DMC 160 U (FD) duoBLOCK
With the new duoBLOCK series, every component becomes a masterpiece.
Max. X-axis travel
1600 mm
63 in.
Max. Y-axis travel
1600 mm
63 in.
Max. Z-axis travel
1100 mm
43.3 in.
Max. workpiece diameter
1600 mm
63 in.
Max. workpiece height
1350 mm
53.1 in.
Max. workpiece weight
4000 kg
8818.5 lbs.
Control & software alternatives
SIEMENS
HEIDENHAIN
Highlights
Complete machining
- Milling and turning in one setup with the DirectDrive table and rotational speeds up to 400 rpm
- Best surface quality with technology integration grinding
Precision
- Maximum accuracy through completely water-cooled feed drive
- SGS: Spindle growth gensor for compensation of spindle increase
- Significantly improved temperature response
Performance
- Fast, very compact rotating pallet changer for main time parallel setup as standard
- Also available in mill- /turn - version
- powerMASTER motorspindle with 737.6 ft lb and 103.3 hp
- 5X torqueMASTER with 1,327.6 ft lb and 69.7 hp
Efficiency
- Low space requirements, extremely compact wheel magazine with short tool replenishment time of max. 5.6 sec with 453 tool pockets
- Optimal ease of maintenance and ideal ergonomics thanks to unrestricted accessibility
- High machine availability with 96 %
Sample applications
Automation
Standard automation and customized solutions in VERTICO design
Automation is a key element of digital production. Every DMG MORI machine can be upgraded with standard automation or with a customized automation solution for flexible manufacturing systems:
RPS duoBLOCK
RPS 6 / 7 / 12 - Machine-integrated automation with minimum space requirement
- Unmanned shifts due to circular storage system with up to 12 pallets
- Handling of workpieces up to ø 1,600 × 1,350 mm, 4,000 kg max.
- Reduction of non-productive time due to loading and unloading during production
- Easy operation via machine control with intuitive, integrated Pallet Manager software
- Pallet Master – for convenient and simple control of the automation directly via the machine control
AMR 2000
Holistic automation on the shop floor
- Collaborative automation solution with free layout design
- Omnidirectional movement for minimal space requirements (turning radius 0m)
- Basis for additional tasks, e.g. B. tool handling, chip disposal, etc.
- Material transport from Euro pallets 1,200 x 800 mm
- Maximum transport weight of up to 2,000 kg
- Security based on Sick and Siemens technology
Highlights
AMR 2000 Material
- Autonomous transport of material pallets
- Transport of different load carriers
- Integration into DMG MORI automation systems for workpiece handling – exchange of finished part and raw part pallets
- Integration into existing processes
- Scalable and expandable at a later date
AMR 2000 chips
- Autonomous transport of chip containers
- Automatic transport order from the master computer
- Extended autonomy of the machine tool
- Material and chip transport can be combined
AMR 2000 tool handling
- Tool identification in the standard
- Autonomous transport and exchange of tools between machines and tool storage systems
- Max. tool dimensions ø 280 / 400 mm
- Max. tool weight 30 kg
- Transport weight 720 kg (24× 30 kg)
- Maximum number of tools: 24 pcs
LPP
Advanced pallet storage solution for up to 8 machines and 99 pallets
- Handling of workpieces up to ø 3,400 x 2,000 mm, 10,000 kg
- Very flexible pallet pool system with up to 8 machines, 99 pallets and 5 setup stations
- Handling of up to three different pallet sizes possible in one system (2 sizes for machine pallets and one size for material pallets)
- Control directly via DMG MORI master computer software LPS
- Integration into customer network / workflow possible
- Monitoring and management tools for all relevant areas (planning, workpieces, clamping, tools, etc.)
- Tool management system MCC-TMS
CTS - Central Tool Storage (Wheel type)
Flexible tool magazine for more than 4,000 tools
- Modular concept with step-by-step extension possibility by 360 / 240 shapes (ISO 40 / 50 recording)
- Very small footprint with only 29 m2
- Integrated tool loading solution for portal tool shuttle or with AMR 2000 tools
- Highest transport capacity through the tool - shuttle
- Transfer of up to 8 tools simultaneously
- Proven wheel magazine technology with over 1,600 units sold
Highlights
AMR 2000 Tooling
- Autonomous transport of up to 24 tools between the CTS (central tool magazine) and the machine
- Quick installation of the automation system
- Integration into existing production possible
- Max. tool dimensions ø 280 / 650 mm
- Max. tool weight 30 kg
- transport weight 720 kg (24 × 30 kg)
Portal tool handling
- Portal tool handling for highest efficiency, transport of up to 80 tools per hour.
