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June 2015

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Machining Center for 5-Axis Milling Operations and Mill-Turn Machining



DMG MORI offers its latest model DMC 80 FD duo BLOCK universal machining center that is designed for enhanced flexibility and productivity. According to the company, it features improvements of 30% in precision, performance and efficiency.

The 4th generation DMC 80 FD duoBLOCK has a newly developed B-axis milling head. It has a swivel range of 210° with a swivel of 30° in the negative direction. According to the company, the larger axis bearing results in a 20% increase in rigidity. The extended swivel range and reduced interference contour, in conjunction with the cable conduit integrated into the housing, enable a wider range of customer-specific complete machining operations to be carried out. Idle times are reduced due to shortened B-axis movements, and the extended life of the integral cables has a positive effect on high machine availability.

DMG MORI offers the combination of a redesigned B-axis with a stiffer and more accurate milling/turning table with pallet system. In the DMC 80 FD duoBLOCK, this is also fitted with larger bearings and improved clamping.

In the 4th generation, the duoBLOCK machine concept has been made more stable due to its 30% greater rigidity. With an 8% larger work area of 0.715 dm3 / 43.6 in3 and a Z-axis traverse of 850 mm / 33.5", the DMC 80 FD duoBLOCK has increased overall rigidity despite a reduced footprint. This is based on structural optimization of the reinforced, in some areas wider, machine beds and columns made of high-quality castings (GGG 60). In addition, the supporting surfaces of the machine beds have been enlarged, stronger 55 mm / 2.2" linear guides fitted on the Y-axis and 50 mm / 2" diameter ballscrew drives incorporated.

The company reported that these measures and the larger bearings in the B-axis and C-axis result in a gain of approximately 20% in overall rigidity in the 4th generation DMC 80 FD duoBLOCK. This makes it possible for heavy duty milling to be carried out with the new powerMASTER 1000 spindle and HSK 100 toolholder interface in the B-axis. The spindle has a power rating of 77 kW / 103.2 HP, the maximum speed is 9,000 RPM and the torque is 1,000 Nm / 737.6 ft-lbs. The B-axis provides a 120% power increase compared to previous motor spindles and offers enhanced milling performance and chipping power. "In comparison with the competition, the 4th generation universal milling centers achieve 75% greater metal removal rates during 5-axis milling," said a company spokesperson.

Motor spindles with the HSK 63 tool interface up to 18,000 RPM for high-speed cutting (HSC machining) is a further option for the duoBLOCK. Alternatively, Torquemaster gear-driven spindles with 1,053 or 1,424 Nm / 776.7 or 1,050.3 ft-lbs. at 8,000 RPM and 37 or 44 kW / 49.6 or 60.0 HP for HSK 100 can be used in the machines when carrying out high-performance cutting operations (HPC machining).

"An almost constant overall machine temperature is achieved with the DMC 80 FD duoBLOCK universal machining center during chip removal," said the spokesperson. "This is achieved by structurally strengthened and thermo-symmetrical machine design along with additional cooling measures. Additional cooling channels in the machine bed and column, together with the liquid cooling of the feed drives on all linear axes, including the rotary table with C-axis motor, dissipate the heat produced during chip removal."

The previous cooling measures in the whole B-axis/milling head area and in the electrical cabinet have been adapted to suit the re-engineered machine structure. Electronic compensation devices eliminate the residual displacement caused by temperature or the effects of static or dynamic forces. The devices, which are included as standard, are supplemented by the effective use of the Spindle Growth Sensor (SGS) to prevent axial spindle displacement.

"The option of careful temperature control of the coolant during machining is also recommended," said the spokesperson. "The combination of all these measures leads to 30% greater workpiece accuracy when milling or during mill/turn machining with the 4th generation duoBLOCK universal machining centers."

Tool and workpiece changeover were also redesigned on the 4th generation duoBLOCK machines. Space-saving wheel magazines featuring 123 tool pockets reduced space requirements by approximately 40%. The parallel arrangement of up to four wheel magazines with a total capacity of 243 tool pockets is designed to meet the increasing number of possible applications of the 4th generation universal machining centers and the global upward trend in process automation. Short traverse distances and cam-controlled changers enable short times to be achieved when changing and presenting tools during production.

The idle time of the machines and pallet changer have been improved by increasing the table speed of the 4th axis to 40 RPM in rapid traverse and re-engineering the sequence. Additional devices for enhanced process automation can be selected from the DECKEL MAHO modular system and connected accordingly. The same applies to the systems from the company's external partners. The use of pallet magazines, gantry loaders and robots as well as the integration of the universal machining centers into flexible manufacturing systems enables unattended automatic operations to be carried out.

