DMU 600 P XXL milling machines - DMG Mori · PDF fileXXL milling machines. ... DMU 600 G linear with its high gantry design is dedicated to the dynamic and ... with C / A and C / B

DMU 600 P

DMU 600 FD

DMU 600 G linear

www.dmgmori.com

Universal and HSC machines for

5-side / 5-axis machining of large workpieces

XXL milling machines

Die & mouldAluminium mould tool for a vehicle hood; Dimensions 2,000 × 2,200 × 450 mm

02

5-axis machines in highly stable portal and gantry design generate maximum precision with the highest dynamics. Besides drilling and milling work, the mill-turn machines also allow turning in the same set-up. Large traverses and high table loads up to 40 t make this possible. The dual-table configuration allows set up during machining for maximum productivity.

DMU 600 P / FD and DMU 600 G linear

The new benchmark in 5-axis machining.

Applications and parts

Machine and technology

Control technology

Technical data

03Tool and mould makingBumper mould

Energy technologyPelton wheel

AerospaceIntegral component

Mechanical engineeringSpiral bevel gear

04

The portal machine DMU 600 P with a traverse of 6 m is able to

machine workpieces weighing

up to 40 tonnes

+ Portal design for maximum precision and dynamics up to 3 m/s2

+ Bed and column made from EN-GJS-600-3 (GGG60) cast iron with high static temperature stability and damping characteristics

+ Outstanding cutting power with up to 2,500 Nm

DMU 600 P

+ Modular concept based on the proven portal design

+ In spite of the high maximum load, it features rapid traverse and feed speeds up to 30 m/min in the X / Y / Z axes

+ Rack and pinion drive in the X / Y axes, ball screws in the Z / W axes

+ Consistently high precision with a water-cooled machine structure and drive elements

+ Vertically adjustable cross rail (W axis) optionally available

The XXL range for all sizes and applications!

Gigantic!Large machines designed intelligently – dynamic machining of large parts up to 40 t: The DMU 600 P, together with the universal machines in the 210, 270 and 340 series, forms a uniquely successful range of portal machines for large workpieces. The DMU 600 G linear with its high gantry design is dedicated to the dynamic and precise 5 axes machining e.g. in Die & mould and Aerospace applications.



ê Highlights

Control technology

Technical data

05

Designed for highly dynamic

finishing processes (milling)

with the highest standards of

contouring accuracy

DMU 600 G linear

+ Ram in the Z axis with strokes up to 2,000 mm

+ Y axis crossbeam with 3,500 mm and optional 4,500 mm traverse

+ The X axis, 6,000 mm as standard, can be freely extended

+ Consistently high precision with a water-cooled machine structure and drive elements; optimised ThermoShield technologies

+ Long-term accuracy with the contact-free drive (wear-free), 5-year warranty on linear motors

+ Direct Drive technology in all axes for superior surface quality and highest dynamic (linear drives: X, Y, Z axes; torque drives: A, C rotary axes)

+ Large closed-loop control spectrum and free from gear meshing frequencies

+ Fewer contouring errors compared to rack and pinion drive technology (approx. 30 % fewer)

The high-gantry machine DMU 600 G linear

06

Cast iron with large dimensions guarantees high stiffness and stability. Comprehensive cooling achieves remarkable long-term accuracy and precision. The entire feed drive is cooled, which guarantees higher workpiece accuracy.

Maximum stiffness and high temperature stability

+ Portal fixed to the foundation and bolted to machine bed

+ Optimised machine concept based on FEM and modal analysis in portal design

+ Large dimensions with high temperature stability

+ Machine bed, column and crossbeam from EN-GJS-600-3 (GGG60) with excellent damping characteristics



ê DMU 600 P

Control technology

Technical data

DMU 600 P

True greatness knows no limits!

07

All relevant heat sources are liquid-cooled

+ All drive motors

+ Additional cooling of the X axis drive

+ Interchangeable heads, swivel axes including main drive (cooling of structure, drives and components)

+ Z axis: Ball screw and bearing

+ Ram guideways

+ Cutomised cooling to suit ambient conditions

+ Modern machine enclosure to insulate the machine structure from external temperature influences

Compensation of the main sources of heat

08

Designed and built for the best surface quality and the highest dynamics with innovative, contactless linear motor drive technology. The machine structure has been optimised for static and dynamic stiffness and guarantees consistent temperature stability through comprehensive temperature control of the structure, components and guideways. Energy-efficient consumption with efficient cooling technology and on-demand accumulator activation.

DMU 600 G linear

Unique precision with linear motors!

Consistently high precision with temperature stability of the machine structure

+ Cooled feed axes: Precision cooler for primary compo-nents, cooling bands for secondary components

+ Cooled linear guideways in the X / Y / Z axes

+ Cooled main spindle, including sensor-based spindle compensation

+ Optional TTC (temperature thermal control) package: ThermoShield, coolant temperature control and structural cooling

+ Geometric stability with structural cooling, prevents components from warping as a result of temperature gradients

+ Energy-efficient coolant units

+ Optional conncection to on-site / customer-site cooling circuit



ê DMU 600 G linear

Control technology

Technical data

Machine structure

+ Maximum static and dynamic stiffness with FEM-optimised machine structure from EN-GJS-600-3 (GGG60) _ Crossbeam _ X axis beds _ Ram _ Y / Z slide

The XXL Centre – the world's most modern XXL machine production plant: The new XXL Centre at DECKEL MAHO in Pfronten.