- Transport of 16 tools (2×8 units)
- Fast tool change by means of rotating unit
- Max. linear speed: 80 m/min
- Tool Loading Station TLS - interface on machine and CTS
Tool transfer
- To change tools between the shuttle and the machine or on the CTS, the TLS moves upwards in each case.
PH-AMR
Pallet automation with maximum flexibility through free layout design
- Modular concept with flexible layout design
- Driverless transport systems without guide rails or tracks
- Collaborative: Man and machine in one system
- Navigation through natural navigation
- Pallet sizes from 500 × 500 mm to 1,600 × 1,250 mm
- Workpieces up to 5,000 kg and ø 1,600 mm
Highlights
Free accessibility
- Best visibility into the workspace at any time
- Manual or crane loading still possible
- Collaborative system – man and machine in one system
Modular concept with free layout design
- No safety housing for the automation system necessary
- Free positioning possibility of the individual modules
- Subsequent integration into existing production
Simple expansion of automation system
- Additional shelf modules to increase the number of storage places
- Additional AMRs can be integrated in the system
- Machines with an automation interface can be integrated very quickly afterwards
Minimum space requirement
- Free pallet handling system without fixed installation requirements on hall floor
- AMR paths remain walkable and passable
- Laser scanners guarantee personal protection in driving direction
- Omnidirectional movement for minimum space requirements (turning circle 0m)
- Flexible automation concept - Automation of different machine types with one system
Control & software
CELOS
Integrated digitization of the DMG MORI machines & the shop floor:
- CELOS Machine: APP-based user interface with access to all production-related information
- CELOS Manufacturing: 27 CELOS APPs for the optimal preparation & processing of orders
- Digital Factory: Continuous digital workflows from planning to production & service
gearQUALITY
- Non-contact measurement with the laser scanner
- Measurement and evaluation of gears according to common standards analog to coordinate measuring machines
- Fast measurement with max. 70,000 points / sec. or up to 200,000 points / sec. depending on the laser source
Highlights
Customer Benefits
- Technology and measurement system integration eliminate unnecessary handling of components
- High flexibility in gear measurement and reduction of reaction times during process start-up
- Measurement of gear teeth and scanning of free-form surfaces possible
Left : Simulation of the generated measurement program / Right : Evaluation mask with color-coded result display
Profile Dressing
- Dressing of a profile on the grinding wheel by means of driven profile rollers (negative)
- Full utilisation of AE sensor and integrated dressing strategies
- High time saving as well as high dressing accuracy due to customised dressing wheel development
Highlights
Customer benefits
- Tool and workpiece protection
- Optimized tool process
- Monitoring of the radial and axial spindle load depending on the actual pull-in force
Left: Parameterised input for the production of profiles; Right: Dialogue-guided contour dressing cycle
Flat Grinding
- Technology integration flat grinding on standard machines for best surface results
- Possibility of straightness compensation by definition of calibration points
- Acoustic emission sensor assisted approaching cycle
- ECS nozzle unit for best possible flushing of the grinding gap optionally available
Highlights
Customer Benefits
Machining strategies
- Easy programming with the integrated input parameters
- Complete machining with one setup
Optional rotating dressing unit incl. dressing cycles
In-Machine Tool Balancing
- Balancing of tools in the machine for high surface requirements and machine protection
- Checking the balancing quality of the spindle
- Balancing quality up to 0.3 g/mm
Highlights
Customer benefits
User Interface
- Better surfaces due to balancing of the entire system in the clamped state
- Balancing of the tool under machining conditions (machining position -vertical / horizontal, with / without internal cooling supply, speed)
- Economical, as no external balancing device is required
Left: Measurement result with balancing outside the machine - 3 [g]; Right: Measurement result after balancing in the machine - 0.3 [g]
Fit in – B-axis Plunging
- Full utilization of the working space during internal machining of high workpieces with long tools
- Positional changes of the B axis during the turning are balanced by the X and Y axes
- The Z-axis remains at the retracted position while the B axis is moving
Highlights
Customer Benefits
Inner and outer travel of the B-axis.
