DMC 160 U (FD) duoBLOCK
With the new duoBLOCK series, every component becomes a masterpiece.
Max. X-axis stroke
1,600 mm
Max. Y-axis stroke
1,600 mm
Max. Z-axis stroke
1,100 mm
Max. workpiece diameter
1,600 mm
Max. workpiece height
1,350 mm
Max. workpiece weight
4,000 kg
Control & software alternatives
SIEMENS
HEIDENHAIN
Highlights
Complete machining
- Milling and turning in one setup with the DirectDrive table and rotational speeds up to 400 rpm
- Best surface quality with technology integration grinding
Precision
- Maximum accuracy through completely water-cooled feed drive
- SGS: Spindle Growth Sensor for Compensation of spindle increase
- Significantly improved temperature response
Performance
- Fast, very compact rotating pallet changer for main time parallel setup as standard
- Also available in mill- /turn - version
- powerMASTER motorspindle with 1,000 Nm and 77 kW
- 5X torqueMASTER with 1,800 Nm and 52 kW
Efficiency
- Low space requirements, extremely compact wheel magazine with short tool replenishment time of max. 5.6 sec with 453 tool pockets
- Optimal ease of maintenance and ideal ergonomics thanks to unrestricted accessibility
- High machine availability with 96 %
Application Examples
Automation
Standard automation and customised solutions in the VERTICO design
Automation is a key element of digital production. Every DMG MORI machine can be upgraded with standard automation or with a customised automation solution for flexible manufacturing systems:
RPS duoBLOCK
RPS 6 / 7 / 12 - Machine-integrated automation with minimum space requirement
- Unmanned shifts due to circular storage system with up to 12 pallets
- Handling of workpieces up to ø 1,600 × 1,350 mm, 4,000 kg max.
- Reduction of non-productive time due to loading and unloading during production
- Easy operation via machine control with intuitive, integrated Pallet Manager software
- Pallet Master – for convenient and simple control of the automation directly via the machine control
CTS - Central Tool Storage
Flexible tool magazine for more than 4,000 tools
- Modular concept with step-by-step extension possibility by 360 / 240 shapes (ISO 40 / 50 recording)
- Very small footprint with only 29 m2
- Integrated tool loading solution for portal tool shuttle or with AMR 2000 tools
- Highest transport capacity through the tool - shuttle
- Transfer of up to 8 tools simultaneously
- Proven wheel magazine technology with over 1,600 units sold
Highlights
AMR 2000 Tooling
- Autonomous transport of up to 24 tools between the CTS (central tool magazine) and the machine
- Quick installation of the automation system
- Integration into existing production possible
- Max. tool dimensions ø 280 / 650 mm
- Max. tool weight 30 kg
- transport weight 720 kg (24 × 30 kg)
Portal tool handling
- Portal tool handling for highest efficiency, transport of up to 80 tools per hour.
- Transport of 16 tools (2×8 units)
- Fast tool change by means of rotating unit
- Max. linear speed: 80 m/min
- Tool Loading Station TLS - interface on machine and CTS
Tool transfer
- To change tools between the shuttle and the machine or on the CTS, the TLS moves upwards in each case.
PH-AMR
Pallet automation with maximum flexibility through free layout design
- Modular concept with flexible layout design
- Driverless transport systems without guide rails or tracks
- Collaborative: Man and machine in one system
- Navigation through natural navigation
- Pallet sizes from 500 × 500 mm to 1,600 × 1,250 mm
- Workpieces up to 5,000 kg and ø 1,600 mm
Highlights
Free accessibility
- Best visibility into the workspace at any time
- Manual or crane loading still possible
- Collaborative system – man and machine in one system
Modular concept with free layout design
- No safety housing for the automation system necessary
- Free positioning possibility of the individual modules
- Subsequent integration into existing production
Simple expansion of automation system
- Additional shelf modules to increase the number of storage places
- Additional AMRs can be integrated in the system
- Machines with an automation interface can be integrated very quickly afterwards
Minimum space requirement
- Free pallet handling system without fixed installation requirements on hall floor
- AMR paths remain walkable and passable
- Laser scanners guarantee personal protection in driving direction
- Omnidirectional movement for minimum space requirements (turning circle 0m)
- Flexible automation concept - Automation of different machine types with one system
AMR 2000
Holistic automation on the shop floor
- Collaborative automation solution with free layout design
- Omnidirectional movement for minimal space requirements (turning radius 0m)
- Basis for additional tasks, e.g. B. tool handling, chip disposal, etc.
