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www.dmgmori.com
Universal milling machines for five-sided / five-axis machining
DMU / DMC duoBLOCK®
World premiere
4th Generation duoBLOCK®
DMU 80 P / FD duoBLOCK®
DMC 80 U / FD duoBLOCK®
DMU 100 P duoBLOCK®
DMU 125 P / FD duoBLOCK®
DMC 125 U / FD duoBLOCK®
02
DMU / DMC P / U / FD duoBLOCK® series
The new benchmark in five-axis machining.
Applications and parts
Highlights
Control technology
Overview
Technical data
The five-axis machines in the highly stable duoBLOCK® design with 30 % more 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.
AutomotiveSteering knuckles for Infinity
Red Bull Racing Formula 1 cars
03
Tool and mould makingTube mould
Energy technologyDrill head for the oil and gas drilling sector
AerospaceChassis components
Machine constructionMould carrier for PET bottles
30%
30%
30%
04
Applications and parts
Highlights
Control technology
Overview
Technical data
4th Generation duoBLOCK® – added value for you
Unique!
m
or
e i
nn
ov
at
i ve
more prec ise
m o re e f f i c i e n t
s tronger
c
elo
s®
DMU / DMC P / U / FD duoBLOCK® series
Unique
Precision
+ 30 % greater precision
+ Full cooling of the axis drives with the precision package
+ Comprehensive cooling measures
+ Significantly improved temperature response
+ SGS: Spindle Growth Sensor
Performance
+ 30 % more overall stiffness
+ powerMASTER 1000 motor spindle rated at 1,000 Nm and 77 kW
+ 5X-torqueMASTER® rated at 1,300 Nm and 37 kW
+ Table with 76 % greater stiffness
+ 50 mm diameter ball screw
+ 55 mm wide linear guides
With the new duoBLOCK® series, every component becomes a masterpiece. Comprehensive cooling and the optimised stiffness of the new redesigned duoBLOCK® concept are the basis for the highest possible levels of precision and machining performance.
The stiffness of the highly stable and highly precise duoBLOCK® concept has been improved by 30 %. The new innovative wheel magazine provides the highest flexibility with up to 453 tools and minimal space requirements.
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.
30%
30%
30%
05
m
or
e i
nn
ov
at
i ve
more prec ise
m o re e f f i c i e n t
s tronger
c
elo
s®
Efficiency
+ 30 % lower energy consumption
+ Lower space requirements, extremely compact wheel magazine with shortest setting time
+ High machine availability
+ Optimal ease of maintenance and the best ergonomics thanks to unrestricted accessibility
+ B-axis: improved interference contour, higher stiffness!
CELOS®
+ CELOS® by 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 programmes
4th GenerationduoBLOCK®
Precision Performance Efficiency CELOS®
06
Applications and parts
Highlights
ê Precision
Control technology
Overview
Technical data
DMU / DMC P / U / FD duoBLOCK® series
The masterpiece. Always precise!
The entire feed drive is cooled
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 up to 30 % higher component precision.
Standard cooling measures
Headstock
Headstock housing Motor spindle B-axis motor
NC rotary table
C-axis motor C-axis gears
Basic construction
Y- / Z-axis motor X- / Y- / Z-feed axes: Ball screw bearing X- / Y- / Z-linear guides
30%
07
Precision Performance Efficiency CELOS®
duoBLOCK® 4th generation
duoBLOCK® 3rd generation
Competition
Precision package with coolant
temperature control(optional)
X- / Y- / Z-ball screw nut
Cooling bars on the machine bed and column
X-axis motor
Thermo Shield
30 % improved temperature
stabilisation thanks to more
intensive cooling measures
76%
12% 20%
3
08
Applications and parts
Highlights
ê Stiffness / Performance
Control technology
Overview
Technical data
DMU / DMC P / U / FD duoBLOCK® series
The greatest stiffness for maximised machining performance!
Precision Performance Efficiency CELOS®
Premium class!
4
duoBLOCK® 4th generation
duoBLOCK® 3rd generation
Competition
The overall stiffness of the highly stable and highly precise duoBLOCK® concept was improved by over 30 %. The structure of the basic concept was optimised further using FEM calculations and the components were strengthened.
With the powerMASTER 1000, this is converted into more stiffness and maximised machining performance with 1,000 Nm torque.
Increased structural
stiffness up to:
B-axisnc rotary taBle machine structure
130%
1
2
4
5
45 kW 100%
580 Nm 100%
54 kW 40%
77.5 kW 15%700 Nm 40%
1,000 Nm 15%80
50
40
15
1,000
700
600
100
Torque(Nm)
Spe
ed(r
pm)
Power(kW)
20 740
3,00
0
9,00
0
09
powerMASTER 1000
powerMASTER 1000
130 % increase in torque
duoBLOCK® 4th generation
duoBLOCK® 3rd generation
Competition
powerMASTER SK50 / HSK-A100* motor spindle
9,000 rpm / 77.5 ** kW / 1,000 ** Nm
* optional, ** 15 % DC (2 min)
1 Optimised component structure
12 % higher stiffness thanks to an elevated column with a wider support
2 Size 50 ball screw in all axes
Large drive systems and internally cooled ball screws as standard
3 Size 55 linear guides in the Y-axis
Wide linear guides for a maximum table load of 2,500 kg
4 Larger YRT bearing on the B- and C-axis
Improved stiffness thanks to the larger bearing diameter
5 Optimised three-point support
100 mm wider supporting area
0 K
WH
5
10
15
21
25 KW
H
706
6.2
m2
3.7
m2
30%
10
Applications and parts
Highlights
ê Efficiency
Control technology
Overview
Technical data
Precision Performance Efficiency CELOS®
DMU / DMC P / U / FD duoBLOCK® series
Manufacture more efficiently!