Temperature control

Consistently high precision with a liquid-cooled machine structure and drive components

Maximum precision and optimal contouring accuracy

+ Long-term accuracy with contact-free drive (wear-free) 5-year warranty on linear motors

+ Optimal drive stiffness with linear motors (theoretically infinite)

Axial dynamic linear motor

Jerk m/s³ Three times higher than with rack and pinion drive

Path acceleration m/s² Two times higher than with rack and pinion drive

Kv factor m/(min × mm) Three times higher than with rack and pinion drive

Axis speed m/min 45 (30 with rack and pinion drive)

Axial precision linear motor

Kv factor m/(min × mm) Three times higher than with rack and pinion drive

Positioning / circularity µm Two times lower than with rack and pinion drive

Consistent dynamic meets

the highest standards

+ Connected directly to the machine structure

+ Very high surface quality due to absence of gear meshing frequencies from the drive train

+ Closed-loop control spectrum

+ Improved axis parameters compared to conventional drive technology

Linear motors + Optimal surface quality with

contact-free drive components

+ Maximum precision

+ High uptime thanks to maintenance-free motors

+ > 15 years of experience with linear drive technology in the DMG MORI Group: More than 30 machine types

Legendary technology made contemporary: The dynamic linear drive from DMG MORI is at home in every workshop.

Individual The right ram and milling head for every application.

+ Modular concept based on proven portal elements

+ Portal design for maximum precision and dynamics up to 3 m/s²

+ Single-piece EN-GJS-600-3 (GGG60) cast iron substructure / bed

+ Portal attached to foundation and bolted to machine bed for maximum stiffness

+ Ram with 600 mm nominal cross-section, up to 1,500 mm travel and up to 2,500 Nm

+ Workpiece weight up to 40 tonnes

+ Rack and pinion drive in the X / Y axes, ball screws in the Z / W axes

+ Short installation times due to user-friendly design of individual modules



ê Modular system

Control technology

Technical data

DMU 600 P

Large parts up to 40 tonnes, traverses up to 18 m and Ram with up to 1,500 mm travel.

13

DMU 600 P DMU 600 FD

Travel X / Y / Z mm 6,000 / 4,200 (4,800)* /1,250 (1,500)*

6,000 / 4,200 /1,250 (1,500)*

W axis mm 1,600 (2,000)* 1,600 (2,000)*

Table size mm 5,000 × 2,800 5,000 × 2,800 / ø 3,200

Maximum table load kg 25,000 (40,000)* 25,000 (35,000)*

Maximum workpiece dimensions mm

* Optional ** Passage without interchangeable milling heads

max. 6,000

Portal 3,500

max, 3.000

2,60

0**

(3,0

00**

)*

2,60

0**

(3,0

00**

)*

max. ø 5,000 (6,000 × 3,000)

Portal 3,500

Portal, crossbeam, X slide Z axis ram and interchangeable milling heads

Z axis ram for interchangeable milling heads

Interchangeable heads

Tool magazines

Tables

Rigid table5,000 × 2,800 mmDual-table configuration

Mill / turn table*ø 3,200 mm

Tool store with 268 tools

Chain magazine with up to 180 tools

* Optional

Y = 4,200 mm(4,800 mm)*

Modules of the DMU 600 P

Milling head changer 3 – 6* stations

Z = 1,250 mm(1,500 mm)*

W = 1,600 mm*(2,000 mm)*

1,000 mm

C axis

X = 6,000 mm

Basic construction with W axis*

+ Modular concept based on proven XXL modules

+ High-gantry design for unbeatable dynamics

+ Single-piece EN-GJS-600-3 (GGG60) casting for Y crossbeam and X traverse

+ Foundation / side walls made of special concrete

+ Flexible interchangeable milling heads with C / A and C / B kinematics similar to the DMU 600 P

+ Ram with optimised interference contour with up to 2,000 mm travel and 1,445 Nm

+ Clamping platens in various widths and lengths and with a maximum point load of 15,000 kg/m2

+ Machine concept ideal for wet and dry machining

+ Non-contact linear drives in all linear axes with a 5-year warranty and 45 m/min axial speed

+ Integrated C axis with n × 360° and Direct Drive available

+ C axis with Direct Drive integrated into the ram optionally available as an axis with endless rotation

DMU 600 G linear

Maximum precision and dynamics.

14



ê Modular system

Control technology

Technical data

Chain-type tool magazine and head changing stations Z axis ram Interchangeable milling heads


Chain magazine with 30 / 60* / 120* / 180* tools

Changing station for milling heads, 2 – 5* pockets

Portal, crossbeam, chip conveyor

Tables

Clamping platen 3 × 5 m

Clamping platen 4 × 5 m*

Chip conveyor

DMU 600 G linear

Travel X / Y / Z mm 6,000 / 3,500 (4,500)* /1,500 (2,000)*

W axis mm –

Table size mm 5,000 × 3,000

Point load kg/m2 15,000

Maximum load kg/m 30,000

Maximum workpiece dimensions mm

* Optional, ** Passage without interchangeable milling heads

Modules of the DMU 600 G linear

15

Z = 2,000 mm* Z = 1,750 mm* Z = 1,500 mm

as standard

SK50 / HSK100 and HSK63

X = 6,000 mm

Y crossbeam = 4,500 mm*

* Optional

Z = 1,500 mm

Y = 3,500 mm

5,000 (n+1)*

Portal 4,700 / 5,700*

3,000 (4,000)*

2,50

0(3

,000

**)*

16

Due to the high long-term accuracy of their stable portal and gantry design, optimal accessibility of their working areas and set-up stations through the large doors and their fully enclosed working areas, the machines in the 600 series are the benchmark for 5-sided to 5-axis simultaneous machining.


Built-in C axis with Direct Drive technology as standard, selective with ±185° or as an endless rotating axis n × 360°.

