It can be integrated into a user's digital infrastructure and is compatible with the manufacturer's exclusive technology cycles, such as in-cycle gear skiving or grinding, which run in either the CELOS with Siemens or Heidenhain control.
Compared to the previous machine model that has been superseded, the DMF 400|11 is nearly one-third larger in capacity as well as being 20 percent stiffer to enable more precise, vibration-free operation. An optional partition wall creates two separate workspaces for pendulum machining, allowing set-up of the next workpiece while the previous part is being produced.
Stable machining performance is largely a result of a massive cast iron bed and three cooled linear guideways in the X-axis over which the column moves. In a double ballbar test, the DMF 400|11 achieves an accuracy of 5 µm, making the machine ideal for producing large moulds, dies and tools, as well as precision structural parts within the machine's 4,000 x 1,100 x 1,050mm working envelope.
The fixed table accepts components weighing up to eight tonnes for 3- or 4-axis machining of large components. One or two flush rotary C-axis tables may be integrated for fully interpolative 5-axis machining, each capable of supporting components weighing 1,200 kg, while a torque table option is offered for demanding mill-turn applications. An add-on table as an A-axis with a load capacity of 500 kg is also available.
The ±120-degree B-axis houses an integrated, 15,000 rpm speedMASTER spindle as standard, but is available in a 20,000 rpm version, or as a 12,000 rpm powerMASTER spindle having higher torque at 288 Nm. All carry a 36-month warranty, irrespective of the hours the spindle has run. The standard tool magazine accommodates 40 HSK-A63 cutters up to 400 mm long (540 mm for the optional HSK-A100 interface), although the number of pockets can be extended to 120.
Tool change is now carried out in an enclosed area behind the worktable, which is a special feature of the latest DMF generation. It gives the machines a high level of process reliability by eliminating the risk of collision and allowing workpieces to be placed on the table without restriction. The linear guideways are similarly located outside the work area, protecting them from abrasive materials and contributing to the longevity of the components.
A highlight of the cantilevered design of the spindle head is that the distance between the column casting and the centre of the spindle is always the same, irrespective of the position in the Y-axis, improving stiffness and machined surface quality. The constant overhang ensures consistent rigidity over the entire travel, allowing users to program maximum power at any time, regardless of the transverse position of the spindle.
As standard, the DMF 400|11 is supplied with ballscrew drives in Y and Z but a linear drive in X having a rapid traverse rate up to 80 m/min for elevated levels of productivity, which becomes even higher if optional linear drives are fitted to the other orthogonal axes.
Automation options also raise production output and DMG Mori has pre-installed appropriate interfaces, for example for the integration of robotic handling. All solutions for autonomous running are manufactured in-house, so the user has a single point of contact for the entire installation.