energy s av ing
duoBLOCK® 4th generation
duoBLOCK® 3rd generation
Ch
ip C
on
ve
yo
r
KSS
SyS
tem
Coolant unit main Spindle
miSCellaneouS
The new duoBLOCK® series reduces energy consumption by up to 30 % thanks to its intelligent accumulators and, thanks to its maximised availability, provides the best conditions for efficient production. The new, most compact tool magazine on the market significantly reduces the footprint, and optimal accessibility offers the ultimate in ease of maintenance.
Save energy with efficient features
* Energy required for the complete machining of a machine component on the duoBLOCK®
706
6.2
m2
3.7
m2
11
DMU / DMC P / U / FD duoBLOCK® series
Obvious!
old chain magazine* new wheel magazine*
* DMU 80 P duoBLOCK®
2.5 m2 saving
opt imal work i ng a re a access iB i l i ty
Compact magazineThe new wheel magazine is the most compact on the market, reducing the footprint by 41 % compared to its predecessors. Example: Magazine for 123 tools with SK50 tool holder
The best ease of maintenanceWith its large viewing panels, the Fluidbox provides optimised accessibility for unrivalled ease of maintenance.
The duoBLOCK® has always been the benchmark for optimised accessibility and large working volumes that are open on three sides. The large operating doors allow quick and ergonomic set-up and adjustment. Additionally, unrestricted crane access from above to over the centre of the table promotes ease of loading and unloading.
41%
12
DMU / DMC P / U / FD duoBLOCK® series
Innovative down to the smallest detail!
duoBLOCK® 4th generation
duoBLOCK® 3rd generation
Competition
41 % decrease in footprint
with the 123 station magazine
Highlights
+ Set-up during machining and idle times (two wheels or more)
+ The most compact magazine on the market (41 % lower machine width with the 123 pocket magazine)
+ Up to 453 tool pockets: call-up time of up to 5.6 seconds
+ Patented design
+ Extremely short tool-changing time of just 0.5 second (0.8 second with the HSK-A100)
+ Safe tool retention thanks to the toolholder
+ No disassembly required to transport up to 123 (SK50) or 183 (SK40) tools of size 80 and up to 63 tools of size 100 / 125
Applications and parts
Highlights
ê Innovation
Control technology
Overview
Technical data
The new, innovative wheel magazine provides the highest flexibility and productivity due to the fact that it can be set up during machining or idle time and thanks to its compactness, with up to 41 % smaller footprint. With the shortest tool call-up times of up 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.
–30°
+180°2
1
13
Precision Performance Efficiency CELOS®
DMU / DMC P / U / FD duoBLOCK® series
Powerful! 5X-torqueMASTER®
80 % higher torque
1,300 Nm, 37 kW power, SK50 / HSK-A100 tool holder and up to 8,000 rpm
B-axis with motor spindle5-axis universal milling head with gear-driven spindle. Significantly improved interference contour and higher stiffness!
duoBLOCK® 4th generation
duoBLOCK® 3rd generation
Competition
1 20 % more stiffness thanks to the
large YRT bearing
a further improvement to the already highly stiff B-axis concept with a 45° swivel plane
2 Integrated cable carrier
improved interference contour, higher quality thanks to a better sealed housing, longer life thanks to positively driven cables
20%
20 % more
stiffness
14
APP menu: Central access to all available applications
Precision Performance Efficiency CELOS®
Applications and parts
Highlights
ê CELOS®
Control technology
Overview
Technical data
standard
Standard user interfaces for all new high technology 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.
ERGOline® Control with 21.5" multi-touch-screen and Siemens.
15
DMU / DMC P / U / FD duoBLOCK® series
– From the idea to the finished product.CELOS® from DMG MORI enables consistent administration, documentation and visualisation of order, process and machine data. CELOS® can be extended with apps and is also compatible with your company’s existing infrastructures and programs.
CELOS® APPs facilitate quick and easy operation: three examples »
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
CAD-CAM VIEWVisualise workpieces and improve program data.
+ Direct remote access to external CAD / CAM workstations
+ Central master data as basis for component viewing
+ Immediate change options for machining steps, NC programs and CAM strategies, directly in the CNC system
+ 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 MANAGERSystematic planning, administration and preparation of work orders.
16
Applications and parts
Highlights
Control technology
ê Software and cycles
Overview
Technical data
STANDARD
MPC – Machine Protection
Control
Protecting machines with an emergency shut-off function
Vibration sensors on the milling spindle
Emergency shut-off function with teach function
Process monitoring by means of a bar graph
Milling spindle bearing diagnostics
Grinding
Machining with the highest surface precision
Grinding on a universal milling machine
For internal, external and face grinding
Truing cycles for truing the grinding wheel
SGS – Spindle Growth
Sensor
Improved precision by measuring spindle displacement
Measurement of the axial displacement of the rotor compared to the stator in real time
The CNC system compensates for the actual displacement
ATC – Application Tuning
Cycle
Process optimisation at the push of a button
Process-oriented feed-drive tuning
Minimised machining time with maximised component quality, irrespective of workpiece weight
Exclusive, optionally available DMG MORI technology cycles
3D quickSET®
Quick and easy for the highest precision
Toolkit for checking and correcting the kinematic precision of four- and five-axis machine configurations
All head variants and all table axes
Interpolation turning
Machining 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 package
Enhanced 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
Multi-tool
Save time by efficiently using tools
Several ”sister tools” on one tool holder
Save tool-changing time and magazine pockets
17
DMU / DMC P / U / FD duoBLOCK® series
High-end CNCs for safe machining and maximum precision.
