DMG MORI has expanded its software portfolio for integrated gear machining. The portfolio targets CNC job shops and medium-sized manufacturers that want to add selected gear-cutting operations without dedicated gear-cutting machines. The approach combines gearMILL software with technology cycles for broaching, shaping, hobbing and skiving. It is intended to reduce outsourcing, shorten lead times and combine machining and measurement in one process chain.
For manufacturers producing prototypes, replacement parts or small batches, gear cutting is often a specialist operation handled externally. This can add transport, coordination and re-clamping steps to the production process. DMG MORI aims to bring selected gear-cutting operations to suitably equipped machining centres, turn-mill centres and 5-axis machines already used for other tasks.
The software solutions are dialogue-guided. They support both programming and execution of the respective gear-machining process. Therefore, gear cutting becomes an additional capability within the CNC environment rather than a separate production area. Depending on machine configuration and component requirements, turning, milling, gear cutting and measurement can be combined in a single setup.
Software for variable gear geometries
The gearMILL software is designed to produce complex gear geometries. It also supports customised profile and flank modifications. According to DMG MORI, users can adapt load patterns and meet component-specific requirements. An integrated CAM module supports programming with standard tools. This avoids the stated need for special gear-cutting tools in this application area.
The achievable gear quality is specified as grade 5 or better according to DIN/ISO. DMG MORI positions this capability for prototypes, replacement parts and small production runs. In these applications, geometry flexibility can be more important than a dedicated high-volume process.
When recurring component geometries justify a more specialised process, the company offers additional technology cycles. gearHOBBING covers spur gears and helical spur gears. gearBROACHING is intended for position-oriented broaching of internal and external gear teeth up to module 4. gearSHAPING supports internal and external gear shaping.
The gearSKIVING 2.0 cycle is specified for internal and external gears up to module 11. It achieves gear quality grade 7 or better. On NTX and CTX TC turn-mill centres, the cycle can also be used for helical gears with tooth offset. DMG MORI states that it can be up to eight times faster than conventional hobbing.
In-process measurement reduces handling
Optical gear measurement is another element of the proposed process chain. A laser scanner measures gear teeth directly on the machine. The stated scanning rate is 70,000 points per second. More than 80 percent of measurement points are said to lie within ±2 μm. DMG MORI compares this result with results from an external coordinate measuring machine.
The practical benefit primarily lies in avoiding separate measurement and re-clamping operations. DMG MORI states that the number of process steps can fall from ten to six. Total process time can also be reduced by more than 50 percent. Since machining and measurement take place in one clamping operation, correction values can be returned directly to the process.
This can be particularly relevant for larger components. Additional handling and internal transport can affect both throughput and process control. The CTX TC and NTX turn-mill series are intended to perform turning, milling, gear cutting and measurement in one setup. This includes six-sided machining without manual re-clamping.
According to the company, this creates a basis for standard automation systems such as Robo2Go. DMG MORI also states that the technology cycles are available as software retrofits for new and existing machines. Manufacturers can therefore introduce gear cutting for individual jobs first. They can add process-specific cycles, automation or digital modules when demand becomes more regular.
