The gearMILL software and the technology cycles gearBROACHING, gearSHAPING, gearHOBBING, and gearSKIVING enable selected gearing operations on appropriately equipped machining centers, turning-milling centers, and 5-axis machines. The dialog-based software solutions assist users in programming and executing various gearing processes, thus facilitating entry into economical gearing machining without special machines. Especially job shops and medium-sized contract manufacturers can thus discover new opportunities for themselves without having to pass on gearing orders to external specialized companies. This reduces internal interface effort, shortens lead times, cuts costs, and ensures shorter delivery times. The benefit lies not only in the additional value creation. Furthermore, the possibilities for complete machining expand: turning, milling, gearing, and measuring can be integrated even more strongly into a continuous process chain. Moreover, complete machining can open the door to standard automation and pave the way for higher utilization rates of the machines.
DMG MORI gearMILL: Gearing even with standard tools
DMG MORI gearMILL is not a technology cycle in the true sense, but rather software for producing complex gearing geometries, with which individual profile and flank modifications can be easily realized. This also allows for easy adjustments to load images and customer-specific requirements. The integrated CAM module subsequently ensures effective programming using standard tools. The achievable gearing quality here is ≥ 5 according to DIN/ISO, which meets the requirements for prototypes, spare parts, and small series in many industries.
Technology cycles for recurring gearing tasks
As soon as defined gearing geometries occur regularly, the step to process-specific cycles is worthwhile. gearSKIVING 2.0 (gear skiving) is up to eight times faster than conventional gear shaping and allows for internal and external gearing up to module 11 at quality ≥ 7. This also applies to bevel gears with tooth offset on NTX and CTX TC series turning-milling centers. gearHOBBING covers the gear milling of spur and helical gears. gearBROACHING is designed for position-oriented broaching of internal and external gears up to module 4. gearSHAPING supports the production of internal or external gears with gear shaping. All cycles can be retrofitted as pure software solutions in new and existing machines.
Integrated measuring: 40 percent fewer process steps
A central productivity lever is optical measurement via laser scanner for gears directly in the machining process. With 70,000 sampling points per second and more than 80 percent of the measurement points within ±2 µm, the solution achieves the accuracy of an external coordinate measuring machine. Compared to the conventional process with separate measuring and clamping steps, the number of process steps is reduced from ten to six, and the total process time decreases by more than 50 percent. Machining and measurement take place in a single clamping. Correction values are thus immediately fed back, which offers advantages in terms of quality and logistics, especially for larger components.
Complete machining in a single setup
Turning, milling, gearing, and measuring can be represented on DMG MORI turning-milling centers in a single clamping. The CTX TC and NTX series also enable 6-sided complete machining without manual re-clamping. This creates optimal conditions for the cost-effective use of standard automation solutions such as Robo2Go. Small and medium-sized service companies can thus benefit from shorter lead times, less internal transport, and a predictable manufacturing flow without sacrificing flexibility in day-to-day business.
Modular roadmap for medium-sized enterprises
DMG MORI positions universal gearing as a practical entry point into machining transformation (MX) – especially for small and medium-sized CNC companies that want to strategically expand their range of services with existing machines. A two-step approach is recommended: In the first step, DMG MORI gearMILL opens up new order fields for prototypes, spare parts, and small series for users, without the need for special gearing machines or special tools. In the second step, process-specific cycles, automation solutions, and digitalization components can be added as soon as gearing tasks occur regularly or medium batch sizes are to be economically implemented. All DMG MORI technology cycles are retrofittable as software solutions, making them investment-friendly accessible even for existing machines.
Contact:
