DMG Mori dmc 80h Horizontal machining centre

DMG 1V10R1

Horizontal Machining Centre
DMC 80 H duoBLOCK

World Premiere
duoBLOCK
4th Generation

Applications and Parts
Machine and Technology
Control Technology
Technical Data

4th Generation of duoBLOCK
The New Benchmark in High Efficiency Heavy Machining

Production at the highest level: The horizontal machining centres in the rigid duoBLOCK design, with 30% more precision, performance, and efficiency, allow for the best machining performance and maximum component precision with the highest dynamics. From heavy machining, for instance, in mechanical engineering, to highly efficient series production in the automotive industry, the 4th generation DMC 80 H duoBLOCK is best suited for efficiently and cost-effectively producing complex components in the shortest possible time.

Applications
Automotive: Cylinder Block, Cylinder Head
Mechanical Engineering: End Housing made of GGG60
Railways: Axle Bearing made from GS45

Machine and Technology

4th Generation of duoBLOCK - Added Value for You

Powerful
With the new DMC 80 H duoBLOCK, every component becomes a masterpiece in no time. The larger working area with a 31% larger horizontal passage, the high pallet load of 1,400 kg, the space-saving innovative wheel magazine, and many other features allow for highly efficient production. For example, the stiffness of the highly stable and highly precise duoBLOCK concept was increased by 30%. The new geared spindle with a torque of up to 1,425 Nm rounds off this powerful concept.

DMC 80 H duoBLOCK
Precision, Performance, Efficiency

30% higher precision

30% higher overall stiffness

30% lower energy consumption

Precision

Complete feed drive cooling with the precision package

Comprehensive cooling measures

High machine availability

Stiff ball screw with a 50 mm diameter

55 mm wide linear guides on the Z-axis

Performance

High-performance geared spindle rated at 1,425 Nm

powerMASTER 1000 motor spindle rated at 1000 Nm and 77 kW

Efficiency

Lower space requirements, extremely compact wheel magazine

Shortest tool readiness time

CELOS - Excellence Redefined

CELOS from DMG MORI enables consistent administration, documentation, and visualization of work orders, processes, and machine data. CELOS can be extended with apps and is also compatible with your company’s existing infrastructure and programs.

The Masterpiece. Always Precise

Comprehensive cooling measures achieve the highest long-term accuracy and precision. Together with the precision package, the entire feed drive is cooled, and the machine bed is temperature-controlled, resulting in up to 30% higher component accuracy.

Standard Cooling Measures

Headstock housing and motor spindle

NC rotary table and B-axis motor

X/Y/Z feed axes: ball screw bearings and linear guides

Precision Package

Cooling bars on the machine bed and column

Thermal shield for improved temperature response

Permanent thermal stability

The Highest Stiffness for Maximized Machining Performance

The overall stiffness of the highly stable and accurate duoBLOCK concept was improved by over 30%. FEM calculations optimized the structure, and components were strengthened. This stiffness translates into maximized machining performance with geared spindles delivering up to 1,425 Nm torque.

Geared Spindles

Speeds of up to 8,000 rpm

Spindle torques of 1,053 Nm and 1,425 Nm

Manufacture More Efficiently

The new DMC 80 H duoBLOCK reduces energy consumption by up to 30% thanks to intelligent, requirements-based motors. The new compact tool magazine reduces the machine footprint by 41%.

Compact and Fast Wheel Magazine

Most compact magazine on the market

Tool magazine with up to 243 tools

Tool-changing time of just 5 seconds

Automation Solutions

Flexible production cells

Manufacturing systems with central tool magazines

Articulated robot arm and pallet handling options

Performance Chart
DMC 80 H duoBLOCK
Performance chart
SK50 / HSK-A100 geared

The DMC 80 H duoBLOCK is a high-efficiency horizontal milling machine designed for complex, precise, and heavy-duty machining applications. Below, I’ve distilled the key highlights, specifications, and capabilities for better comprehension:

Key Highlights:

Efficient and Precise Milling:

High stiffness: The optimized design reduces overhang, improving machining precision and reliability.

Thermosymmetrical coolant nozzle alignment ensures thermal stability during operation.

Innovative Milling Heads:

FEM-optimized structure for heavy machining with geared spindles rated up to 1,425 Nm.

H head improvements with 20% higher stiffness and optimized interfering contours.

Optional intelligent tool management for enhanced productivity.

Tool Management:

Available with 8-slot tombstone for high-efficiency production setups.

Flexible tool magazine with up to 303 tool slots, supporting rapid tool changes.

Heavy-Duty Machining:

Hydraulic NC rotary table clamp with 6,000 Nm detent torque.