Operate 4.5 on Siemens 840D solutionline
+ 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)
+ Graphic 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
+ DECKEL MAHO Package MDynamics, optional optimisation of surface finish and speed for smoothing surface transitions
* optional
Heidenhain 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®*
+ 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)
+ Dynamic look-ahead function with no line restrictions
+ Adaptive AFC feed controller as standard
+ Dynamic Efficiency with adaptive feed control AFC and trochoidal milling as standard (Active Chatter Control ACC optional)* optional
Besides Siemens 840D solutionline, the new duoBLOCK® generation is equipped with the new ERGOline® control panel with 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, 3D quickSET® and DMG Virtual Machine are available, which directly influence either workpiece quality or process optimisation.
18
Applications and parts
Highlights
Control technology
Overview
Technical data
DMU 80 P duoBLOCK® DMU 100 P duoBLOCK® DMU 125 P duoBLOCK®
Travels X / Y / Z mm 800 / 1,050 / 850 1,000 / 1,250 / 1,000 1,250 / 1,250 / 1,000
Table size mm ø 900 × 700 ø 1,100 × 900 ø 1,250 × 1,100
Load weight kg 1,500 2,200 2,500
Workpiece measurements mm
1,60
0
1,100
1,45
0
950
DMU / DMC P / U / FD duoBLOCK® series
4th Generation duoBLOCK® – for 30 % more precision, performance and efficiency!
Highlights:
+ Precision: up to 30 % higher component precision with the fully water-cooled feed drive
+ Performance: up to 30 % higher stiffness for maximum cutting performance
+ Efficiency: up to 30 % lower energy consumption with intelligent accumulators
+ Highest flexibility and shortest machining times with the new B-axis with 20 % greater stiffness, swivel range of 210° and integrated cable carrier
+ Fast, innovative wheel magazine with tool-changing time of 0.5 second and up to 453 tools within a small footprint
+ Fast rotary pallet changer for off-line workpiece set-up as standard
+ Milling and turning in one set-up with DirectDrive table and rotary speed up to 800 rpm
1,60
0
1,250
19
DMC 80 U duoBLOCK® DMC 125 U duoBLOCK®
Travels X / Y / Z mm 800 / 1,050 / 850 1,250 / 1,250 / 1,000
Table size mm ø 800 × 630 ø 1,000 × 800
Load weight kg 1,400 2,000
Workpiece measurements mm
Wheel magazine
Tables Pallet changer
Machine bed and column
1 to 5 wheels, up to 453 tools (DMC)
Milling heads
5X-torqueMASTER®
A-axis B-axis
The duoBLOCK® series modular design with B-axis as standard equipment.
1,45
0
900
NC Rotary table (DMU)
Milling / Turning table (DMU)
Turn-mill pallet table (DMC)
NC Pallet table (DMC)
Pallet changer (DMC)
1,60
0
1,250
20
DMU P / FD und DMC U / FD duoBLOCK® series
DMU FD and DMC FD duoBLOCK® – Maximum productivity through complete machining on one machine.
DMU 80 FD duoBLOCK® DMC 80 FD duoBLOCK® DMU 125 FD duoBLOCK® DMC 125 FD duoBLOCK®
Travels X / Y / Z mm 800 / 1,050 / 850 800 / 1,050 / 850 1,250 / 1,250 / 1,000 1,250 / 1,250 / 1,000
Table size mm ø 800 ø 800 × 630 ø 1,250 ø 1,100
Load weight kg 1,300 1,200 2,300 2,000
Workpiece measurements mm
1,45
0
900
1,45
0
900
Applications and parts
Highlights
Control technology
Overview
Technical data
1,60
0
1,250
1,60
0
1,250
21
Milling / turning cycles for every requirement
+ Exclusive milling / turning cycles by DECKEL MAHO
+ Imbalance determination, control and monitoring
+ Automatic speed adjustment in case of part vibration
+ Measuring cycles for the (L-) measuring probe: Calibrate measuring probe in the work area; undercuts, recesses, etc. measurement
+ Measurement data storage, distribution and transfer
+ Tilted turning with A-axis
+ Deployment of long tools in the workpiece
+ Grinding cycles, example: calibrating the dressing station and dressing of the grinding disc
+ Alternating speed for vibration-critical machining
* optional
Standard milling / turning cycles
+ Recessing, undercutting, metal removal, threading, etc.
