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Spindle Service

Unique DMG MORI Gear Cutting solutions …

… to increase your own added value!

Do you already utilize your machine’s full potential? Increase your own added value with DMG MORI technology cycles!

Overview

DMG MORI gearSKIVING 2.0

UTILIZE YOUR MACHINE’S FULL POTENTIAL?

You might well know the problem. You get an enquiry for a range of components that, at first sight, are ideal for your machines. But the devil is in the detail. Special operations are needed, e. g. internal teeth which you are unable to reproduce. You now have to choose whether to turn down the order or buy-in the service from outside. However, this can be avoided by using our exclusive DMG MORI technology cycles. On the following pages, you will find out how to overcome these challenges as well, and increase your own added value with a simple software upgrade.

FASTER: thanks to menu-guided entry of gear parameters
SIMPLE: Automatic calculation of NC program based on gear parameters
RETROFITTABLE: Pure software solution – integration in new and existing machines*

*Retrofittability of gearBROACHING and gearSKIVING depending on the control version

UNIQUE DMG MORI GEAR CUTTING SOLUTIONS

CONVERSATIONAL PROGRAMMING IS 60 % FASTER

The exclusive DMG MORI technology cycles  are genuine assistive systems for shopfloor programming that boost productivity and safety  as well as enhancing machine capability.

  • Clear programming structure
  • Up to 60 % faster programming
  • Error reduction thanks to conversational  programming
  • New technologies (gear-cutting, grinding)
  • Technology know-how saved in the program

55 DMG MORI TECHNOLOGY  CYCLES

COMPLEX MACHINING  IMPLEMENTED WITH EASE

  • 23 MACHINING CYCLES
    e. g. new machining processes and  enhanced machine capability such as  gear machining
  • 15 HANDLING CYCLES
    e. g. simplification of machine operation  and automated sequences
  • 9 MEASURING CYCLES
    e. g. increased machining accuracy  and transparency of QA processes
  • 8 MONITORING CYCLES
    e. g. increased machine safety and  process reliability


TECHNOLOGY INTEGRATION

GEAR CUTTING SOLUTIONS

INTERNAL & EXTERNAL GEARS
ø 3,200mm MAX. DIAMETER

SPUR GEARS

  • Spur, helical and  double-helical gears  
  • Segments

BEVEL GEARS

  • Spur, helical, spiral and hypoid gears              
  • Axis angles other than 90
  • Klingelnberg Zyklo-Palloid®
  • Gleason

WORM GEARS

  • Profil ZA
  • Profil ZN
  • Profil ZI
Gear cutting technology cycles for Mill & Turn and Turn & Mill machines
gearSKIVING - up to 8 times faster than broaching.
gearMILL - gear cutting on standard machines with standard tools

Gear cutting technology cycles for Mill & Turn and Turn & Mill machines

ULTRASONIC main
  • Gear cutting on 5-axis milling, mill-turn and turn-mill machines: External & internal gear cutting up to Ø 3,200 mm and gear quality > 5
  • Maximum flexibility: Demand-driven utilisation of machines for gear cutting operations, as a supplement to milling and/or turning operations.
  • Fast: Through conversational input of the gear parameters
  • Simple: Automatic calculation of the NC program based on the gear parameters
  • Retrofittable: A pure software solution - integration into new and existing machines
  • DMQP: Always the optimal tools from our cooperation partners


Webspecial

gearSKIVING - up to 8 times faster than broaching.

ULTRASONIC highlight 1
  • Gear skiving of internal and external gears up to MODULE 11
  • Straight and helical external or internal spur gears and splines; internal gears possible without an angle head
  • Synchronisation and tool path controlled by cycle
  • Available for machines with SIEMENS / CELOS with SIEMENS and MAPPS / CELOS with MAPPS
  • TURN & MILL and DMF 
    • Herringbone gears with tooth offset
    • Crowned gears by mathematical transformation of the 6th virtual axis on TC & DMF machines


Webspecial

gearMILL - gear cutting on standard machines with standard tools

ULTRASONIC highlight 2
  • Gear cutting with standard tools ≥ MODULE 3
  • Program generation based on drawings or gear data, contact pattern individually modifiable
  • Postprocessor for SIEMENS, HEIDENHAIN and MAPPS
  • Spur gears, bevel gears and worm wheels
  • Interface for coordinate measuring machines (Klingelnberg, Leitz, Zeiss)
  • In-process measuring: Tactile via touch probe and optical via laser scanner, accuracy comparable to a coordinate measuring machine


Webspecial

Measurement

OPTICAL ON-MACHINE MEASUREMENT

Non contact profile measurement by laser scanning probe          

  • 70,000 scan points per second
  • Enable to evaluate free form surface

Reduced number of processes & time

  • 6 instead 0 process steps and > 50 % reduced process time       
  • Machining & measurement in a single set-up

Same accuracy as CMM

  • More than 80% measuring points within ± 2 µm
  • Improvement of machining accuracy

Gear measurement & evaluation

  • Automatic scanning path generation, incl. visualization
  • Professional solution easy to use for every operator
Technology Cycles

EXAMPLE: HELICAL GEAR

ø 300 mm // 73 Teeth

  

CMM

OPTIC

  

40 min

13 min

Alignment   

20 min (manual)           

3 min (automatic)

4 Teeth   

7 min (6 lines)

4 min (whole flank)

Index Error    

13 min

6 min

> 50% reduced process time

CUSTOMER VOICES & VIDEOS

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