DECKEL MAHO DMU 160 P hi-dyn – 5-Axis CNC Universal Machining Center

DECKEL MAHO DMU 160 P hi-dyn – 5-Axis CNC Universal Machining Center

1. GENERAL MACHINE INFORMATION

Manufacturer: DECKEL MAHO

Model: DMU 160 P hi-dyn

Machine Type: CNC Universal Milling Machine / 5-Axis Machining Center

Year of Manufacture: 2003

Serial Number: 1122000643

CNC Control: HEIDENHAIN iTNC 530

Software Version: 340422 14 SP3

Number of Axes: 5

Machine Configuration: Universal Machining Center with NC Rotary Table and Automatically Swiveling Milling Head

2. WORKING AREA AND AXIS TRAVELS

X-Axis Travel: 1,600 mm

Y-Axis Travel: 1,250 mm

Z-Axis Travel: 1,000 mm

Feed Rate X/Y/Z: 20–15,000 mm/min

Rapid Traverse X-Axis: 60 m/min

Rapid Traverse Y-Axis: 60 m/min

Rapid Traverse Z-Axis: 60 m/min

Automatic Swiveling Milling Head

Controlled B-Axis Integrated into the Universal Milling Head

NC-Controlled Rotary Table

3D Contouring Control for Complex Milling Operations

Reinforced Ball Screw on Z-Axis with 20 mm Pitch

Reinforced Z-Axis Weight Compensation System

3. MAIN SPINDLE AND MILLING HEAD

Spindle Type: Integrated Motor Spindle

Maximum Spindle Speed: 18,000 rpm

Tool Holder: HSK-A 63 According to DIN 69893 (Documented Equipment Option)

Universal Milling Head with Controlled B-Axis

Automatically Swiveling Milling Head

Through-Spindle Coolant Supply

Spindle Cooling Air Supply

Spindle Motor Power, Original Basic Configuration, 40% Duty Cycle: 28 kW

Spindle Motor Power, Original Basic Configuration, 100% Duty Cycle: 19 kW

Original Basic Configuration Spindle Speed: 12,000 rpm

Original Basic Configuration Tool Holder: SK 40 According to DIN 69871

Note: The power ratings of the original basic configuration have not been separately confirmed for the 18,000 rpm motor spindle.

4. NC ROTARY TABLE AND WORKPIECE CAPACITY

Table Length: 1,500 mm

Table Width: 1,250 mm

Maximum Table Load: 4,000 kg

NC-Controlled Rotary Table

Number of T-Slots: 8

T-Slot Width: 18 mm

T-Slot Spacing: 125 mm

5. AUTOMATIC TOOL CHANGER AND TOOL MAGAZINE

Automatic Tool Changing System

Tool Changing System: Horizontal Tool Changer with Double Gripper

Tool Magazine: Rack-Type Magazine with 60 Tool Positions According to Optional Equipment Documentation

Tool Holder: HSK-A 63 According to Documented Conversion

Automatic Tool Change

Original Basic Configuration: 30 Tool Positions for SK 40

6. COOLANT SYSTEM AND CHIP REMOVAL

Coolant Tank Capacity According to Machine Data Sheet: 1,000 Liters

Coolant System Capacity According to Original Equipment Documentation: 900 Liters

Through-Spindle Coolant Supply

Coolant Pressure, Original Basic Configuration: 40 bar

Coolant Pressure Upgrade According to Optional Equipment: Switchable Between 40 and 80 bar

Paper Band Coolant Filtration System

Minimum Quantity Lubrication Through Spindle

External Minimum Quantity Lubrication via Nozzles

Through-Spindle Air Cooling

Coolant Functions Selectable via M-Codes

Chip Conveyor

Rotating Inspection Window

Coolant Washdown Gun with Separate Pump

Washdown Gun Performance: 1 bar / 40 l/min (Theoretical Pump Capacity)

Hydraulic and Cooling Units Mounted on Rubber Vibration Dampers

7. MEASURING SYSTEMS AND WORKPIECE INSPECTION

Infrared Workpiece Touch Probe

Manufacturer: M&H

Model: PS 25.00

BLUM Laser Tool Measuring System Inside the Working Area

Automatic Retraction of the Laser Measuring Unit into a Protective Housing

Tool Length Measurement

Tool Diameter Measurement

Horizontal and Vertical Tool Measurement

M&H 3D Form Inspect Software

Electronic Handwheel

8. CNC CONTROL, SOFTWARE AND ADDITIONAL FUNCTIONS

CNC Control: HEIDENHAIN iTNC 530

3D Contouring Control

German-Language CNC Interface

German-Language Electrical Documentation

German-Language Machine Documentation

M&H 3D Form Inspect Software

DMG Netservice (Original Equipment)

