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DMG

Aerospace Industry

www.gildemeister.com DMG – innovative technologies

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Complete machining of a

compressor housing with a

DMC 160 FD duoBLOCK® -m

and turning in a single setu

FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 7

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 theglobal 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 manu-

facturing, 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.

321 The 3 main groups in the

DMG application spectrum:

|1| Structural components

|2| Engine components

|3| Landing gear com-

ponents


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.

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

a

b

c

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

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 cm3/min

(15,000 rpm. up to 30,000 rpm., max. 100 kW)

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.

a

b

c


5 6

31

4

8 9

7

2

Landing gear components machined on the

DMU / DMC duoBLOCK® Series:

|7| Actor |8–9| Connecting bracket

sk.Structural components

ng

tive angles up to 30°

ty

)

kpieces

p to 10,000 cm3/min

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Landing gear components

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


9

6 7

8

3 4

2

5

1Engine 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

Engine components

Engine components – machined on

LASERTEC 80 PowerDrill:

|8| HP turbine rotor blade

|9| HP turbine rotor blade guide vane


The GMX linear Series – milling-turning centers for the 6-sided complete machining of complex workpieces.

LASERTEC 80 PowerDrill – The technological leader for the precise laser boring of turbine components.

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

GMX l inear 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

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 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, [email protected], www.gildemeister.com

Our top priority is to provide you with

the best possible training for the per-

sonnel 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 tech-

nology. DMG training puts you on the

course for success and secures your

competitive edge.

As the largest global producer of metal

cutting machine tools and the tech-

nology 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 machin-

ing and HSC-milling all the way to the

revolutionary use of future-oriented

laser technology.

Rotary and linear magazines

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 produc-

tivity and availability for your opera-

tions. DMG Spare-parts Service offers

the best availability worldwide and the

shortest delivery times.

DMG technology and key competency

DMG TrainingComprehensive Training

DMG Service Solutions

DMG in the aerospace industry:Your demands are our benchmark

MO

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RT

WERBUNG

FLY

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3922

/080

6US

Tec

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pdat

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res

erve

d. We automate your production

Workpiece handling with robot Flexible pallet systems

he 3 main groups in the

MG application spectrum:

| Structural components

| Engine components

| Landing gear com-

ponents


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