3-axis machining up to 5-axis simultaneous machining

+ Interchangeable milling heads are held by a ram with 1,250 (1,500 to 2,000)* mm traverse (Z axis) and integrated C axis, swivel range ±185° (optional endless 360° rotation)

+ Vertical milling head with gears for 3-axis rough machining with 1,445 (2,500**) Nm torque

+ Gear-driven angular milling heads, e.g. 800 mm long

+ B axis head for simultaneous 5-axis milling _ Torque model with 1,445 Nm _ Built-in 28,000 rpm motor spindle with 38 Nm torque

or 12,000 rpm motor spindle with 300 Nm torque

+ A axis motor spindle head for simultaneous 5-axis milling of negative angles up to –30° _ Built-in 28,000 rpm motor spindle with 38 Nm torque

or 12,000 rpm motor spindle with 300 Nm

* Optional ** DMU 600 P



ê 5-axis machining

Control technology

Technical data


5-axis machining – the 600 milling machine series with individual interchangeable milling heads.

C axis Main drive

1 2

17

Vertical head Vertical head B axis MSP B axis MSP B axis gear

Milling heads

Tool interface SK50 / HSK100 SK50 / HSK100 SK50 / HSK100 HSK63 SK50 / HSK100

Length mm 350 700 800 800 660

Speed U/min 6,000 6,000 12,000 28,000 6,000

Torque Nm 1,445 1,445 300 38 1,445

Power kW 50 50 42 27 50

Main drive

Main drive required Main drive not required

A axis MSP* A axis MSP Vertical head MSP Vertical head MSP

Milling heads

Tool interface SK50 / HSK100 HSK63 SK50 / HSK100 HSK63

Length mm 1,020 – 900 700

Speed U/min 12,000 28,000 12,000 28,000

Torque Nm 300 38 300 38

Power kW 42 27 42 27

Main drive

Main drive required Main drive not required * only for the DMU 600 P

1: Head changing stations2: Head change:

Ram in changing position

Head changing station with storage stations

+ Two stations in the base machine (gantry), three as standard in the portal

+ Can be modularly expanded to have up to five (gantry) or six (portal) stations

+ Optimal use of space with positions under the crossbeam (gantry) or on the side of the longitudinal axis (portal)

+ Optimal protection against contamination with individually controlled compartments (no interference in the working area)

Insertion diameter 380 mm

Insertion diameter 250 mm

18

The gear cutting software DMG MORI gearMILL® facilitates the complete machining of a wide range of gear types on the machines in the Portal series. Gears up to 5,000 mm in diameter and racks over 6,000 mm in length can be produced efficiently.

Highlights

The highest flexibility and shortest machining times with:

+ Standard tools

+ Standard machines

+ No complex conversion work

+ Soft and hard machining on one machine

+ Complete machining on one machine with milling, drilling and turning in one set-up

+ Electronic balancing on the machine (FD range)

+ Gear wheels up to ø 5,000 mm

Highlights of the gear cutting software

DMG MORI gearMILL®

+ Enter the gear-cutting parameters

+ Calculate the tooth space geometry

+ Optimise the tooth root geometry

+ Customised contact pattern modelling

+ Generation of 5-axis milling programs

+ Machine simulation Design module: Tooth space geometry calculation program Measurement module: Measurement data generator CAM module: Semi-automatic CNC program generation Training module: Basic courses, individual courses, training on site, ramp-up support

DMG MORI gearMILL® – the software package

for various gear cutting operations

Spur gear package

External teeth: Straight, angular, double helical

Bevel spur gear package

Angle = < > 90°:Spiral, straight

Worm gear packageZA / ZN / ZI flank profile


Gear milling – with standard tools on standard machines.



ê Special solutions

Control technology

Technical data

1 2 3 4 5 6 7 8 9 10

MillingTurningBoring

Tapping

Set-upReclamp

MillingTurningBoring

Tapping

Unclamp

Machine 1

TurningSet-up

ReclampTurning Set-up

MillingBoring

Tapping

Set-upReclamp

MillingBoring

TappingSet-up

Precision turning

Unclamp

Machine 1 Machine 2 Machine 3

19

Sixteen years of turn-mill technology with over 1,000 sold machines

+ Complete machining with milling and turning on one machine in one set-up

+ The strongest turn-mill table in its class

+ Lower unit production costs with maximum precision thanks to faster machining; lower logistics expenses thanks to the absence of idle periods and fewer operations

+ Exclusive DMG MORI mill-turn cycles

+ Less time needed and higher precision thanks to the absence of set-up work

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

+ Oil mist filter and shatter-proof safety glass panels as standard

+ Combined tool measurement

+ Heavy workpieces up to 35,000 kg and maximum workpiece diameters of 5,000 mm

+ Electronic balancing

Maximum productivity thanks to complete machining

with the Portal FD range

Full machining process:1 machine4 machining steps300 % higher productivity

Conventional machining process:3 machines10 machining steps

DMU 600 FD – full machining process

Single-purpose machines – conventional machining process

Tool magazines DMU 600 P / FD DMU 600 G linear

HSK-A63

Chain magazine, 30 pockets – Standard

Chain magazine, 60 pockets –

Chain magazine, 120 / 180 pockets

SK50 (HSK-A100)

Chain magazine, 30 / 60 pockets –

Chain magazine, 120 pockets Standard

Chain magazine, 180 pockets

Tool store, up to 268 pockets –

Interchangeable milling heads

Station for interchangeable milling heads, standard 3 2

Station for interchangeable milling heads, optional 6 5

Magazine types Chain magazine Tool store

Toolholder HSK-A63 / SK50 (HSK-A100) SK50 (HSK-A100)

Measurements (occupied adjacent pockets), mm ø 110 ø 140

Measurements (free adjacent pockets), mm ø 250 ø 400

Boring bar measurements, mm ø 250 × 400 ø 150 × 600

Tool length, mm 650 900

Weight, kg 15 / 30 up to 80

Chip-to-chip time (HSK), seconds 10 15

Number of tools 30 / 60 / 120 / 180 up to 268

20



ê Tool handling

Control technology

Technical data


Innovative tool and milling head handling.

Chain magazine with tool change system

+ 30 – 180 tools

+ Tool length 650 mm

+ Tool diameter 110 mm (250 mm with free adjacent pockets)

+ Tool magazine with 4-position gripper for SK50 / HSK100 and HSK63 interfaces

+ Positioned underneath the crossbeam

Tool store

for up to 268 tools, tools weighing up to 80 kg

21

22



ê Example applications

Control technology

Technical data


Spindles for special materials and applications.