- Material transport from Euro pallets 1,200 x 800 mm
- Maximum transport weight of up to 2,000 kg
- Security based on Sick and Siemens technology
Highlights
AMR 2000 Material
- Autonomous transport of material pallets
- Load capacity up to 2000 kg
- Compact and manoeuvrable
- Integration into existing processes
AMR 2000 chips
- Autonomous transport of chip trolleys
- Automatic pick-up order from the DMGMORI master computer
- Integration into existing material processes
- Extension of machine tool autonomy over the night or weekend
- Fleet ready
AMR 2000 tool handling
- Tool identification in the standard
- Quick installation of the automation system
- Reliable technology with proven components
- Integration into existing production possible
- Max. tool dimensions ø 280 / 400 mm
- Max. tool weight 30 kg
- Transport weight 720 kg (24× 30 kg)
- Maximum number of tools: 24 pcs
LPP
Advanced pallet storage solution for up to 8 machines and 99 pallets
- Handling of workpieces up to ø 3,400 x 2,000 mm, 10,000 kg
- Very flexible pallet pool system with up to 8 machines, 99 pallets and 5 setup stations
- Handling of up to three different pallet sizes possible in one system (2 sizes for machine pallets and one size for material pallets)
- Control directly via DMG MORI master computer software LPS
- Integration into customer network / workflow possible
- Monitoring and management tools for all relevant areas (planning, workpieces, clamping, tools, etc.)
- Tool management system MCC-TMS
Control & Software
Flat Grinding
- Technology integration flat grinding on standard machines for best surface results
- Possibility of straightness compensation by definition of calibration points
- Acoustic emission sensor assisted approaching cycle
- ECS nozzle unit for best possible flushing of the grinding gap optionally available
Highlights
Customer Benefits
Machining strategies
- Easy programming with the integrated input parameters
- Complete machining with one setup
Optional rotating dressing unit incl. dressing cycles
Maintenance Package i4.0
- Automatic recognition of tool pull-in force for consistently high process stability.
- Predefined cycle for automatic lubrication, every 75h or after 20,000 tool changes.
- Detection of leakage and measuring of usage of pneumatics system.
Highlights
Customer Benefits
- Efficient and timesaving lubrication without operator intervention
- High transparency by displaying the lubrication cycles and the current pull-in force.
- Data recording in combination with the optionally available Condition Analyzer for additional analyzes of air consumption and changes of the pull-in force
Detection of leakage and measuring of usage of pneumatics system.
Simple query of the monitoring parameters and the current pull-in force.
Tilted Measuring Cycle
- Measuring with tilted tool axis
- Dialog-guided programming of the measuring cycles
- Positioning of the measuring points with rotary axis
Highlights
Customer Benefits
- Increase in component accuracy
- Reduction of set-up time
- Collision-free measuring thanks to tilted tool axis possible
- Further processing of the measurement results
Left : 1. circumferential measurement, 2. alignment surface, 3. alignment hole / Right : Dialog-guided programming
TCC – Tool Control Center
- Chip detection on plan pad and tool cone
- Monitoring of pull-in force
- Cutting edge control in process by symmetry monitoring of the bending moment per cutting edge
- Visualization of the bending moment over time via Graph
Highlights
Customer Benefits
- Tool and workpiece protection
- Optimized tool process
- Monitoring of the radial and axial spindle load depending on the actual pull-in force
Left: NEW; Middle: Wear; Right: Cutting edge break
angularTOOL
- Highest flexibility in the machining of structural components due to variable alignment of the angle head
- Automatic CAD / CAM programming
- Automatic calculation of the TCP and combination with existing control functions
Highlights
Customer Benefits
- Machining of inaccessible positions on the workpiece.
