www.gildemeister.com DMG innovative technologies DMG Aerospace Industry
Complete machining of a compressor housing with a DMC 160 FD duoblock -milling and turning in a single setup.
DMG Your High-tech partner in the global aerospace process chain. Unlike any other company, DMG has a complete range of machine tools for the aerospace manufacturing sector. We offer complete Milling / Turning machines and for new machining methods, we offer Ultrasonic and Laser technology. To compliment our machines DMG Service Solutions provides complete training, software and tool measurement products to enhance your production performance. Integrated milling and turning centers manufacture turbine components made from high-strength materials, vertical lathes deliver maximum productivity in the cylinder production of aircraft motors, LASERTEC 80 PowerDrill machines have revolutionized the production of shaped holes in engine manufacturing, and the duoblock portal machines in the DMU / DMC Series deliver maximum performance for sophisticated 5-axis / 5-sided machining in the production of integral aluminum components. All these are examples of DMG the global partner for the international aerospace industry. 1 2 3 The 3 main groups in the DMG application spectrum: 1 Structural components 2 Engine components 3 Landing gear components
DMU / DMC duoblock Series The right solution for every 5-axis machining task. The duoblock -design from DECKEL MAHO has become the standard strategic platform for milling applications up to 4,000 kg and has led to unprecedented flexibility in the manufacturing of parts such as bladed disks (blisks), casings and housings. c a b a Spindle options for more complex machining _ Automatic swivel milling head H / V _ NC-swivel milling head as an A-axis for negative angles up to 30 _ NC-swivel milling head as a B-axis (swivel range 0 210 ) with maximum rigidity b Spindle options for maximum flexibility _ Motor spindle for HSC-machining (10,000 rpm. to 18,000 rpm., 121 to 288 Nm) _ Gearbox spindle for machining of heavy workpieces (6,300 rpm. to 8,000 rpm., 727 to 1,100 Nm) _ Aerospace spindle for max. chipping rates up to 10,000 cm 3 /min (15,000 rpm. up to 30,000 rpm., max. 100 kw) c Table options _ NC-rotary table _ NC-swivel rotary table _ NC-milling / turning table (up to 800 rpm.) Automated production: Flexible manufacturing system with five DMC 160 FD Milling-Turning centers for the fully automatic machining of combustion chamber housings. duoblock Series Production Highlights Standard version: _ Production package: Coolant tank 600 / 980 l, coolant through the spindle center (40 Bar), chip conveyor and Rotoclear _ High precision package: TPC (Table Precision Control) for the identification and correction of the pivot point of the NC-rotary table; HPC (Head Precision Control) for the identification and correction of the pivot point of the spindle head _ Chain magazine with 40 pockets (DMU 80 / 100 / 125P) or 60 pockets Turning-Milling: _ 5-axis milling and turning in a single setup _ Electronic balancing on the machine _ Concentric trueing in the setup area _ Setup area with a powered rotary pallet (DMC 200 / 340 FD) _ New FD-drives with DirectDrive technology, rotational speeds up to 800 rpm., more torque (up to 40 kw) and max. table loads up to 7,000 kg Technical Data DMU 80 P DMC 80 U DMU 100 P DMC 100 U DMU 125 P DMC 125 U DMU 160 P DMC 160 U X- / Y- / Z-axis mm 800 / 800 / 800 1,000 / 1,000 / 1,000 1,250 / 1,000 / 1,000 1,600 / 1,250 / 1,000 Main drive (40 / 100% DC) kw 28 / 19 28 / 19 28 / 19 28 / 19 Torque (40 / 100% DC) Nm 121 / 82 121 / 82 121 / 82 121 / 82 Speed range rpm. 12,000 12,000 12,000 12,000 (8,000 / 10,000 / 18,000)* (8,000 / 10,000 / 18,000)* (8,000 / 10,000 / 18,000)* (6,300 / 10,000 / 18,000)* Feed and rapid traverse X/Y/Z m/min 60 60 60 60 Tool holder SK40 (SK50)*** SK40 (SK50)*** SK40 (SK50)*** SK40 (SK50)*** Number of magazine pockets 40 60** 40 60** 40 60** 60**** Table size (NC-rotary table) mm 900 x 700 800 x 630 1,100 x 900 1,000 x 800 1.,250 x 1,100 1,000 x 800 1,500 x 1,250 1,250 x 1,000 DMG ControlPanel with 15" TFT-screen and 3D-software, Controls: Siemens 840D powerline, Heidenhain itnc 530, Heidenhain MillPlus it, Siemens 840D powerline * Optional, ** Optional: 60 / 120 / 180 / 240 / 300 / 354, *** Optional: HSK-A63 / HSK-A100, **** Optional: 120 / 180 / 240
Structural components 1 2 3 4 5 6 Structural components machined on the DMU / DMC duoblock -Series: 1 Structural wing component 2 3 Structural fuselage components 4 Structural wing component 5 6 Structural fuselage components Landing gear components 7 8 9 Landing gear components machined on the DMU / DMC duoblock Series: 7 Actor 8 9 Connecting bracket