As a result of the improved machine temperature control in the 4th generation machines, the cooling unit has an increased energy requirement. For this reason, only highly efficient, energy-saving cooling units, the power of which is adjusted automatically to the machine cooling requirements, are used in the 4th generation duoBLOCK universal machining centers. For example, the 80 bar / 1160.3 PSI coolant pump is equipped with a speed controller to reduce energy losses, which prevents unnecessary heating of the coolant.

The continuous power display on the CELOS interface indicates to the machine user the current energy being used and analyzes the consumption at a specific point in time. Appropriate responses can lead to further energy savings.

The 8% larger work area with the 6% longer vertical travel of 850 mm / 33.5" is easily accessible from the side and from above. Despite a larger work area, the footprint has been reduced to 21.4 sq. m / 230.4 sq. ft. According to the company, the user-friendly ergonomics of the machine have been further improved with the re-engineered machine design, which features ease of operation and an easily accessible set-up station. These are important for effective workpiece fixturing and for work area visibility. Automation devices external to the machine can also be connected to the enclosures. The central location of easily accessible valves and pumps at the rear of the machine simplifies maintenance and, if it should be necessary to replace a window, this can now be carried out from the outside.

The DMC 80 FD duoBLOCK is presented with CELOS with 21.5" ERGOline panel and Siemens control. CELOS from DMG MORI is designed to simplify and accelerate the process from the idea to the finished product. CELOS APPs provide the user with integrated management, documentation and visualization of order, process and machine data. CELOS is compatible with MRP and ERP systems, can be networked with CAD/CAM applications and is ready for future CELOS APP extensions. As standard, the machine is equipped with Operate 4.5 on Siemens 840D solutionline and includes a 19" ERGOline panel.

Technical data:

  • Axis travels (XYZ): 800 mm / 1,050 mm / 850 mm (31.5" / 41.3" / 33.5")
  • Max. speed (standard): 12,000 RPM
  • Drive power (40 / 100% DC): 35 / 24 kW (46.9 / 32.2 HP)
  • Torque (40 / 100% DC): 130 / 86 Nm (95.9 / 63.4 ft-lbs.)
  • Rapid traverse (XYZ): 60 / 60 / 60 / m/min (2,362.2 / 2,362.2 / 2,362.2 IPM)
  • Feed force max.: 13 / 9 / 13 kN (2,922.5 / 2,023.3 / 2,922.5 lbf)
  • Clamping surface: 800 mm x 630 mm (31.5" x 24.8")
  • Table load max.: 1,400 kg (3,086.5 lbs.)
  • NC rotary table: 40 RPM
  • Swivel range B-axis: -70° / +180°
  • Tool magazine: 63 (123 / 183 / 243 / 273 / 363) pockets.

For more information contact:

DMG MORI USA

2400 Huntington Blvd.

Hoffman Estates, IL 60192

847-593-5400

www.us.dmgmori.com

Southwest

DMG MORI - Dallas

9001 Currency Street #200

Irving, TX 75063

972-929-8321

www.us.dmgmori.com

TX, LA

DMG MORI Ellison Technologies - Dallas

9001 Currency Street #200

Irving, TX 75063

972-812-5500

www.ellisontechnologies.com

DMG MORI Ellison Technologies - Houston

3403 N. Sam Houston Pkwy. West #100

Houston, TX 77086

713-365-9500

www.ellisontechnologies.com

OK

DMG MORI - Tulsa

7633 E 63rd Place, Suite 300

Tulsa, OK 74133

918-932-2893

www.us.dmgmori.com

Southeast

DMG MORI - Charlotte

4345 Morris Park Drive

Charlotte, NC 28227

704-940-3380

www.us.dmgmori.com

VA, NC, SC

DMG MORI Ellison Technologies - Charlotte

4345 Morris Park Drive

Charlotte, NC 28227

704-545-7362

www.ellisontechnologies.com

S. AL, GA, MS, TN

DMG MORI Ellison Technologies - Nashville

7118 Crossroads Blvd.

Brentwood, TN 37027

615-661-6800

www.ellisontechnologies.com

FL

Mike Tyler

DMG MORI - Florida Sales

537 US Highway 301 South

Tampa, FL 33619

727-530-1490

mtyler@dmgmori-usa.com

www.dmgmori-usa.com

Northeast

DMG MORI - Newark

1160 Parsippany Blvd, Suite 103

Parsippany, NJ 07054

973-257-9620

www.us.dmgmori.com

DMG MORI Tyler Machine Tool

111 Ledge Rd.

Seabrook, NH 03874

603-474-7730

www.us.dmgmori.com

DMG MORI Tyler Machine Tool

68 Nutmeg Road South

South Windsor, CT 06074

860-528-4010

www.us.dmgmori.com

Boldt Machinery, Inc.