Motor spindle rated at 28,000 rpm / 27 kW / 38 Nm (100 % DC)

Workpiece material Aluminium

Material removal rate 1,638 cm3/min

Tool Milling head ø 42 mm (3 cutting edges)

Spindle speed 10,000 rpm (Vc = 1318 m/min)

Feed 7,800 mm/min (Fz = 0.26 mm)

Depth / width of cut 6 / 35 mm

Vertical head drive 6,000 rpm / 60 kW / 2,500 Nm (100 % DC)

Workpiece material Steel (Ck45)

Material removal rate 1,800 cm3/min


Spindle speed 500 rpm (Vc = 250 m/min)



Torque spindle rated at 12,000 rpm / 42 kW / 300 Nm (100 % DC)

Workpiece material Steel (Ck45)

Material removal rate 864 cm3/min


Spindle speed 1,000 rpm (Vc = 500 m/min)



23


Example applications

Machining a cable drum

Industry Mechanical engineering Spindle speed 12,000 rpm

Tool Angle milling head ø 125 mm Power 42 kW

Material S 235 JR (ST37) Torque 300 Nm

Machining focus: 5-sided machining NC-controlled B axis with gear-driven spindle, roughing and finishing; no post-processing work required

Complete machining of a cylinder block

Industry Energy technology Spindle speed 6,000 rpm

Tool Boring bar ø 340 mm Power 53 kW

Material EN-GJL-250 (GG25) Torque 1,445 Nm

Machining focus: 5-sided machining NC-controlled B axis with gear-driven spindle and use of special heads

Rough machining of a compressor case

Industry Energy technology Spindle speed 445 rpm

Tool Face milling cutter ø 100 mm Power 53 kW

Material EN-GJS-400-15 (GGG40) Torque 1,445 Nm

Machining focus: 5-sided machining NC-controlled B axis with gear-driven spindle

Machining a 210 series machine bed

Industry Mechanical engineering Spindle speed 6,000 rpm

Tool Milling cutter ø 100 mm Power 53 kW

Material EN-GJS-600-3 (GGG60) Torque 1,445 Nm

Machining focus: 3-axis machining with a straight attachment unit, Complete machining in one set-up

Finishing of a mould insert

Industry Die & mould Spindle speed 28,000 rpm

Tool Ball nose cutter ø 2 mm Power 27 kW

Material 40CRMnNiMo8-6-4 Torque 38 Nm

Machining focus: 3 + 2-axis machining with NC-controlled B axis with motor spindle for finishing, complete machining in one set-up

35 kW S6/40%

27 kW S1/100%

48 Nm S6/40%

38 Nm S1/100%

20 63 400

1,00

0

2,50

0

6,30

0

28,0

00

40

16

10

4

1.25

0.6

1,000

315

125

50

12.5

5

Spe

ed(r

pm)

Power(kW)

Torque(Nm)

6,91

2

53 kW 100%

74 kW 40%

20 50 350

1,00

0

2,50

0

6,00

0

8050

10

5

2

1

0.6

2,0001,000

500315

100

25

10

5

Spe

ed(r

pm)

Power(kW)

Torque(Nm)

1,445 Nm 100%

2,024 Nm 40%

1,18

5

3,15

0

1,70

0

57

79

289405

42 kW 100%

300 Nm 100%

52 kW 40%

430 Nm 40%

20 50

1,00

0

2,50

0

6,30

0

12,0

00

50

20

10

5

2

1

0.9

1,000

500

250

100

50

25

10

5

Spe

ed(r

pm)

Power(kW)

Torque(Nm)

52 kW 40%

42 kW 100%

280 Nm 100%

404 Nm 40%

15,0

00

1,00

0

1,31

01,

710

100

10,0

00

50

45

40

35

30

25

400

350

300

250

Spe

ed(r

pm)

Power(kW)

Torque(Nm)

200

150

100

50

20

15

10

5

24


Power charts



ê Power charts

Control technology

Technical data

Motor spindle SK50 / HSK-A100

12,000 rpm / 42 kW / 300 Nm

Motor spindle HSK-A100

15,000 rpm / 42 kW / 280 Nm

DMU 600 P / FD and DMU 600 G linear: Interchangeable milling heads

Speed / toolholder / power / torque (100 % DC) DMU 600 P DMU 600 FD DMU 600 G linear

Gear-driven vertical head6,000 rpm / SK50 / HSK-A100 / 53 kW / 1,445 Nm6,000 rpm / SK50 / HSK-A100 / 60 kW / 2,500* Nm

Gear-driven angle milling head3,000 rpm / SK50 / HSK-A100 / 40 kW / 700 Nm

Gear-driven B axis head 6,000 rpm / SK50 / HSK-A100 / 53 kW / 1,445 Nm

Motor spindle vertical head28,000 rpm / HSK-A63 / 27 kW / 28 Nm15,000 rpm / HSK-A100 / 42 kW / 280 Nm12,000 rpm / SK50 / HSK-A100 / 42 kW / 300 Nm

B axis motor spindle head28,000 rpm / HSK-A63 / 27 kW / 38 Nm12,000 rpm / SK50 / HSK-A100 / 42 kW / 300 Nm15,000 rpm / HSK-A100 / 42 kW / 280 Nm

A axis motor spindle head28,000 rpm / HSK-A63 / 27 kW / 38 Nm12,000 rpm / SK50 / HSK-A100 / 42 kW / 300 Nm*

Optional * Only for the DMU 600 P / FD

Motor spindle HSK-A63

28,000 rpm / 27 kW / 38 Nm

Main drive / vertical milling head

6,000 rpm / 53 kW / 1,445 Nm

Universal With multiple tables, the DMU 600 P facilitates 5-axis complete machining of large parts weighing up to 75 tonnes and measuring up to 18 × 3 × 3.5 m.