+ Use of multi-station tools (up to nine cutters)
+ Milling and turning tool measurement
Milling and mill-turning
Grinding + For internal, external and face grinding
Highlights
+ Calibration cycle: Calibration of dressing station
+ Dressing cycle: Dressing the grinding wheel
+ Surface grinding cycle: Grinding flat surfaces on round, centrally clamped workpieces
+ Longitudinal grinding cycle: Grinding cylindrical surfaces on centrally clamped workpieces
Grinding package measures
+ Linear guideways and ball screws with additional wipers
+ Sealing air for all linear scales
+ Reduction of the lubrication intervals
+ Observance of additional maintenance instructions
+ Dressing station
+ Centrifugal filter
+ Sensors for dressing, tool measurement and process-oriented probing
22
DMU / DMC P / U / FD duoBLOCK® series
Example applications
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Example applications
ê Technology integration
Knuckle – dimensions (unfinished part): 270 × 210 × 320 mm Machining time: 24 hours, clamping operations: 3
Sector Motor sport Spindle 18,000 rpm
Number of tools 77 Power 35 kW
Material Aluminium alloy Torque 130 Nm
Machining focus: Surfaces from 0.4 Ra up to 0.6 Ra, precise position and size tolerance, contains 3 + 2 axis machining and full five-axis simultaneous machining
Chassis components – dimensions: 1,080 × 610 × 210 mm Machining time: 23 hours, clamping operations: 3
Sector Aerospace Gear-driven 6,300 rpm
Number of tools 21 Power 32 kW
Material Titanium 10-2-3 Torque 1,100 Nm
Machining 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
Tube mould – dimensions: 680 × 470 × 335 mm Machining time: 4 hours 56 min., clamping operations: 2
Sector Mould making Spindle 12,000 rpm
Number of tools 6 Power 52 kW
Material Aluminium / C45 Torque 430 Nm
Machining focus: High surface finish of up to Ra 0.35, 3 + 2 axis and five-axis simultaneous machining, two components on the machine
Mould for manufacturing PET bottles – dimensions: 400 × 360 × 400 mmMachining time: 86 min., clamping operations: 3
Sector Mould making Spindle 12,000 rpm
Number of tools 62 Power 52 kW
Material GGG60 Torque 430 Nm
Machining focus: Complete machining including in-process measuring with automatic contours and fully automatic serial production by means of a pallet system (FMS) including workpiece loading by a robot
Drilling head – dimensions: 330 × 40 × 400 mmMachining time: 18 hours, clamping operations: 1
Sector Oil / gas drilling sector Spindle 12,000 rpm
Number of tools 20 Power 44 kW
Material 21CrNiMo2 (1.6523) Torque 288 Nm
Machining 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
23
1 2 3 4 5 6 7 8 9 10
Complete machining process:1 machine4 machining steps300 % higher productivity
Conventional machining process:3 machines10 machining steps
MillingTurningDrilling
Threading
Set-upReposition
MillingTurningDrilling
Threading
Unclamp
Machine 1
TurningSet-up
RepositionTurning Set-up
MillingDrilling
Threading
Set-upReposition
MillingDrilling
ThreadingSet-up
Precision turning
Unclamp
Machine 1 Machine 2 Machine 3
DMU / DMC 80 FD, DMU / DMC 125 FD – complete machining process
Single-purpose machines – conventional machining process
16 years of turn-mill technology with over 1,000 machines sold
+ Complete machining, including milling and turning, on one machine in a single clamping with Direct Drive technology for up to 800 rpm
+ The strongest turn-mill table in its class, rated at up to 5,400 Nm
+ Lower unit production costs with the highest precision thanks to faster machining; lower handling costs thanks to reduced idle times and process steps
+ Exclusive DMG MORI turn-mill cycles
+ Less time needed and higher precision thanks to easy set-up
+ Less investment and lower space requirements with the use of just one machine
+ Oil mist filter and shatterproof safety glass panels as standard
+ Integral tool measurement
+ High workpiece weights of up to 2,300 kg and maximum workpiece diameter of 1,250 mm
+ Electronic balancing
Maximum productivity thanks to complete machining with
the duoBLOCK® FD series
DMG gearMILL® software – the software
package for various gear production operations
Highlights of the DMG gearMILL® software
+ Calculation of the tooth geometry of spur gears, straight and angular gear teeth, double angular gear teeth (double helical gears), couplings
+ Calculation of the tooth geometry of bevel spur gears with straight and angular gear teeth, spiral-toothed, shaft angle even or uneven 90°, with and without offset (hypoid gear)
+ Calculation of the tooth geometry of worm gears, worm gear-toothed module, ZA flank profile, ZN flank profile, ZI flank profile
+ Generation of individual contact patterns
+ Individual tooth flank and profile modifications
+ Generation of four- and five-axis milling paths
+ Generator for 3D measurement data
+ Machine simulation
+ Quality control on the CNC milling machine with output protocol
+ Custom training concept with technology transfer
1 2
3
24
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Example applications
ê Technology integration
DMG gearMILL®
Gear production – complete machining.
Highlights
+ Complete machining on one machine for lower overall investment and space requirements:
Turning Drilling Gear hobbing
+ Soft and hard machining
+ Attainable gear quality Bevel spur gear DIN ≤5 Spur gear DIN ≤6 (depending on the pitch circle diameter)
1: Turning 2: Tapping 3: Gear hobbing with standard tools
1 32
25
Advantages of ULTRASONIC
+ Reduced process forces for outstanding surface finishes Ra <0.2 µm, minimised micro- cracks in the material, longer tool service life
+ Up to twice the removal rates compared to conventional grinding processes
+ The cutting edge sharpens itself thanks to micro-splinters in the diamond grains
+ Optimised particle removal in the active zone
The operating principle – flexible ULTRASONICS integration via HSK
When changing to the HSK tool holder, inductive transmission of the ULTRASONIC frequency takes place from the fixed transmitter segment at the spindle tip to the rotating coil on the HSK holder.