- Easy programming
- Collision-free plunging in the workpiece
- Safely coming out from the workpiece after machining
Efficient Production Package
- Solutions for a safe process and for the efficient use of important machining steps
- Applications: cone cleaning, tool data monitoring, safe withdrawal movement, tapping, deep hole drilling, external thread and spigot milling, internal thread and circular milling, reverse countersink cycle
- 12 stored machining strategies for stock removal, deep hole drilling, Pocket milling machines*
Highlights
Customer Benefits
- Runtime optimization according to individual application
- Safe retraction after program break
- Tool data monitoring
Left : Input mask for universal cycle pocket milling. / Right : Input mask for tapping cycle
gearSKIVING 2.0
- Straight and helical external or internal spur gears and splines
- Arrow teeth with tooth offset Turn-mill machines
- Ball-shaped toothing by mathematical transformation of the 6th virtual axis
Highlights
Customer Benefits
- Internal toothing without angular head possible
- Short processing times, 10 x faster than shaping
- Synchronization and tool path controlled by the Cycle
Left : Inside gear profile machining. / Right : Outside gear profile machining.
TCC – Tool Control Center
- Chip detection on plan pad and tool cone
- Monitoring of pull-in force
- Cutting edge control in process by symmetry monitoring of the bending moment per cutting edge
- Visualization of the bending moment over time via Graph
Highlights
Customer Benefits
- Tool and workpiece protection
- Optimized tool process
- Monitoring of the radial and axial spindle load depending on the actual pull-in force
Left: NEW; Middle: Wear; Right: Cutting edge break
Grinding
Turning
- Turning, milling and grinding in one clamping
- Grinding cycles for internal, external and face grinding as well as dressing cyclesn
- Body-borne sound sensors for start-up and dressing
- Full integration of measurement module for relative and absolute LIVE-Measuring – parallel to main time
Milling
- Better surface quality through integration of the grinding technology
- Grinding cycles for internal, external and face grinding as well as dressing cycles
- Body-borne sound sensors for start-up and dressingn
- 1,300 l Cooling system with integrated centrifugal filter for The filtration of particles > 10 μ
- AKZ nozzle unit optionally available for best possible Flushing of the grinding gap
Highlights
Turning Customer Benefits
- Expansion of the technological limits of the CTX TC
- Surface accuracy < 0.4 μm
- Roundness < 5 μm
- Quality IT5 for ø > 30 mm
Left : External, internal and circular grinding. Grinding with straight / angle or cup disc. / Right : Dressing straight, angled or cup discs simply visualized.
Milling Customer Benefits
- Surface accuracy < 0.4 μ
- Roundness < 5 μ
- Quality 5 for ø < 120 mm
- Quality 4 for ø > 120 mm
Left: Spiral plane grinding or osscillating plane grinding. / Right: Longitudinal grinding.
Tilted Measuring Cycle
- Measuring with tilted tool axis
- Dialog-guided programming of the measuring cycles
- Positioning of the measuring points with rotary axis
Highlights
Customer Benefits
- Increase in component accuracy
- Reduction of set-up time
- Collision-free measuring thanks to tilted tool axis possible
- Further processing of the measurement results
Left : 1. circumferential measurement, 2. alignment surface, 3. alignment hole / Right : Dialog-guided programming
Maintenance Package i4.0
- Automatic recognition of tool pull-in force for consistently high process stability.
- Predefined cycle for automatic lubrication, every 75h or after 20,000 tool changes.
- Detection of leakage and measuring of usage of pneumatics system.
Highlights
Customer Benefits
- Efficient and timesaving lubrication without operator intervention
- High transparency by displaying the lubrication cycles and the current pull-in force.
- Data recording in combination with the optionally available Condition Analyzer for additional analyzes of air consumption and changes of the pull-in force
Detection of leakage and measuring of usage of pneumatics system.
Simple query of the monitoring parameters and the current pull-in force.
VCS Complete
- Geometric fingerprint of the machine Volumetric calibration at the touch of a button
- Detection and compensation of geometrical, positioning and angular errors of all axes
- Easy handling and implementation by the customer directly at the machine
Highlights
Customer Benefits
- Regular compensation of the machine geometry over the entire life cycle of the machine
- Dialogue-led operation for easy and fast handling
- Data recording for further analysis
Possible accuracy deviation without VCS-Complete.