- Savings in non-productive time due to fewer tool changes
- High cost savings due to the use of fewer tools
Left : Tool driven by KSS during drilling operation / Right : Parameter mask for variable angle setting
Profile Dressing
- Dressing of a profile on the grinding wheel by means of driven profile rollers (negative)
- Full utilization of AE sensor and integrated dressing strategies
- High time saving as well as high dressing accuracy due to customized dressing wheel development
Highlights
Customer benefits
- Tool and workpiece protection
- Optimized tool process
- Monitoring of the radial and axial spindle load depending on the actual pull-in force
Left: Parameterised input for the production of profiles; Right: Dialogue-guided contour dressing cycle
Grinding
Turning
- Turning, milling and grinding in one clamping
- Grinding cycles for internal, external and face grinding as well as dressing cyclesn
- Body-borne sound sensors for start-up and dressing
- Full integration of measurement module for relative and absolute LIVE-Measuring – parallel to main time
Milling
- Better surface quality through integration of the grinding technology
- Grinding cycles for internal, external and face grinding as well as dressing cycles
- Body-borne sound sensors for start-up and dressingn
- 1,300 l Cooling system with integrated centrifugal filter for The filtration of particles > 10 μ
- AKZ nozzle unit optionally available for best possible Flushing of the grinding gap
Highlights
Turning Customer Benefits
- Expansion of the technological limits of the CTX TC
- Surface accuracy < 0.4 μm
- Roundness < 5 μm
- Quality IT5 for ø > 30 mm
Left : External, internal and circular grinding. Grinding with straight / angle or cup disc. / Right : Dressing straight, angled or cup discs simply visualized.
Milling Customer Benefits
- Surface accuracy < 0.4 μ
- Roundness < 5 μ
- Quality 5 for ø < 120 mm
- Quality 4 for ø > 120 mm
Left: Spiral plane grinding or osscillating plane grinding. / Right: Longitudinal grinding.
gearQUALITY
- Non-contact measurement with the laser scanner
- Measurement and evaluation of gears according to common standards analog to coordinate measuring machines
- Fast measurement with max. 70,000 points / sec. or up to 200,000 points / sec. depending on the laser source
Highlights
Customer Benefits
- Technology and measurement system integration eliminate unnecessary handling of components
- High flexibility in gear measurement and reduction of reaction times during process start-up
- Measurement of gear teeth and scanning of free-form surfaces possible
Left : Simulation of the generated measurement program / Right : Evaluation mask with color-coded result display
In-Machine Tool Balancing
- Balancing of tools in the machine for high surface requirements and machine protection
- Checking the balancing quality of the spindle
- Balancing quality up to 0.3 g/mm
Highlights
Customer benefits
User Interface
- Better surfaces due to balancing of the entire system in the clamped state
- Balancing of the tool under machining conditions (machining position -vertical / horizontal, with / without internal cooling supply, speed)
- Economical, as no external balancing device is required
User Interface
Excentric turning and milling
- Superposition of the turning movement by additional X- and Y-traverses
- Applicable for turning and milling
Highlights
Customer Benefits
- Eccentric geometries easy to manufacture
- Exact axis coupling and synchronization in the background
Left : Enter the parameters for the position of the external workpiece area. / Right : Graphical representation of the position within the workpiece.
L-Measuring probe packet
- Measurement of webs and grooves on components
- Measurement of diameter in difficult to access places
- Available with manual and retractable Calibration unit Package content
- L-Measuring probe according to Customer-specific design
Highlights
Customer Benefits
- Flexible application possibilities
- In process measurement
Left : Semi-automatic Measurement solution. / Right : Automatic measurement solution.
