Integration of Gear Machining on Multi-Tasking Centers

DMG MORI has introduced a suite of software solutions and technology cycles designed to integrate comprehensive gear machining processes into standard 5-axis machining centers and turn-mill machines. This development allows contract manufacturers and job shops across various industrial manufacturing sectors to perform specialized gear-cutting operations without investing in dedicated single-purpose machinery.

Process Integration and Geometric Modifications
The gearMILL software provides a computer-aided manufacturing module that utilizes standard cutting tools to produce complex gear geometries. This solution enables custom profile and flank modifications to adapt load patterns according to specific application requirements. It achieves a gear quality grade of greater than or equal to 5 in accordance with DIN/ISO standards, making it suitable for prototypes, replacement parts, and small-scale production series.

Process-Specific Cycles for Production Efficiency
For recurring manufacturing tasks, the system offers specific technology cycles that can be retrofitted to new or existing machinery as software installations. The gearSKIVING 2.0 cycle operates at speeds up to eight times faster than traditional methods, producing internal and external gears up to module 11 with a quality grade of greater than or equal to 7. On turn-mill centers within the NTX and CTX TC series, this capability extends to helical gears with tooth offset. Additional options include gearHOBBING for spur and helical spur gears, gearBROACHING for position-oriented internal and external teeth up to module 4, and gearSHAPING for targeted gear shaping operations.

In-Process Metrology and Automation
The integration of an optical laser scanner allows for closed-loop measurement directly within the machining workspace during production. The scanner captures 70,000 data points per second, maintaining over 80 percent of the measurement points within a tolerance of plus or minus 2 micrometers, matching the precision of external coordinate measuring machines. This in-situ metrology eliminates separate part transfer and re-clamping steps, reducing the total process steps from ten to six and shortening overall manufacturing cycle times by more than 50 percent. This single-setup method supports six-sided complete machining, facilitating the deployment of automated handling systems such as the Robo2Go.

Additional Context
This section details technical specifications and competitive benchmarking not included in the original product announcement.

Multi-tasking gear machining represents a shift from traditional dedicated hobbing and shaping machines to multi-functional computer numerical control platforms. Comparable industry solutions from alternative machine tool builders similarly employ specialized software cycles to synchronize rotational axes for skiving and hobbing operations. While dedicated gear-cutting machines achieve higher throughput for high-volume automotive manufacturing, multi-tasking centers utilizing integrated software provide the geometric flexibility and single-setup precision required for low-to-medium volume contract manufacturing. The achieved accuracy of DIN quality 5 via standard milling tools establishes a baseline that matches the technical demands of standard industrial machinery components without requiring secondary finishing operations on specialized equipment.

Edited by Evgeny Churilov, Induportals Media - Adapted by AI.

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