Damper shoes for the Y-axis provide stability for challenging materials.

Active Chatter Control (ACC) for vibration-free performance.

Energy Efficiency:

Frequency-controlled high-pressure cutting fluid pumps reduce energy consumption by 30–50%.

Savings of up to 7,200 kWh annually in production energy costs.

Automation & Monitoring:

3D quickSET for quick setup.

Infrared measuring sensors (Heidenhain/Renishaw) and laser tool measurement for real-time accuracy.

CELOS control system with Siemens 840D solutionline for seamless operation.

Technical Specifications:

Working Area:

X / Y / Z travel: 800 x 850 x 1,050 mm.

Maximum workpiece diameter: 900 mm.

Maximum workpiece height: 1,450 mm.

Maximum pallet load: 1,400 kg.

Main Drive:

Motor spindle speeds: 12,000 min-1 (standard) or 8,000 min-1 for heavy machining.

Power: 44 kW (short-term duty) / 32 kW (continuous).

Torque: 1,053 Nm for high-performance tasks.

Toolchanger:

Tool magazine: 63 to 303 slots.

Chip-to-chip time: Efficient for high-speed operations.

Machining Performance:

Linear axis traverse rate: 60,000 mm/min.

Acceleration: 7 m/s² across X, Y, Z axes.

Coolant System:

High-pressure internal coolant supply: 80 bar, frequency-controlled.

Coolant unit: 980 liters, with temperature control for stability.

Machine Dimensions:

Space requirements: Approx. m² with chip conveyor.

Machine height: 3,400 mm.

Machine weight: 18,000 kg.

Example Applications:

Automotive:

Cylinder block machining: Full machining, crankshaft machining, and cylinder boring.

Material: GG25.

Dimensions: 1,027 x 395 x 505 mm.

Cycle time: 24 minutes.

Tools: Up to 280.

Cylinder head machining: Includes camshaft boring and valve seat turning.

Dimensions: 1,054 x 370 x 200 mm.

Cycle time: 21–24 minutes.

Railway:

Axle bearings: Precision boring and hydraulic clamping.

Dimensions: 850 x 244 x 366 mm.

Cycle time: 18 minutes.

Mechanical Engineering:

End housings: Achieves planarity and coaxiality requirements.

Dimensions: 210 x 235 x 100 mm.

Tools: 49, using multi-slot tombstone.

Efficiency Features:

Energy Savings:

Frequency-controlled coolant systems reduce power consumption.

Needs-based pressure adjustments lower costs during smaller tool operations.

Reduced Wear:

Hydraulic positioning and active damping reduce tool wear and improve surface quality.

High Reliability:

Improved thermal symmetry and structural stiffness deliver consistent performance for demanding production environments.

Optional Features:

Measuring sensors (Heidenhain T5640 or Renishaw OMP 60).

Minimum quantity lubrication.

Torque support and U-axis options.

Advanced tool holder compatibility (HSK-A100, BT50, CAT 50).

Here’s a concise breakdown of the SIEMENS 840D solutionline options for the DMC 80 H duoBLOCK:

SIEMENS 840D Solutionline Options:

Control and Monitoring:

Electronic SIEMENS 840D Handwheel:

Offers precise manual control for fine-tuning and machine setup.

Control Console for Tool Magazine Loading Station:

Simplifies tool management and loading operations directly at the magazine.

3D Machining and Tool Correction:

Includes real-time surface normal vector-based 3D tool correction for enhanced machining precision.

Advanced Machining Features:

TRANSMIT Lateral Surface Transformation:

Enables cylinder path milling for complex geometries, ideal for advanced contour machining.

CompCad Compressor Function:

Optimized for high-speed machining, reduces processing times for intricate parts while maintaining accuracy.

General Options:

Clamping Hydraulics:

Integrated hydraulic clamping system ensures secure, vibration-free workpiece holding.

Shatterproof Safety Glass Viewing Panel:

Provides safety and a clear view of the machining process, suitable for heavy-duty operations.

Operating Mode 4:

Allows efficient process monitoring during production, enabling operators to oversee real-time performance.

Precision and Heavy-Duty Machining:

Package for Increased Precision:

Focused on enhancing accuracy with features like:

Thermally symmetric designs.

Advanced sensors for real-time adjustments.

Heavy-Duty Machining Package (Optional):

Includes upgrades like:

Hydraulic NC rotary table clamps (6,000 Nm torque).

Damper shoes on the Y-axis for added stability.

Vibration reduction with Active Chatter Control (ACC).

These options significantly enhance the DMC 80 H duoBLOCK's performance, precision, safety, and operational flexibility, making it a highly capable solution for various industries. Let me know if you need details on any specific feature!