Interpolation turning 2.0 – turning recessing cycle
- With interpolation turning, the tool cutter follows a circular movement, where the cutter is always oriented towards the center Of the circle.
- Possible for external and internal machining
- Synchronization and tool path controlled by the cycle
- NEW: in version 2.0 complex turning contours are possible (currently only available on the DMU 50, other machine types will follow)
Highlights
Customer benefits
- Easy manufacturing of sealing surfaces where milling operation might not be possible.
- Complete component processing in one clamping possible
- Reduced investment costs for tools
gearSKIVING 2.0
- Straight and helical external or internal spur gears and splines
- Arrow teeth with tooth offset Turn-mill machines
- Ball-shaped toothing by mathematical transformation of the 6th virtual axis
Highlights
Customer Benefits
- Internal toothing without angular head possible
- Short processing times, 10 x faster than shaping
- Synchronization and tool path controlled by the Cycle
Left : Inside gear profile machining. / Right : Outside gear profile machining.
MPC 2.0 – Machine Protection Control
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
Highlights
Customer Benefits
MPC Graph: current and learned process values. / MPC Diagnostics: stock condition, number of impact and crash.
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
Fit in – B-axis Plunging
- Full utilization of the working space during internal machining of high workpieces with long tools
- Positional changes of the B axis during the turning are balanced by the X and Y axes
- The Z-axis remains at the retracted position while the B axis is moving
Highlights
Customer Benefits
Inner and outer travel of the B-axis.
- Easy programming
- Collision-free plunging in the workpiece
- Safely coming out from the workpiece after machining
Alternating speed
- Easy to operate through three parameters and without additional sensors
- Avoiding vibrations by means adaptation of the speed
- Application for the main spindle and counter spindle, or for milling machines with FD tables with Direct Drive
Highlights
Customer Benefits
Input of parameters for speed set-point, differential speed and revolution frequency
- No manual intervention by the operator
- Identical repeatability for all components
- Increased process safety for special applications by avoiding vibrations. example, When using long thin drills or for milling parts with critical clamping
DMG MORI gearMILL
- Productive complete processing
- Cost-effective gear cutting on standard machine with standard tools
- Flexible for different gear geometries
- Quality inspection in the process
Highlights
Customer Benefits
- Program creation based on blank drawings and gear data
- Optimization of workpiece orientation e.g. after heat treatment
- Interface for coordinate measuring device (Klingenberg, Leitz, Zeiss)
Left : Input of the gear parameters for the geometry calculation of a spur gear. / Right : Grafische Betrachtung des Abwälzverfahrens.
3D quickSET
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
Highlights
Turning Customer Benefits
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
Dialogue-guided measurement of the B- and C-axis.
Milling Customer Benefits
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
Define kinematics head
Efficient Production Package
- Solutions for a safe process and for the efficient use of important machining steps
- Applications: cone cleaning, tool data monitoring, safe withdrawal movement, tapping, deep hole drilling, external thread and spigot milling, internal thread and circular milling, reverse countersink cycle
- 12 stored machining strategies for stock removal, deep hole drilling, Pocket milling machines*
Highlights
Customer Benefits
- Runtime optimization according to individual application
- Safe retraction after program break
- Tool data monitoring
Left : Input mask for universal cycle pocket milling. / Right : Input mask for tapping cycle
Application Tuning Cycle
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight
Highlights
Customer Benefits
- User friendly setting of the machine dynamics with included DMG MORI knowhow
- Time saving in roughing
- High surface finish during finishing
Left : ATC 2.0 – Milling: Consideration of table loading. / Right : ATC – Turning: for CTX TC for easy adjustment of the machine dynamics.
Service & Training
Downloads & Technical Data
Workpiece
Max. workpiece diameter
1,600 mm
Max. workpiece height
1,350 mm
Max. workpiece weight
4,000 kg
Max. workpiece weight (Type FD)
3,500 kg
Work Area
Max. X-axis stroke
1,600 mm
Max. Y-axis stroke
1,600 mm
Max. Z-axis stroke
1,100 mm