Receiver Coil
Transmitter Segment
ULTRASONIC HSK-63- actuator system
ULTRASONIC HSK-100- actuator system
max. 18,000 rpm max. 12,000 rpm
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 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.
1: Finish grinding of a chemically resistant Si-quartz pump housing on an ULTRASONIC 125 FD duoBLOCK® 2: ULTRASONIC 60 FD duoBLOCK®: Thin-walled lightweight structures in a Zerodur mirror carrier 3: Silicon nitride camera housing
26
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Tool magazines
ê Milling heads
DMU / DMC P / U / FD duoBLOCK® series
Innovative milling heads and intelligent tool management.
A-axis + More flexible production of complex shapes
thanks to negative angles up to –30°
+ 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°
B-axis + Complete five-axis milling performance
+ 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 behaviour regardless of the direction of the machining forces
+ No axis clamping necessary
+ Also available as a 5X-torqueMASTER® gear-driven spindle with up to 1,300 Nm torque
A-axis B-axis
SK40 / CAT 40 / HSK-A63 SK40 / CAT 40 / HSK-A63
– SK50 / CAT 50 / HSK-A100
NEW!
1
2
3
4
27
Principle of operation1 The selected tool is on wheel 2
2 Free path (three empty pockets) for the shuttle on wheel 1 by turning the wheels
3 The shuttle (double gripper) travels to the selected tool; lift to release the tool from the holder, shuttle travels to spindle
4 Exchange / replacement of the tool and retraction of the double gripper
* FD only with HSK-A tool holder, ** DMU 80 P / FD duoBLOCK®
standard, optional
SK40 / HSK-A63 SK50 / HSK-A100
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 80 P / FD – – – – – – –
DMC 80 U / FD – –
DMU 125 P – – – – – – – – –
DMU 125 FD – – – – – – – – – –
Maximum workpiece dimensions and tool magazine configurations in sizes 80 and 125
SK40 / CAT 40 / HSK-A63
Tool holder SK40 (HSK-A63)*
Magazine type / maximum 453 Pockets
Measurements (adjacent pockets occupied) mm ø 80 // Length 550** / 650
Measurements (adjacent pockets free) mm ø 120 // Length 550** / 650
Boring bar measurements mm ø 280 × 160 // Length 350 (400*)
Weight kg 15
Maximum torque Nm 25
Chip-to-chip time (HSK) sec. 4.2 (applies to the 80 series)
SK50 / CAT 50 / HSK-A100
Tool holder SK50 (HSK-A100)*
Magazine type / maximum 303 Pockets
Measurements (adjacent pockets occupied) mm ø 110 // Length 550** / 650
Measurements (adjacent pockets free) mm ø 200 // Length 550** / 650
Boring bar measurements mm ø 400 × 280 // Length 400 (470*)
Weight kg 30
Maximum torque Nm 70
Chip-to-chip time (HSK) sec. 4.5 (applies to the 80 series)
41 2 3
5
28
1: Manufacturing system with three machining centres, two- level linear storage with 52 workpiece positions and central tool magazine with 400 pockets2: Manufacturing cell for hydraulic components 3: Fully automated production of gearboxes 4: DMC H duoBLOCK® with RS7 / 12 5: RS7 rotary storage
Flexible Manufacturing cell
+ 6 × DMC H duoBLOCK®
with workpiece handling
+ Prioritised processing on the next available machine
+ Simultaneous machining of three different components
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Automation
29
DMU / DMC P / U / FD duoBLOCK® series
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
RS7: 5-pallet rotary storage (7 pallets in the system) – – –
RS12: 10-pallet rotary storage (12 pallets in the system) – –
Container solutions – –
Flexible pallet systems (linear storage) – –
Configuration levels / periphery
Central tool magazines
Wash
Deburr
Measure
Workpiece marking
25 kW 100%
87 Nm 100%
35 kW 40%
130 Nm 40%
40
2014
8
5
2.51.25
0.6
500
315
25012580
31.512.5
5
Torque(Nm)
Spe
ed(r
pm)