DMGplus Messenger

SMS and Email Notifications of Machine Operating Conditions (Originally Specified)

ISDN Router Including Software and Configuration (Originally Specified)

Operating Mode 4 – Process Monitoring During Machining

Manual Intervention with Open Working Area Doors Subject to Checklist Approval

Automatic Night Shutdown After Program Completion via M30

Night Shutdown Function Selectable via Key Switch

9. MACHINE DIMENSIONS AND WEIGHT

Machine Length: 8,800 mm

Machine Width: 6,087 mm

Machine Height: 5,628 mm

Machine Weight According to Machine Data Sheet: 35,000 kg

10. ORIGINAL ACCEPTANCE AND ACCURACY CRITERIA

Form Deviation at 2.5 m/min Feed Rate: Average Maximum 0.005 mm

Maximum Individual Deviation at 2.5 m/min Feed Rate: 0.006 mm

Form Deviation at 5 m/min Feed Rate: Average Maximum 0.010 mm

Maximum Individual Deviation at 5 m/min Feed Rate: 0.011 mm

Y-Axis Dimensional Deviation: ±0.010 mm

Z-Axis Dimensional Deviation: ±0.030 mm

Reference: 5-Axis Machined Acceptance Test Workpiece

Note: These are historical acceptance criteria and do not represent verified current machine accuracy values.

11. TECHNICAL SPECIFICATIONS REQUIRING CONFIRMATION

Actual Installed Tool Holder: HSK-A 63 or SK 40

Actual Tool Magazine Capacity: 30 or 60 Positions

Rated Power of the 18,000 rpm Motor Spindle: Not Confirmed

Actual Availability and Functionality of the 80 bar Coolant System: Not Confirmed

Actual Coolant Tank Capacity: 900 or 1,000 Liters

B-Axis Swivel Range: Not Specified

NC Rotary Table Rotation Range: Not Specified

Current Operating Condition and Functionality of Measuring Equipment: Not Confirmed

MACHINE DESCRIPTION

The DECKEL MAHO DMU 160 P hi-dyn, manufactured in 2003, is a large-scale 5-axis CNC universal machining center featuring an X-axis travel of 1,600 mm, an NC rotary table with a maximum load capacity of 4,000 kg, a documented 18,000 rpm motor spindle option, and extensive measuring and coolant equipment. The machine is particularly suitable for machining large and complex workpieces in the toolmaking, patternmaking, die and mold manufacturing industries, as well as for demanding simultaneous 5-axis milling applications.

DECKEL MAHO DMU 160 P hi-dyn – SERVICE & REPAIR COST SUMMARY

Service Provider: DMG MORI München GmbH

DOCUMENTED ANNUAL SERVICE & REPAIR COSTS

2018: EUR 2,395.79

2019: EUR 14,752.80

2020: EUR 17,021.24

2021: EUR 21,947.68

2022: EUR 2,447.66

2023: EUR 1,334.37

Subtotal 2018–2023: EUR 59,899.53

2024: EUR 147.46

TOTAL DOCUMENTED EXPENDITURE 2018–2024: EUR 60,046.99

MAJOR SPINDLE-RELATED REPAIRS

2019 – 18,000 rpm spindle cartridge replacement, including service and associated costs: EUR 14,752.80

2020 – Motor spindle rotor replacement, including service and associated costs: EUR 13,672.75

2020 – Additional rotor replacement under manufacturer goodwill: EUR 0.00

2021 – Spindle rotor replacement and encoder repairs, including service and associated costs: EUR 19,658.68

Total Spindle-Related Repair Orders: EUR 48,084.23

CURRENT SPINDLE INFORMATION

Last Spindle Rotor Replacement: March 2021

Operating Hours Since Replacement: 10,081 Hours

NOTE

All amounts are calculated from the documented DMG MORI order positions, including listed service, spare parts, freight charges and credits. VAT is not separately identified. Minor rounding differences may occur. The repair records include an additional spare parts order from 2024.