Engine components Engine components machined on the DMU / DMC duoblock Series: 1 Plenum chamber housing 2 Combustion chamber housing 3 Impeller disk 4 HP compressor housing 5 Turbine housing 6 Compressor annulus 7 Compressor turbine vane 1 2 3 4 5 6 7 Engine components machined on LASERTEC 80 PowerDrill: 8 HP turbine rotor blade 9 HP turbine rotor blade guide vane 8 9
The GMX linear Series milling-turning centers for the 6-sided complete machining of complex workpieces. GMX linear Series Highlights _ Linear drive in the Z-axis ensures maximum precision and dynamics, rapid traverses up to 70 m/min _ High-performance milling spindle with 12,000 rpm. and up to 120 Nm, swivel range 240 _ CAD-data import and multi-axis milling with DMG Programmer 3D Turning (optional) _ DMG ControlPanel with 15" TFT-screen and Siemens 840D powerline, 3D-simulation and collision monitoring (optional) _ 12x-turret with driven tools _ Shelf magazine for 60, 120 or 180 tools Technical Data GMX 200 S 250 S linear GMX 200 linear GMX 250 linear GMX 300 linear GMX 400 linear GMX 500 linear Work area Max. machining diameter mm 640 560 640 640 640 610 Max. machining length (with tailstock) mm 1,185 (1,180) 1,070 (1,000) 1,185 (1,180) 1,585 (1,500) 1,585 (1,500) 1,870 (1,850) Max. bar diameter mm 65 (90)* 65 (90, 102)* 65 (90, 102)* 65 90 (102)* 102 Main- and counter spindle* Max. drive power (40% DC) kw 28 (47)* 37 (45, 45)* 28 (47, 45)* 37 45 (45)* 69 Max. torque (40% DC) Nm 320 (730)* 390 (750, 750)* 320 (730, 750)* 390 750 (750)* 1,000 Turning- / milling spindle Max. spindle speed rpm. 12,000 (18,000)* 12,000 (18,000)* 12,000 (18,000)* 12,000 (18,000)* 12,000 (18,000)* 12,000 Max. drive power (40% DC) kw 22 22 22 22 22 15 Y-axis / B-axis mm / degrees ± 90 / ± 120 ± 80 / ± 120 ± 90 / ± 120 ± 110 / ± 120 ± 110 / ± 120 ± 105 / ± 120 Tool magazine Disk Shelf Shelf Shelf Shelf Chain Number of tools 36 46 (80)* + 4 46 (80)* + 4 60 (120, 180)* + 4 60 (120, 180)* + 4 40 (80)* 12-x turret head with tool drive* Drive power (40% DC) kw 11.7 11.7 11.7 11.7 10 Torque (40% DC) Nm 28 28 28 28 42 DMG ControlPanel with 15" TFT-screen and 3D-software, Controls: Siemens 840D solutionline**, Siemens 840D powerline, Heidenhain PlusIT*** * Optional, ** only for GMX 200 S linear, *** only for GMX 250 S linear LASERTEC 80 PowerDrill The technological leader for the precise laser boring of turbine components. LASERTEC Series Highlights _ 5-axis laser precision boring of cooling air vents and shaped holes in turbine components _ Highest dynamics due to linear drives in X, Y, and Z, with 1.2-g acceleration _ Rotary- and turning axes (B- and C-axis) with torque motor _ Special Lasertec turbine software for simple programming and operation _ Highly precise Nd:YAG-laser for boring and welding Technical Data LASERTEC 80 PowerDrill LASERTEC 80 PD SHAPE Number of machine axes 5 5 Work area X / Y / Z mm 800 / 500 / 700 800 / 500 / 700 Rapid traverse speed linear X / Y m/min 120 120 Max. workpiece weight kg 50 50 Machine precision P max. μm 10 10 Laser sources Nd:YAG or CO2 Nd:YAG DMG ControlPanel with 15" TFT-screen and 3D-software Control: Siemens 840D powerline
DMG in the aerospace industry: Your demands are our benchmark MONTFORT WERBUNG DMG technology and key competency As the largest global producer of metal cutting machine tools and the technology leader for 5-axis machining, DMG presents itself as the optimal partner for the aerospace industry and its suppliers. DMG is a master of all aspects in the aerospace process chain, from highly precise complete machining and HSC-milling all the way to the revolutionary use of future-oriented laser technology. DMG Training Comprehensive Training Our top priority is to provide you with the best possible training for the personnel responsible for the operation and maintenance of your machine tools. You achieve the highest productivity of your manufacturing processes with the help of our practice-oriented training with a global perspective, on machines equipped with the most advanced technology. DMG training puts you on the course for success and secures your competitive edge. DMG Service Solutions Take advantage of our customized service products and service support options for the entire life span of your DMG machine tools and systems. Our expert Service Hotline and DMG Netservice ensures highest productivity and availability for your operations. DMG Spare-parts Service offers the best availability worldwide and the shortest delivery times. We automate your production FLY.SD3922/0806US Technical update rights reserved. Rotary and linear magazines Workpiece handling with robot Flexible pallet systems DMG Vertriebs und Service GmbH: Gildemeisterstraße 60, D-33689 Bielefeld, Tel.: +49 (0) 52 05 / 74-30 13, Fax: +49 (0) 52 05 / 74-30 77, info@gildemeister.com, www.gildemeister.com