Power(kW)
20
2,20
0
4,00
0
6,30
0
12,0
00
14,0
00
25 kW 100%
35 kW 40%
86 Nm 100%
130 Nm 40%
35
20
8
5
1.6
1
0.6
500
315
12580
20
10
5
Torque(Nm)
Spe
ed(r
pm)
Power(kW)
20
2,00
0
15,0
00
18,0
00
52 kW 40%
42 kW 100%
280 Nm 100%
404 Nm 40%50
45
40
35
30
25
400
350
300
250
Torque(Nm)
200
150
100
50
20
15
10
5
15,0
00
1,00
0
1,31
01,
710
100
10,0
00
Spe
ed(r
pm)
Power(kW)
32 kW 100%
44 kW 40%
187 Nm 100%
288 Nm 40%
40
25
10
53.152
630
400
200
160
10063
5
Torque(Nm)
Spe
ed(r
pm)
Power(kW)
20
1,00
01,
400
2,45
0
4,06
0
8,00
0
10,0
00
12,0
00
42 kW 100%
300 Nm 100%
52 kW 40%
430 Nm 40%
50
20
10
5
2
1
0.9
1,000
500
250
100
50
25
10
5
Torque(Nm)
Spe
ed(r
pm)
Power(kW)
20 50
1,00
0
2,50
0
6,30
0
12,0
00
45 kW 100%
580 Nm 100%
54 kW 40%
77.5 kW 15%700 Nm 40%
1,000 Nm 15%80
50
40
15
1,000
700
600
100
Torque(Nm)
Spe
ed(r
pm)
Power(kW)
20 740
3,00
0
9,00
0
30
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Power diagrams
HSK-A100 motor spindle
15,000 rpm / 52 kW / 400 Nm
SK50 / HSK-A100 motor spindle
12,000 rpm / 44 kW / 288 Nm
powerMASTER SK50 / HSK-A100 motor spindle
9,000 rpm / 54 kW / 700 Nm
SK50 / HSK-A100 motor spindle
12,000 rpm / 52 kW / 430 Nm
SK40 / HSK-A63 motor spindle
12,000 rpm / 35 kW / 130 Nm
SK40 / HSK-A63 motor spindle
18,000 rpm / 35 kW / 130 Nm
DMU / DMC P / U / FD duoBLOCK® series
Power diagrams
All data collected with 40 % DC
27 kW 100%
831 Nm 100% 37 kW 40%
1,300 Nm 40%
20 190
400
1,40
0
8,00
0
64
32
16
8
4
2
2,048
512
128
32
Spe
ed(r
pm)
Power(kW)
Torque(Nm)
31
5X-torqueMASTER® SK50 / HSK-A100 geared spindle
8,000 rpm / 37 kW / 1.300 Nm
UniversalWith a large spindle range from the 18,000 rpm motor spindle rated at 130 Nm to the new high-performance 9,000 rpm powerMASTER motor spindle rated at up to 1,000 Nm and 77 kW.
Spindle range
Speed // tool holderPower (40 / 100 % DC), torque (40 / 100 % DC)Spindle run-up time
12,000 rpm // SK40 / HSK-A63*35 / 25 kW, 130 / 86 Nm0 – 12,000 rpm: 1.4 sec.
18,000 rpm // SK40 / HSK-A63*35 / 25 kW, 130 / 86 Nm0 – 18,000 rpm: 2.2 sec.
8,000 rpm // SK50 / HSK-A100*37 / 27 kW, 1,300 Nm / 835 Nm
9,000 rpm // SK50 / HSK-A100*77.5** / 54 / 45 kW, 1,000** / 700 / 580 Nm0 – 9,000 rpm: 2.2 sec.
12,000 rpm // SK50 / HSK-A100*44 / 32 kW, 288 / 187 Nm0 – 12,000 rpm: 3.5 sec.
12,000 rpm // SK50 / HSK-A100*52 / 42 kW, 430 / 300 Nm0 – 12,000 rpm: 4.5 sec.
15,000 rpm // HSK-A100*52 kW, 404 Nm0 – 12,000 rpm, 4.7 sec.
* optional, ** 15 % DC (2 min)
Spindle data only applicable to clockwise rotation. Data for anti-clockwise rotation available on request.
1 2 3
32
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Machining examples
12,000 rpm / 35 kW / 130 Nm motor spindle
High-performance milling High-performance drilling Tapping
Workpiece material Steel (Ck45) Steel (Ck45) Steel (Ck45)
Material removal rate 224 cm3/min 205 cm3/min –
Tool Indexable insert cutter D = 80 (6 inserts)
Modular drill D = 44 Tap M20
Spindle speed 995 rpm (Vc = 250 m/min) 905 rpm (Vc = 125 m/min) 240 rpm (Vc = 15 m/min)
Feed 1,492 mm/min (Fz = 0.25 mm) 135 mm/min (Fz = 0.15 mm) 597 mm/min (Fz = 2.5 mm)
Cutting depth / width 2.5 / 60 mm – / – – / –
1 2 3
18,000 rpm / 35 kW / 130 Nm motor spindle
High-performance milling High-performance drilling Tapping
Workpiece material Steel (Ck45) Steel (Ck45) Steel (Ck45)
Material removal rate 242 cm³/min 214 cm3/min –
Tool Indexable insert cutter D = 80 (6 inserts)
Modular drill D = 44 Tap M24
Spindle speed 995 rpm (Vc = 250 m/min) 905 rpm (Vc = 125 m/min) 80 rpm (Vc = 6 m/min)
Feed 1,611 mm/min (Fz = 0.27 mm) 141 mm/min (Fz = 0.16 mm) 240 mm/min (Fz = 3.0 mm)
Cutting depth / width 2.5 / 60 mm – / – – / –
1 2 3
DMU / DMC P / U / FD duoBLOCK® series
High-performance milling, drilling and tapping.