25

26

Together with SIEMENS 840D solutionline, the Portal series is equipped with the new ERGOline® Control 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 MORI Virtual Machine are available, which are able to directly influence either workpiece quality or process optimisation.



Control technology

ê DMG MORI technology cycles

Technical data


High-end CNCs for safe machining and maximum precision.

Exclusive, optionally available DMG MORI technology cycles

3D quickSET®

Quick and easy for maximum precision

Tool kit for checking and correcting the kinematic precision of 4 and 5-axis machine configurations

All head variants and all table axes

Laser measuring sensor

package

Enhanced measuring options with the laser measuring sensor

Measurement of pockets and grooves

Measurement in hard-to-reach areas

Measurement of individual points

Package with manual and automatic calibration

Interpolation turning

Machining of faces and recesses without a turn-mill table

The machining process takes place in a circular movement around or within the workpiece

The spindle is perpendicular to the direction of movement

Efficient production package

Safe and efficient production – optimisation of the production potential

Extended milling strategies

Simple programming of recurring machining steps

Safe retraction from all potential collisions

Reduced programming times

Reduction of errors caused by program crashes

STANDARD

27

SIEMENS 840D solutionline

+ Highly simplified interactive program-ming with identical “look and feel” for turning and milling

+ SINUMERIK Operate user interface

+ Quick-view simulation of complex parts of the program

+ Efficient tool management

+ Wide range of 5-axis functions with numerous correction and intervention options

+ Advanced Surface – the option for the best surface quality* and an ideal complement to tool and mould making

* Optional

HEIDENHAIN iTNC 530

+ Workshop or DIN-ISO programming

+ Rapid program generation with plain-text programming

+ Graphical programming

+ Upwards compatibility

+ 3D workpiece simulation

+ smarT.NC – user-friendly interface

+ Wide range of cycles as standard

+ Efficient tool management

+ DXF converter*

+ AFC – Adaptive Feed Control*

* Optional

HEIDENHAIN TNC 640

+ Unique, highly detailed 3D simulation display

+ New optimised TNC user interface

+ HSCI – HEIDENHAIN Serial Controller Interface

+ Rapid program generation with plain-text programming

+ Collision monitoring (DCM)

+ ATC*, 3D quickSET®*

+ Powerful processor (Intel i7-3, two cores)

+ New optimised ADP movement guide for improved surfaces and quicker machining (block processing time of just 0.5 ms)

* Optional

MPC – Machine Protection

Control

Protecting machines with an emergency shut-off function

Vibration sensors on the milling spindle

Emergency shut-off with teach function

Process monitoring by means of a bar graph

Milling spindle bearing diagnostics

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 control system compensates for the actual displacement

Grinding

Machining with the highest surface precision

Grinding on a universal milling machine

For internal, external and face grinding

Dressing cycles for dressing the grinding wheel

ATC – Application Tuning

Cycle

Process optimisation at the push of a button

Process-oriented feed drive tuning

Minimised machining time with maximised component quality, even taking into account the workpiece weight

ERGOline® Control with 21.5" multi-touch- screen and SIEMENS.

Simple

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

Continuous

Consistent administration, documentation 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.

28

Simplified machine operation. The holistic integration of the machine into the company organisation.

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

SMARTkey®

Personalised user authorisation: Individually adapted access privileges

to the control system and the machine.



Control technology

ê CELOS®

Technical data

CELOS® APPs – 3 examples:

29

CELOS® features a standard user interface for all new high-tech machines from DMG MORI. CELOS® APPs enable the consistent administration, documentation and visualisation of order, process and machine data. They also simplify, standardise and automate the operation of the machine. 16 standard APPs help the machine operator prepare, optimise and systematically process production jobs.

JOB MANAGERSystematic planning, administration and preparation of orders.

+ Machine-related creation and configuration of new orders

+ Structured saving of all production-related data and documents

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

JOB ASSISTANTProcess-defined orders.

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

+ Reliable error prevention thanks to work instructions with mandatory acceptance function

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

+ Displays all tools required for a job, including automatically generating a loading list

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


– From the idea to the finished product.

30


Technical dataMachine type DMU 600 P DMU 600 FD DMU 600 G linear

Working area

X / Y / Z axis mm 6,000 × 4,200 (4,800)* × 1,250 (1,500)*

6,000 × 4,200 (4,800)* × 1,250 (1,500)*

6,000 (n × 1,000)* × 3,500 (4,500)* × 1,500 (1,750 / 2,000)*

W axis 1,600 (2,000)* 1,600 (2,000)* –

Portal passage

Horizontal mm 3,500 3,500 4,700 (5,700)*

Vertical mm 2,600 (3,000)* 2,600 (3,000)* 2,500 (2,750 / 3,000)*

Distance from spindle nose to table centre

Horizontal milling head mm on request on request on request

Vertical milling head mm (Centre of head holder) (Centre of head holder) (Centre of head holder)

Table type Rigid table Mill-turn table Rigid table

Table size mm 5,000 × 2,800 ø 3,200 integrated into 5,000 × 2,800 –

Maximum table load kg 25,000 (40,000)* 25,000 (35,000)* –

Mill-turn table (milling / turning) rpm – 170 –

Table size mm – 5,000 × 3,000

Maximum table load kg/m2 // kg/m – 15,000 // 30,000

5-axis options

Interchangeable milling head as an NC-controlled B axis

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

Rapid traverse and feed rpm 30 30 30

Interchangeable milling head as an NC-controlled A axis – –

Swivel range (0 = vertical / –90 = horizontal) Degrees –120 / +135 –120 / +135 –120 / +135

Rapid traverse and feed rate rpm 30 30 30

Ram with integrated C axis Standard Standard Standard

Turning range // Rapid traverse and feed Degrees // rpm ±185 (optionally 360° infinite) // 40 ±185 (optionally 360° infinite) // 40 ±185 (optionally 360° infinite) // 40

