9 , 6 1 0 2 , 3 4 9 9 , 8 9 7 6 , 6 3,244 9,715 DMC 210 U / FD Side view DMC 210 U / FD with chain magazine with 60 positions Plan view Footprint 106.0 m2 28 6,540 Transport length without base 8 7 9 , 4 9 0 1 , 5 r e t l i f t s i m l i o h t i w 3 4 1 , 1 1 0 1 4 , 9 6 9 5 , 1 DMU 270 P / FD Side view DMU 270 P / FD with wheel magazine with 63 positions Plan view Footprint 96.6 m2 11,267 1,650 3 0 7 , 4 0 6 8 , 1 4 0 9 , 5 ) s l o o t 3 6 l e e h W ( 3 5 7 , 9 5 8 8 , 7 0 9 0 , 3 i g n n e p o r o o D 1,800 with max. workpiece ø 3,000 Y travel 2,700 9,900 2 7 7 , 2 8 8 8 , 4 5 4 5 , 1
DMC 270 U / FD Side view 9 1 6 , 4 5 1 3 , 3 0 7 6 , 2 1 6 1 , 2 DMU 340 P / FD Side view 7 0 1 , 5 r e t t u h s g n i l l o R 0 2 6 , 1 i g n n e p o 1,650 Motor spindle 0 3 8 , 1 0 3 7 , 1 g e W - Z 0 0 6 , 1 0 3 1 100 4 5 1 0 Y travel 2,700 1,922 DMC 270 U / FD with chain magazine with 60 positions Plan view Footprint 151.1 m2 1 2 4 , 2 1 5 8 5 , 1 1 0 8 4 , 3 i g n n e p o r e t t u h s g n i l l o R 5 , 2 2 6 , 3 3 6 9 , 5 2,860 3,612,5 13,045 2 7 7 , 2 8 8 8 , 4 3 6 4 , 3 DMU 340 P / FD with chain magazine with 60 positions Plan view Footprint 101.3 m2 292929 4 4 8 , 9 0 0 2 , 6 3 9 5 , 6 10,539 10,539 DMC 340 U / FD Side view DMC 340 U / FD with chain magazine with 60 positions Plan view Footprint 174.7 m2 3 2 0 , 5 8 5 4 , 3 5 9 8 , 6 5 3 5 , 2 1 13,937
Applications and Parts Machine and Technology Control Technology Technical Data DMU P / FD PORTAL SERIES Technical data Working area X / Y / Z-axis Distance from spindle centre to table surface Horizontal milling head Vertical milling head Distance from spindle nose to table centre Horizontal milling head Vertical milling head Tables NC rotary table Speed Mill-turn table (milling / turning) Table size Maximum table load 5-axis options NC-controlled swivelling milling head (B-axis) 3030 Swivel range (0 = vertical / 180 = horizontal) Rapid traverse and feed NC-controlled swivelling milling head (A-axis) Swivel range (0 = vertical / −90 = horizontal) Rapid traverse and feed 5X torqueMASTER – NC-controlled B-axis with gear-driven spindle Swivel range (0 = vertical / 180 = horizontal) Rapid traverse and feed Main drive Integrated SK50 motor spindle Integrated HSK-A100 motor spindle Power (40 / 100 % DC) | Torque (40 / 100 % DC) Integrated gear-driven spindle for holding exchangeable milling heads Power (100 % DC) | Torque (100 % DC) SK50 tool magazine – tool magazine Linear axes (X / Y / Z) Machine weight Pmax (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 Psmax (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 Control System CELOS with SIEMENS 840D solutionline Operate HEIDENHAIN TNC640 • standard option mm mm mm mm mm rpm rpm mm kg Degrees rpm Degrees rpm Degrees rpm rpm rpm kW | Nm rpm kW | Nm Positions m/min kg µm µm DMU 210 P 2,100 × 2,100 × 1,250 130 – 1,380 230 – 1,480 −750 – 1,350 −850 – 1,250 Standard 12 – ø 1,700 8,000 (10,000)* Standard −70 / +180 30 −130 / +45 30 0 / +180 30 12,000 – 44 / 32 | 288 / 187 – – 60 / Chain 60 / 40 / 40 43,000 10 6 •
Applications and Parts Machine and Technology Control Technology Technical Data › Options DMU P / FD | DMC U / FD PORTAL SERIES Options Table options NC rotary table RS 3 / RS 2 rotary pallet storage, including 3 / 2 additional pallets (only for DMC maschines) Tool carrier HSK-A63 / BT 40 / CAT 40 (HSK for turn-mill machines, FD, as standard) HSK-A100 / BT 50 / CAT 50 (HSK for turn-mill machines, FD, as standard) Automation / measurement / monitoring 3D quickSET Infrared measuring probe Wireless measuring probe (used with pick-up spindle or exchangeable milling head) Tool measuring in working area, Blum Laser NT hybrid (standard with the pick-up spindle) Mechanical tool breakage monitor Combined tool measurement in the working area, laser system for milling tools, 3D scanner for turning tools Quad-colour signal lights Coolants / chip disposal Protective cabin 34 34 Production package with 980-litre coolant unit, paper band filter, 40-bar internal coolant supply Production package with 2,500-litre coolant unit, paper band filter, 40-bar internal coolant supply Internal coolant supply, 80 bar, frequency-controlled Coolant temperature control for internal coolant supply unit Spray gun with 2-bar pump, 40 litres per minute Minimum quantity lubrication through the spindle centre internally and through nozzles externally Oil and emulsion mist separator Air blast cooling through the spindle centre Optional TNC 640 control systems Application Tuning Cycle ATC Electronic handwheel TNC 640 Control panel for tool magazine loading station ACC – Active Chatter Control Optionen SIEMENS 840D solutionline Electronic handwheel SIEMENS 840D Control panel for tool magazine loading station DECKEL MAHO MDynamics General options Shatter-proof safety glass viewing window Operating mode 4 “Processor monitoring in production” Package for increased accuracy • standard option – not available *only in combination with pick-up motor spindle DMU 210 P DMC 210 U • RS 5 • – • • • • • •
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