In modern production with difficult-to-machine materials and high quality requirements, tools made from ultra-hard cutting materials such as PKD, CVD, MKD, and CBN are becoming increasingly important. Users benefit from optimal cutting speeds, longer tool life, and better surfaces. Machining these cutting materials is more demanding than that of conventional hard metals, driving the development of innovative manufacturing solutions for these advanced tools. At GrindingHub in Stuttgart, DMG MORI presents various solutions.
LASERTEC SLM: Ultra-hard milling heads from the powder bed
Both the LASERTEC 12 SLM exhibited at GrindingHub and the larger LASERTEC 30 SLM 3rd generation serve as productive solutions for the additive manufacturing of milling heads in the powder bed. The decisive advantage over conventional manufacturing processes lies in the complex geometries that the additive process realizes. For example, internal cooling channels can be integrated, ensuring optimal heat dissipation when machining with ultra-hard cutting materials. The LASERTEC SLM machines are equipped with CELOS X with easyAM on the control side, making the powder bed machines easy to operate and maintain. rePLUG powder modules also enable quick changes between different materials.
LASERTEC 20 PrecisionTool: Edge rounding in a single setup
DMG MORI offers advanced finishing of cutting edges with the LASERTEC 20 PrecisionTool. The 5-axis laser machine rounds cutting edges without post-processing in a single setup at a speed of up to 5 mm/min with 1.6 mm thick PKD. Measuring the stroke profile of the round laser bevel as well as individualization or adaptation are also possible on the machine. The LASERTEC 20 PrecisionTool produces cutting edges with a sharpness of under 1 µm and a defined edge rounding of 3 µm, 6 µm, 9 µm, and 15 µm. Negative bevels are also possible. Furthermore, the process-safe laser machining contributes to higher cost-effectiveness by increasing tool life by a factor of 2.5.
LASERTEC 50 PrecisionTool Femto: Miniature tools
In addition to this process chain, DMG MORI serves another highly dynamic market segment with micro tool machining on the LASERTEC 50 PrecisionTool Femto. The focus is on miniature tools starting from a diameter of 0.2 mm, made from sintered PKD diamonds and manufactured extremely delicately using ultra-short pulsed femto laser ablation. Especially at these tool dimensions, traditional mechanical machining processes such as grinding or wire EDM often reach their technological limits. High process forces, tool wear, and complex and fragile geometries often make reproducible machining impossible.
In contrast, the femto-laser technology of the LASERTEC 50 PrecisionTool enables nearly force-free material removal with the highest geometric accuracy. This allows even the most demanding cutting geometries and defined cutting edge qualities to be realized, which represents a decisive advantage, especially in applications with the highest requirements for precision, tool life, and process reliability. Users benefit not only from the laser machining itself but also from DMG MORI's comprehensive machine, control, and process expertise in the field of precision tool manufacturing.
Vertical Mate 85 2nd generation: Multi-process grinding for demanding industries
With the multi-process grinding machine Vertical Mate 85 2nd generation, DMG MORI builds on the success of the predecessor model. It allows the machining of inner and outer diameters as well as flat surfaces in a single setup. Its speedMASTER LongNose spindle achieves a power of 18.5 kW, 35.3 Nm torque, and a speed of 10,000 min-1. An optimized machine structure and high thermal stability contribute to high-precision machining, as does the linear measuring rod in the X-axis. The Vertical Mate 85 2nd generation achieves a roundness of 1 µm and thus masters precision applications in challenging industries such as mobility, semiconductor, or aviation.
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