On standard machines for precision gear cutting
Metalworking service providers who only machine what they are familiar with lose out on orders they could actually fulfill. DMG MORI addresses this gap with a modular portfolio of specialized software and exclusive DMG MORI technology cycles that enable gear production on standard machining centers and turn-mill centers. For example, DMG MORI’s gearMILL enables productive complete machining—including gear cutting—on standard machines using standard tools. gearBROACHING, gearSHAPING, gearHOBBING, and gearSKIVING also support more specialized gear-cutting tasks.
DMG MORI gearMILL: Standard tools instead of special investments
The core element of the portfolios is DMG MORI gearMILL. The software is designed for complex gear geometries and, in particular, simplifies the implementation of custom profile and flank modifications. This also makes it easy to adapt load patterns and meet customer-specific requirements. The integrated CAM module then ensures effective programming using standard tools. The achievable gear quality is ≥ 5 according to DIN/ISO—a level that is sufficient for prototypes, replacement parts, and small production runs in many industries.
A key factor in cost-effective implementation: DMG MORI gearMILL enables gear cutting (even) with standard tools. In addition, DMG MORI supports its customers in process design through the global DMQP partner network, which includes tool manufacturers such as HORN, Sandvik Coromant, Ceratizit, Kennametal, Ingersoll, and Kyocera.
Technology Cycles: Productivity for Recurring Interconnections
Once certain gear geometries begin to appear regularly, it is advisable to transition to process-specific technology cycles. gearSKIVING 2.0 (gear skiving) holds a special position in this regard: The process is up to eight times faster than conventional gear broaching and enables the production of internal and external gears up to module 11 with a quality grade of ≥ 7. On turning-milling centers from the NTX and CTX TC series, it is also possible to produce helical gears with tooth offset—a geometry that would otherwise require specialized machines.
gearHOBBING covers the hobbing of spur and helical spur gears. gearBROACHING handles position-oriented broaching of internal and external gear teeth up to module 4 on the main and counter spindles. And gearHONING, as a finishing cycle for surface quality and load-bearing performance, rounds out the DMG MORI portfolio in this area.
40 percent fewer process steps thanks to integrated measurement
Measurement technology is a key driver of productivity. DMG MORI integrates optical measurement using a laser scanner directly into the machining process. The scanner captures 70,000 measurement points per second; more than 80 percent of the measurement points fall within an accuracy of ±2 µm—comparable to an external coordinate measuring machine. Compared to the conventional process with separate measurement and re-clamping steps, the number of process steps is reduced from ten to six, and the total process time is cut by more than 50 percent. Machining and measurement take place in a single setup. Correction values are thus fed back immediately, which offers quality and logistical advantages, particularly for larger components.
Complete machining in a single setup
Turning, milling, gear cutting, and measuring can all be performed on DMG MORI turn-mill centers in a single setup. This eliminates internal transport routes, reduces setup errors, and measurably shortens cycle times. Turnmill centers in the CTX TC and NTX series also enable complete 6-side machining without manual reclamping—a prerequisite for integrating automation solutions such as the Robo2Go.
A real-world example illustrates the potential: A manufacturer produces up to 2,500 crane wheels per month on a DMC 80 FD duoBLOCK in combination with gearSKIVING. The integrated pallet changer enables setup during active production time. Batch sizes of up to 20 parts are processed automatically via a Robo2Go.
Modular roadmap for small and medium-sized service providers
DMG MORI positions universal gear cutting as a scalable entry point into Machining Transformation (MX). For job shops, a two-step approach is recommended: In the first step, DMG MORI gearMILL opens up new areas of business for users with their existing machine fleet. In the second step—once defined gear geometries are being produced on a regular basis—process-specific cycles, automation solutions, and advanced digitization modules are added to the process. Technology cycles can be retrofitted as software solutions, making them accessible for existing machines at a low cost.