4 5 6
33
powerMASTER 9,000 rpm / 77.5* kW / 1,000* Nm torque spindle
High-performance milling High-performance drilling Tapping
Workpiece material Steel (Ck45) Steel (Ck45) Steel (Ck45)
Material removal rate 1,680 cm3/min 900 cm3/min –
Tool Indexable insert cutter D = 100 (11 inserts)
Modular drill D = 100 Tap M42
Spindle speed 900 rpm (Vc = 280 m/min) 673 rpm (Vc = 200 m/min) 60 rpm (Vc = 8 m/min)
Feed 14,000 mm/min (Fz = 1.42 mm) 115 mm/min (Fz = 0.18 mm) 270 mm/min (Fz = 4.5 mm)
Cutting depth / width 2 / 60 mm – / – – / –
* 15 % DC (2 min)
4 5 6
12,000 rpm / 44 kW / 288 Nm motor spindle
High-performance milling High-performance drilling Tapping
Workpiece material Steel (Ck45) Steel (Ck45) Steel (Ck45)
Material removal rate 812 cm3/min 708 cm3/min –
Tool Indexable insert cutter D = 100 (7 inserts)
Modular drill D = 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 = 0.8 mm) 371 mm/min (Fz = 3.5 mm)
Cutting depth / width 3.5 / 80 mm – / – – / –
4 5 6
12,000 rpm / 52 kW / 430 Nm torque spindle
High-performance milling High-performance drilling Tapping
Workpiece material Steel (Ck45) Steel (Ck45) Steel (Ck45)
Material removal rate 864 cm3/min 800 cm3/min –
Tool Indexable insert cutter D = 160 (9 inserts)
Modular drill D = 80 Tap M42
Spindle speed 1,000 rpm (Vc = 500 m/min) 900 rpm (Vc = 225 m/min) 46 rpm (Vc = 6 m/min)
Feed 1,800 mm/min (Fz = 0.2 mm) 144 mm/min (Fz = 0.16 mm) 207 mm/min (Fz = 4.5 mm)
Cutting depth / width 4 / 120 mm – / – – / –
4 5 6
34
Applications and parts
Highlights
Control technology
Overview
Technical data
DMU / DMC P / U / FD duoBLOCK® series
Technical data
DMU 80 P / FD dB® DMU 100 P dB® DMU 125 P / FD dB®
Working area
X-, Y- and Z-axes mm 800 × 1,050 × 850 1,000 × 1,250 × 1,000 1,250 × 1,250 × 1,000
Distance from spindle centre to table
Horizontal milling head mm 50 to 900 50 to 1,050 50 to 1,050
Vertical milling head mm –300 to 750 –300 to 950 –300 to 950
Distance from spindle nose to table
Horizontal milling head mm –200 to 850 –200 to 1,050 –200 to 1,050
Vertical milling head mm 150 to 1,000 150 to 1,150 150 to 1,150
Table / Workpiece mounting surface / Workpieces
NC rotary table rpm 40 35 35
Table size mm Ø 900 × 700 Ø 1,100 × 900 Ø 1,250 × 1,100
Maximum table load kg 1,500 2,200 2,500
Turn-mill table (FD) rpm 800 – 500
Table size mm Ø 800 – Ø 1,250
Maximum table load kg 1,300 – 2,300
NC-controlled swivelling milling head (B-axis) standard standard standard
Swivel range (0 = vertical / 180 = horizontal) Degrees –30 to 180 –30 to 180 –30 to 180
Rapid traverse and feed rpm 30 30 30
Five-axis options
5X torque MASTER® – NC-controlled B-axis with gear-driven spindle
Swivel range (0 = vertical / 180 = horizontal) Degrees 0 to +180 0 to +180 0 to +180
Rapid traverse and feed rpm 30 30 30
NC-controlled swivelling milling head (A-axis)
Swivel range (0 = vertical / –90 = horizontal) Degrees –120 / +10 –120 / +10 –120 / +10
Rapid traverse and feed rpm 30 30 30
Main drive
Integrated motor spindle rpm 12,000 12,000 12,000
Tool holder SK 40 / HSK-A63* SK 40 / HSK-A63 SK 40 / HSK-A100*
Power (40 / 100 % DC) kW 35 / 25 35 / 25 35 / 25
Torque (40 / 100 % DC) Nm 130 / 86 (FD: 111 / 77)
130 / 86 130 / 86(FD: 288 / 177)
Tool changer
Tool holder SK40 SK40 SK40
Tool magazine wheel Pockets 40 (63, 123) 40 (63, 123) 40, 63 (123)
Linear axis (X / Y / Z)
Feed speed, rapid traverse speed m/min 60 60 60
Acceleration m/s2 7 6 / 5 / 6 6 / 5 / 6
Feed force kN 13 / 13 / 9 15 / 18 / 18 15 / 18 / 18
P max. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 µm 5 6 6
P smax. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 µm 4 5 5
Machine data
Space requirements of base machine plus chip conveyor, without internal coolant supply m2 18.7 26 27
Machine height (standard machine) m 3.1 3.4 3.4
Machine weight kg 15,500 24,500 26,000
*HSK-A tool holder included as standard with mill/turn machines
35
DMC 80 U / FD dB® DMC 125 U / FD dB®
Working area
X-, Y- and Z-axes mm 800 × 1,050 × 850 1,250 × 1,250 × 1,000
Distance from spindle centre to table
Horizontal milling head mm 50 to 900 50 to 1,050
Vertical milling head mm –300 to 750 –300 to 950
Distance from spindle nose to table
Horizontal milling head mm –200 to 850 –200 to 1,050
Vertical milling head mm 150 to 1,000 150 to 1,150
Table / Workpiece mounting surface / Workpieces
NC rotary table rpm 40 35
Table size mm Ø 800 × 630 Ø 1,000 × 800
Maximum table load kg 1,400 2,000
Turn-mill table (FD) rpm 800 –
Table size mm Ø 800 –
Maximum table load kg 1,200 –