Main drive

Interchangeable milling head with integrated motor spindle rpm 12,000* 12,000* 12,000

Power (40 / 100 % DC) // torque (40 / 100 % DC) kW // Nm 52 / 42 // 430 / 300 52 / 42 // 430 / 300 52 / 42 // 430 / 300

Integrated gear-driven spindle for accepting interchangeable milling heads rpm 6,000 6,000 6,000

Power (100 % DC) // Torque (100 % DC) kW // Nm 53 // 1,445 (60 // 2,500) 53 // 1,445 (60 // 2,500) 53 // 1,445*

SK50 tool change system – tool magazine Pockets 120 – 180 / chain 120 – 180 / chain 30 / 60 / 120 / 180 / chain

Linear axes (X / Y / Z / W) m/min 23.5 / 30 / 30 / 10 23.5 / 30 / 30 / 10 45 / 45 / 45

P max. (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 15 / 15 / 8 15 / 15 / 8 15 / 15 / 8

Control system

ERGOline® Control with 19" monitor and 3D control system

SIEMENS 840D solutionline,HEIDENHAIN iTNC 530,

HEIDENHAIN TNC 640

SIEMENS 840D solutionline FD SIEMENS 840D solutionline,HEIDENHAIN iTNC 530,

HEIDENHAIN TNC 640

ERGOline® Control with 21,5" multi-touch screen and CELOS® SIEMENS 840D solutionline SIEMENS 840D solutionline FD SIEMENS 840D solutionline

/ * Optional, – Not available



Control technology

Technical data

ê Options

ê Pumps and accumulators

Machine type DMU 600 P DMU 600 FD DMU 600 G linear

Working area

X / Y / Z axis mm 6,000 × 4,200 (4,800)* × 1,250 (1,500)*

6,000 × 4,200 (4,800)* × 1,250 (1,500)*

6,000 (n × 1,000)* × 3,500 (4,500)* × 1,500 (1,750 / 2,000)*

W axis 1,600 (2,000)* 1,600 (2,000)* –

Portal passage

Horizontal mm 3,500 3,500 4,700 (5,700)*

Vertical mm 2,600 (3,000)* 2,600 (3,000)* 2,500 (2,750 / 3,000)*

Distance from spindle nose to table centre

Horizontal milling head mm on request on request on request

Vertical milling head mm (Centre of head holder) (Centre of head holder) (Centre of head holder)

Table type Rigid table Mill-turn table Rigid table

Table size mm 5,000 × 2,800 ø 3,200 integrated into 5,000 × 2,800 –

Maximum table load kg 25,000 (40,000)* 25,000 (35,000)* –

Mill-turn table (milling / turning) rpm – 170 –

Table size mm – 5,000 × 3,000

Maximum table load kg/m2 // kg/m – 15,000 // 30,000

5-axis options

Interchangeable milling head as an NC-controlled B axis

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

Rapid traverse and feed rpm 30 30 30

Interchangeable milling head as an NC-controlled A axis – –

Swivel range (0 = vertical / –90 = horizontal) Degrees –120 / +135 –120 / +135 –120 / +135

Rapid traverse and feed rate rpm 30 30 30

Ram with integrated C axis Standard Standard Standard

Turning range // Rapid traverse and feed Degrees // rpm ±185 (optionally 360° infinite) // 40 ±185 (optionally 360° infinite) // 40 ±185 (optionally 360° infinite) // 40

Main drive

Interchangeable milling head with integrated motor spindle rpm 12,000* 12,000* 12,000

Power (40 / 100 % DC) // torque (40 / 100 % DC) kW // Nm 52 / 42 // 430 / 300 52 / 42 // 430 / 300 52 / 42 // 430 / 300

Integrated gear-driven spindle for accepting interchangeable milling heads rpm 6,000 6,000 6,000

Power (100 % DC) // Torque (100 % DC) kW // Nm 53 // 1,445 (60 // 2,500) 53 // 1,445 (60 // 2,500) 53 // 1,445*

SK50 tool change system – tool magazine Pockets 120 – 180 / chain 120 – 180 / chain 30 / 60 / 120 / 180 / chain

Linear axes (X / Y / Z / W) m/min 23.5 / 30 / 30 / 10 23.5 / 30 / 30 / 10 45 / 45 / 45

P max. (X / Y / Z) – VDI DGQ 3441 / ISO 230-2 µm 15 / 15 / 8 15 / 15 / 8 15 / 15 / 8

Control system

ERGOline® Control with 19" monitor and 3D control system

SIEMENS 840D solutionline,HEIDENHAIN iTNC 530,

HEIDENHAIN TNC 640

SIEMENS 840D solutionline FD SIEMENS 840D solutionline,HEIDENHAIN iTNC 530,

HEIDENHAIN TNC 640

ERGOline® Control with 21,5" multi-touch screen and CELOS® SIEMENS 840D solutionline SIEMENS 840D solutionline FD SIEMENS 840D solutionline

/ * Optional, – Not available


OptionsDMU 600 P DMU 600 FD DMU 600 G linear

Table options

NC Mill-Turn table – –

Slide

Ram with integrated C axis, infinite 360° rotation

Toolholder

HSK-A63 / BT 40 / CAT 40 –

HSK-A100 / BT 50 / CAT 50 (HSK for turn-mill machines, FD, as standard)

Automation / measurement / monitoring

3D quickSET®

Wireless measuring sensor

Blum laser tool measurement in the working area, NT hybrid

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

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 1-bar pump, 40 litres per minute

Minimum quantity lubrication through the spindle centre internally and through nozzles externally