Alternating speed
- Easy to operate through three parameters and without additional sensors
- Avoiding vibrations by means adaptation of the speed
- Application for the main spindle and counter spindle, or for milling machines with FD tables with Direct Drive
Highlights
Customer Benefits
Input of parameters for speed set-point, differential speed and revolution frequency
- No manual intervention by the operator
- Identical repeatability for all components
- Increased process safety for special applications by avoiding vibrations. example, When using long thin drills or for milling parts with critical clamping
3D quickSET
Turning
- Measurement and correction of the position of turning and Pivot axes (C4, C3, B)
- Sag compensation possible
- Can be used in combination with standard probes from customers (recommended Renishaw, Blum)
Milling
- Toolkit for checking and correcting the kinematic accuracy of 4- and 5-axis machine configuration
- All head variations and table axes
Highlights
Turning Customer Benefits
- Reliable re-calibration of the machine before a highly precise processing
- Continuous documentation of machine accuracy
- No rejected parts due to unknown Geometric-deviations
Dialogue-guided measurement of the B- and C-axis.
Milling Customer Benefits
- Periodic recalibration of the machine with comprehensive documentation
- Highest kinematic accuracy in self-regulation
Define kinematics head
Application Tuning Cycle
- Process-oriented adjustment of the feed rate n relation to the table loading
- Minimization of machining time with maximization of the component quality
- NEW: Now also available for CTX TC. Ideal machining result with the highest machine dynamics*
*without consideration of feed weight
Highlights
Customer Benefits
- User friendly setting of the machine dynamics with included DMG MORI knowhow
- Time saving in roughing
- High surface finish during finishing
Left : ATC 2.0 – Milling: Consideration of table loading. / Right : ATC – Turning: for CTX TC for easy adjustment of the machine dynamics.
Multitool
- Efficient use of multi-tip turning tools with more than one cutting edge on turn & mill
- Several "sister tools" on one main tool holder
Highlights
Customer Benefits
- Reduction of tool change times
- Saves tool magazine space
DMG MORI gearMILL
- Productive complete processing
- Cost-effective gear cutting on standard machine with standard tools
- Flexible for different gear geometries
- Quality inspection in the process
Highlights
Customer Benefits
- Program creation based on blank drawings and gear data
- Optimization of workpiece orientation e.g. after heat treatment
- Interface for coordinate measuring device (Klingenberg, Leitz, Zeiss)
Left : Input of the gear parameters for the geometry calculation of a spur gear. / Right : Grafische Betrachtung des Abwälzverfahrens.
Excentric turning and milling
- Superposition of the turning movement by additional X- and Y-traverses
- Applicable for turning and milling
Highlights
Customer Benefits
- Eccentric geometries easy to manufacture
- Exact axis coupling and synchronization in the background
Left : Enter the parameters for the position of the external workpiece area. / Right : Graphical representation of the position within the workpiece.
MPC 2.0 – Machine Protection Control
- Vibration monitoring in the process
- Rapid shutdown in case of a crash
- Manual retraction even in swiveled machining plane
- NEW: Torque monitoring
- New: Recommended with Protection Package for CTX TC machines
Highlights
Customer Benefits
MPC Graph: aktuelle und angelernte Prozesswerte. / MPC Diagnostics: Lagerzustand, Anzahl von Stoß und Crash.
- Avoiding tool breakage
- Increase in machine availability
- Damage reduction
Interpolation turning 2.0 – turning recessing cycle
- With interpolation turning, the tool cutter follows a circular movement, where the cutter is always oriented towards the center Of the circle.
- Possible for external and internal machining
- Synchronization and tool path controlled by the cycle
- NEW: in version 2.0 complex turning contours are possible (currently only available on the DMU 50, other machine types will follow)
Highlights
Customer benefits
- Easy manufacturing of sealing surfaces where milling operation might not be possible.
- Complete component processing in one clamping possible
- Reduced investment costs for tools
angularTOOL
- Highest flexibility in the machining of structural components due to variable alignment of the angle head
- Automatic CAD / CAM programming
- Automatic calculation of the TCP and combination with existing control functions
Highlights
Customer Benefits
- Machining of inaccessible positions on the workpiece.
- Savings in non-productive time due to fewer tool changes
- High cost savings due to the use of fewer tools
Left : Tool driven by KSS during drilling operation / Right : Parameter mask for variable angle setting
Service & training
Downloads & Technical Data
Workpiece
Max. workpiece diameter
1600 mm
63 in.
Max. workpiece height
1350 mm
53.1 in.
Max. workpiece weight
4000 kg
8818.5 lbs.
Max. workpiece weight (Type FD)
3500 kg
7716.2 lbs.
Clearance
Max. X-axis travel
1600 mm
63 in.
Max. Y-axis travel
1600 mm
63 in.
Max. Z-axis travel
1100 mm
43.3 in.