NC-controlled swivelling milling head (B-axis) standard standard
Swivel range (0 = vertical / 180 = horizontal) Degrees –30 to 180 –30 to 180
Rapid traverse and feed rpm 30 30
Five-axis options
5X torque MASTER® – NC-controlled B-axis with gear-driven spindle
Swivel range (0 = vertical / 180 = horizontal) Degrees 0 to +180 0 to +180
Rapid traverse and feed rpm 30 30
NC-controlled swivelling milling head (A-axis)
Swivel range (0 = vertical / –90 = horizontal) Degrees –120 / +10 –120 / +10
Rapid traverse and feed rpm 30 30
Main drive
Integrated motor spindle rpm 12,000 12,000
Tool holder SK 40 / HSK-A63* SK40 / HSK-A 100*
Power (40 / 100 % DC) kW 35 / 25 35 / 25
Torque (40 / 100 % DC) Nm 130 / 86 (FD: 111 / 77)
130 / 86(FD: 288 / 177)
Tool changer
Tool holder SK40 SK40
Tool magazine wheel Pockets 63 (123 / 183 / 273 / 363 / 453)
63 (123 / 183 / 273 / 363 / 453)
Linear axis (X / Y / Z)
Feed speed, rapid traverse speed m/min 60 60
Acceleration m/s2 7 6 / 5 / 6
Feed force kN 13 / 13 / 9 15 / 18 / 18
P max. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 µm 5 6
P smax. (X / Y / Z) – VDI DGQ 3441 / ISO-230-2 µm 4 5
Machine data
Space requirements of base machine plus chip conveyor, without internal coolant supply m2 21.4 30.4
Machine height (standard machine) m 3.4 3.9
Machine weight kg 20,500 28,500
36
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Options
DMU 80 P / FD dB® DMU 100 P dB® DMU 125 P / FD dB®
Manual table options
Hydraulic clamping for table
Tool holder
HSK-A63 / BT40 / CAT40 HSK-A for turn-mill machines as standard
HSK-A100 / BT50 / CAT50 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)
Four-colour signal lights
Coolant / Chip disposal
Production package with 600 litre coolant unit, paper band filter, 40 bar internal coolant supply standard standard standard
Production 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 1-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
Control console for tool magazine loading station
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
optionally available
DMU / DMC P / U / FD duoBLOCK® series
Options
DMG MORI recommends
37
DMC 80 U / FD dB® DMC 125 U / FD dB®
Manual table options
Hydraulic clamping for table
Tool holder
HSK-A63 / BT40 / CAT40 HSK-A for turn-mill machines as standard
HSK-A100 / BT50 / CAT50 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)
Four-colour signal lights
Coolant / Chip disposal
Production package with 600 litre coolant unit, paper band filter, 40 bar internal coolant supply – –
Production package with 980 litre coolant unit, paper band filter, 40 bar internal coolant supply standard standard
80 bar internal coolant supply frequency-controlled
Temperature control for the 600 / 980 litre internal coolant supply system
Coolant gun with 1-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
Control console for tool magazine loading station
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
3,0
59 T
ran
spor
t h
eig
ht
4,465
3,6
55
Op
tion
oil
mis
t fi
lter
975
3,4
27 2,7
48
2,4
34
Tran
spor
t w
idth
wit
hou
t m
agaz
ine
5,534
952
3,2
92.
5 Tr
ansp
ort
hei
gh
t w
ith
out
mag
azin
e
3,8
55.
5 O
pti
onal
oil
mis
t fi
lter
4,964
4,2
23
4,2
23 3,
25
3.5
Tran
spor
t w
idth
3,2
53
.5Tr
ansp
ort
wid
th
6,1446,144
R1,308.5
Chipconveyer
470
952
Out
put
heig
hte
3,29
2.5
Tran
spor
t he
ight
wit
hout
mag
azin
e
3,46
2 M
ax. c
law
hei
ght
(ste
el c
over
)
3,85
5
4,964
R1,308.5
3,57
8 Tr
ansp
ort
wid
th
Hydraulic clamping unit
6,144
Chip conveyer
38
Applications and parts
Highlights
Control technology
Overview
Technical data
ê Floor plans
DMU 80 P / FD duoBLOCK® floor plan
Side view Plan view with wheel magazine, 40 pockets
DMU 100 P duoBLOCK® floor plan
Side view Plan view with wheel magazine, 63 pockets
DMU 125 P / FD duoBLOCK® floor plan
Side view Plan view with wheel magazine, 63 pockets
DMU / DMC P / U / FD duoBLOCK® series
Floor plans
3,6
58
Op
tion
al o
il m
ist
filt
er
3,0
59 T
ran
spor
t h
eig
ht
975
4,999
Chip conveyer
R1,309
6,068
2,74
9 Tr
ansp
ort
wid
th
2,43
4
952
3,3
19.5
Tr
ansp
ort
hei
gh
t w
ith
out
mag
azin
e
3,8
55.
5 O
pti
on o
il m
ist
filt
er
5,822
4,3
48
4,3
48
5,8225,822
3,4
98
.5 T
ran
spor
t w
idth
3,4
98
.5 T
ran
spor
t w
idth
R1,300
Chipconveyer
39DMC 125 U / FD duoBLOCK® floor plan
Side view Plan view with wheel magazine, 63 pockets
DMC 80 U / FD duoBLOCK® floor plan
Side view Plan view with wheel magazine, 63 pockets
PR
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