Oil and emulsion mist deposition equipment

Air blast cooling through the spindle centre

Optional iTNC 530 / TNC 640 control systems

Application Tuning Cycle ATC

Electronic handwheel iTNC 530 / TNC 640

Control console for tool magazine loading station

ACC – Active Chatter Control

Optional SIEMENS 840D solutionline

Electronic SIEMENS 840D handwheel

Control console for tool magazine loading station

DECKEL MAHO MDynamics package

General options

Remote camera system

Shatter-proof safety glass viewing panel

Operating mode 4 “Processor monitoring in production”

Standard, optional, – not available

10 30 50 70 90 110

130

150

5

4

3

2

1

Tim

e(m

in)

Performance(kW)

unregulated accumulator

regulated accumulator

necessary cooling power

10 20 30 40

25

20

15

10

5

Pre

ssur

e(b

ar)

Flow rate(l/min)

Typical saving

7,200 kWh* or € 2,000 per year

* 24 hours per day, 300 days per year, € 0.14 per kWh

Savings with this tool: € 0.38 per hour

Ball nose cutter 12 mm

Boring tool 11.5 mm

Porcupine cutter 40 mm

Mill 80 mm

Solid drill 60 mm

End mill 6 mm

StandardP = 40 barQ = 6.7 l/minPel = 4 kW

Needs-basedP = 10 barQ = 6.1 l/minPel = 1.5 kW

The larger the cooling power of an accumulator, the more energy is saved.

KFW subsidy: Reinvestment: 30 % energy saved compared to existing systems New investment: 15 % energy saved compared to the industry average.

High-efficiency pumps and accumulators.

Efficient machine cooling

+ DMG MORI uses efficient cooling devices which only generate the necessary cooling power

+ The average power of such an accumulator falls by 30 – 50 % during production (representative range) This equals a saving of approximately 2 kW from a 10 kW cooling system

Frequency-controlled coolant pumpThe high-pressure coolant pump requires 22 % of the energy used during the machining process (represent-ative figure). This energy heats up the coolant which has to be cooled with additional energy. Facts

+ Needs-based pressure generates the most efficient use of coolant

The pressure can be lowered for small tools, as high pressure does not increase the quantity of coolant flowing through the tool Conventional technology

+ Pressure reduction with proportional valve technology does not save any energy as the pump continues to run at its nominal rating

Advantage of DMG MORI

+ Speed-regulated high-pressure pumps which only work with the necessary power

16,623

13,961

9,97

8

8,61

43,

237 4,

459

6,279 6,361 1,321

1,20

0

5,74

1

6,59

1 (7

,026

)


Floor plans

DMU 600 P with complete cover

Side view



Control technology

Technical data

ê Layout plans

DMU 600 P with complete cover and chain magazine with 120 pockets

Top view Footprint of 165.9 m²

Maximum (dependent on the chosen equipment)

2,88

2 (3

,382

)

1,20

02,78

2 (3

,282

)

6,90

0 (7

,500

)

6,13

5 (6

,635

)

11,971

12,339

8,27

5 (9

,275

)

35

DMU 600 G linear with complete cover

Side view

DMU 600 G linear with complete cover and chain magazine with 180 pockets

Top view Footprint of 154.2 m²

Maximum (dependent on the chosen equipment)

DMG MORI Europe AGSulzer-Allee 70, CH-8404 WinterthurTel.: +41 (0) 58 / 611 5000, Fax: +41 (0) 58 / 611 [email protected], www.dmgmori.com

Germany: DMG MORI Deutschland Riedwiesenstraße 19 D-71229 Leonberg Tel.: +49 (0) 71 52 / 90 90 - 0 Fax: +49 (0) 71 52 / 90 90 - 20 00 Service Hotline: +49 (0) 180 5 49 00 22

Europe: DMG MORI Europe Sulzer-Allee 70 CH-8404 Winterthur Tel.: +41 (0) 58 / 611 5000 Fax: +41 (0) 58 / 611 5001 Service Hotline: +41 (0) 446 545 670

Asia: DMG MORI Japan 2-3-23 Shiomi Koto-ku, Tokyo JP-135-0052, Japan Tel.: +81 3 - 6758 - 5900 Fax: +81 3 - 6758 - 5919

America: DMG MORI USA 2400 Huntington Blvd. Hoffman Estates, IL 60192 Tel.: +1 (847) 593 - 5400 Fax: +1 (847) 593 - 5433

DMG MORI Austria Oberes Ried 11 A-6833 Klaus Tel.: +43 (0) 55 23 / 69 141 - 0 Fax: +43 (0) 55 23 / 69 141 - 100 Service Hotline: +43 (0) 17 95 / 76 109

_ Stockerau Josef-Jessernigg-Straße 16 A-2000 Stockerau Tel.: +43 (0) 55 23 / 69 141 - 0 Fax: +43 (0) 55 23 / 69 141 - 100

DMG MORI Benelux _ Netherlands Wageningselaan 48 NL-3903 LA Veenendaal Tel.: +31 (0) 318 - 55 76 - 11 Fax: +31 (0) 318 - 52 44 - 29 Service Hotline: +31 (0) 202 00 81 83

_ Belgium Hermesstraat 4B B-1930 Zaventem Tel.: +32 (0) 2 / 7 12 10 - 90 Fax: +32 (0) 2 / 7 12 10 - 99 Service Hotline: +32 (0) 2 / 2 200 62 - 52

DMG MORI Czech Kaštanová 8 · CZ-620 00 Brno Tel.: +420 545 426 311 Fax: +420 545 426 310 Service Hotline: +420 239 000 561

_ Planá Chýnovská 535 CZ-39111 Planá nad Lužnicí Tel.: +420 381 406 914 Fax: +420 381 406 915

_ Slovakia Brnianska 2 SK-91105 Trenčín Tel.: +421 326 494 824

DMG MORI France Parc du Moulin · 1 Rue du Noyer B.P. 19326 Roissy-en-France F-95705 Roissy CDG Cedex Tel.: +33 (0) 1 / 39 94 68 00 Fax: +33 (0) 1 / 39 94 68 58 Service Hotline: +33 (0) 8 10 90 20 20