4803 Pittsburgh Ave.

Erie, PA 16509

814-833-9836

www.boldtmachinery.com

Boldt Machinery, Inc.

104 Boss Rd.

Mattydale, NY 13211

315-463-5754

www.boldtmachinery.com

MD, DE

DMG MORI - Charlotte

4345 Morris Park Drive

Charlotte, NC 28227

704-940-3380

www.us.dmgmori.com

DMG MORI Ellison Technologies - Charlotte

4345 Morris Park Drive

Charlotte, NC 28227

704-545-7362

www.ellisontechnologies.com

Midwest

DMG MORI Ellison Technologies - Chicago

4630 Weaver Parkway

Warrenville, IL 60555

630-393-8900

www.ellisontechnologies.com

DMG MORI - Cincinnati

5333 Mulhauser Road

Hamilton, OH 45011

513-874-2736

www.us.dmgmori.com

DMG MORI Ellison Technologies - Cincinnati

5333 Mulhauser Road

Hamilton, OH 45011

513-874-2736

www.ellisontechnologies.com

DMG MORI Ellison Technologies - Cleveland

6955 Treeline Drive

Brecksville, OH 44141

440-546-1920

www.ellisontechnologies.com

DMG MORI Ellison Technologies - Davenport

145 West 76th Street

Davenport, IA 52806

563-388-0800

www.ellisontechnologies.com

DMG MORI Ellison Technologies - St. Louis

16 MB Corporate Park Ct.

St. Charles, MO 63301

636-946-7077

www.ellisontechnologies.com

DMG MORI - Detroit

29050 Cabot Drive

Novi, MI 48377

248-324-1928

www.us.dmgmori.com

DMG MORI Ellison Technologies - Detroit

29050 Cabot Drive

Novi, MI 48377

248-324-1928

www.ellisontechnologies.com

DMG MORI Ellison Technologies - Grand Rapids

1550 Gezon Parkway SW, Suite B

Wyoming, MI 49509

616-261-8665

www.ellisontechnologies.com

DMG MORI Ellison Technologies - Indianapolis

8930 Bash Road, Suite A

Indianapolis, IN 46256

317-577-3723

www.ellisontechnologies.com

DMG MORI Ellison Technologies - Milwaukee

N29 W23825 Woodgate Court West

Suite 100

Pewaukee, WI 53072

262-523-3400

www.ellisontechnologies.com

DMG MORI Ellison Technologies - Minneapolis

13400 10th Avenue North

Plymouth, MN 55441

763-545-9699

www.ellisontechnologies.com

DMG MORI - Kansas City

7500 College Blvd, 5th Floor

Suites 520/521/522/524

Overland Park, KS 66210

913-871-1373

www.us.dmgmori.com

DMG MORI - Wichita

3450 N Rock Rd

Building 500, Suite 505

Wichita, KS 67266

316-425-7993

www.us.dmgmori.com

West

DMG MORI - Los Angeles

5740 Warland Drive

Cypress, CA 90630

562-430-3800

www.us.dmgmori.com

Southern CA

DMG MORI Ellison Technologies - Los Angeles

9890 Pioneer Blvd.

Santa Fe Springs, CA 90670

562-949-8311

www.ellisontechnologies.com

Northern CA

DMG MORI Ellison Technologies - San Francisco

2607 7th St. Suite C

Berkeley, CA 94710

866-814-7238

www.ellisontechnologies.com

WA, ID, MT

DMG MORI Ellison Technologies - Seattle

19625 62nd Ave. South, Suite A109

Kent, WA 98032

253-872-1661

www.ellisontechnologies.com

OR

DMG MORI Ellison Technologies - Portland

10159 SW Commerce Circle #K

Wilsonville, OR 97070

503-682-3280

www.ellisontechnologies.com

AZ

Ellison Machinery

1610 S. Priest Dr. #101

Tempe, AZ 85281

480-968-5335

www.ellisonaz.com

CO

Triad Machine Tool Co., Inc.

7885 West 48th Avenue

Wheat Ridge, CO 80033

303-424-0268

www.triadmt.com

UT, ID, MT, WY

New West Machine Tool Technologies

7990 South 1530 West

West Jordan, UT 84088

801-561-2001

www.newwestmachine.com

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