_ Lyon Parc des Lumières 1205 Rue Nicéphore Niepce F-69800 Saint-Priest Tel.: +33 (0) 4 / 78 90 95 95 Fax: +33 (0) 4 / 78 90 60 00

_ Toulouse Futuropolis Bat. 2 · 2 Rue Maryse Hilsz F-31500 Toulouse Tel.: +33 (0) 5 / 34 25 29 95 Fax: +33 (0) 5 / 61 20 89 19

_ Haute-Savoie Espace Scionzier · 520 avenue des Lacs F-74950 Scionzier Tel.: +33 (0) 4 / 50 96 41 62 Fax: +33 (0) 4 / 50 96 41 30

DMG MORI Hungary Vegyész u. 17 – 25 · B. Building H-1116 Budapest Tel.: +36 1 430 16 14 Fax: +36 1 430 16 15 Service Hotline: +36 1 777 90 57

DMG MORI Ibérica Pol. Ind. Els Pinetons Avda. Torre Mateu 2 – 8 · Nave 1 E-08291 Ripollet · Barcelona Tel.: +34 93 586 30 86 Fax: +34 93 586 30 91 Service Hotline: +34 91 - 2 75 43 22

_ Madrid C / Alcañiz 23 · E-28042 Madrid Tel.: +34 91 66 99 865 Fax: +34 91 66 93 834

_ San Sebastián Edificio Igaraburu Pokopandegi 11, Oficina 014 E-20018 San Sebastián Tel.: +34 943 100 233 Fax: +34 943 226 929 Service Hotline: +34 91 - 2 75 43 22

DMG MORI Italia Via G. Donizetti 138 I-24030 Brembate di Sopra (BG) Tel.: +39 035 62 28 201 Fax: +39 035 62 28 210 Service Hotline: 199 177 811

_ Milano Via Riccardo Lombardi 10 I-20153 Milano (MI) Tel.: +39 02 48 94 921 Fax: +39 02 48 91 44 48

_ Padova Via E. Fermi 7 · I-35030 Veggiano (PD) Tel.: +39 049 900 66 11 Fax: +39 049 900 66 99

DMG MORI Middle East Jebel Ali Free Zone · JAFZA Towers Lob 18, Office 2403, P.O. Box 262 607 Dubai, U.A.E.Tel.: +971 - 4 - 88 65 740 Fax: +971 - 4 - 88 65 741

DMG MORI Polska ul. Fabryczna 7 · PL-63-300 Pleszew Tel.: +48 (0) 62 / 7428 000 Fax: +48 (0) 62 / 7428 114 Service Hotline: +48 (0) 62 / 7428 285

DMG MORI Romania DN 65B, KM. 4 + 471 RO-110180 Pitesti Tel.: +40 248 610 408 Fax: +40 248 610 409

DMG MORI Russia ul. Novohohlovskaya 23 / 1 RU-109 052 Moscow Tel.: +7 495 225 49 60 Fax: +7 495 225 49 61 Service Hotline: +7 495 912 50 09

_ Jekaterinburg ul. Sofi Kowalewskoj 4, litera Z RUS-620049 Jekaterinburg Tel.: +7 343 379 04 73 Fax: +7 343 379 04 74

_ St. Petersburg pr. Obuhovskoy Oborony 271, litera A RUS-192012 St. Petersburg Tel.: +7 812 313 80 71 Fax: +7 812 313 80 71

DMG MORI Scandinavia _ DMG MORI Finland & Baltics Jasperintie 310 FI-33960 Pirkkala Tel.: +358 10 271 4450 Service Hotline: +358 10 271 4460

_ DMG MORI Sweden E A Rosengrens gata 5 SE-421 31 Västra Frölunda Tel.: +46 (0) 771 364 6674 Fax: +46 (0) 31 476 351 Service Hotline: +46 (0) 771 365 724

_ DMG MORI Denmark Robert Jacobsens Vej 60, 2.tv DK-2300 København S Tel.: +45 70 21 11 11 Fax: +45 49 17 77 00 Service Hotline: +45 70 21 11 12

_ Norway Bergsli Metallmaskiner AS Bedriftsveien 64 NO-3735 Skien Tel.: +47 35 50 35 00 Fax: +47 35 50 35 70

DMG MORI Schweiz Sulzer-Allee 70 CH-8404 Winterthur Tel.: +41 (0) 58 / 611 5000 Fax: +41 (0) 58 / 611 5001 Service Direct Line: +41 (0) 58 / 611 5555 Service Hotline: +41 (0) 446 545 670

DMG MORI South East Europe Ag. Georgiou 5 – Patriarchiko Pylaias, Cosmos Offices, PO 60233 GR-57001 Thessaloniki Tel.: +30 2310 474486 Fax: +30 2310 474487

DMG MORI Turkey Ferhatpaşa Mah. Gazipaşa Cad. No: 11 TR-34885 Ataşehir · İstanbul Tel.: +90 216 471 66 36 Fax: +90 216 471 80 30 Service Hotline: +90 216 47 16 636

DMG MORI UK 4030 Siskin Parkway East Middlemarch Business Park Coventry CV3 4PE · GB Tel.: +44 (0) 2476 516 120 Fax: +44 (0) 2476 516 136 Service Direct Line: +44 (0) 2476 516 130 Service Hotline: +44 (0) 20 30241514

DMG MORI Africa Representative WIN-TECH Machinery & Tooling 90 El Thawra Street El Golf Area Heliopolise 11341 Cairo, Egypt Tel.: +202 2 690 36 08 Fax: +202 2 690 36 09

Headquarters Europe

Always close by! www.dmgmori.com

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Documents

DMU 600 P XXL milling machines - DMG Mori · PDF fileXXL milling machines. ... DMU 600 G linear with its high gantry design is dedicated to the dynamic and ... with C / A and C / B