The integration of technology in multi-axis turn-mill-turn centers of the NT and NTX series enables different gears to be produced in small and medium-sized batches.
The turn-mill centers in the NT and NTX series have a flatbed design.
The BMT turret with powerful directly driven tools
With the turn-mill centers in the NT and NTX series, workpieces can be machined completely, from blank to gear, on a single machine.
Special software and newly developed processes have transformed the turn-mill centers of the DMG MORI NT and NTX series into gear manufacturing machines for small and medium sized batches.
In all of its developments DMG MORI focuses on workpieces and in this case particular attention was given to optimizing productivity for the customer. Gear cutting on standard machines from DMG MORI's range of turn-mill centers is an example. "Outstanding results can now be achieved because of interaction of intelligent programming, excellent tools and high-performance machines developed in part in close cooperation with partner companies," said a company spokesperson.
In the past the only way to perform complex gear cutting jobs was to use special machines that required superior skills and expensive tools. This meant that such orders usually remained in the domain of specialist mass producers. It was not until the integration of different technologies in multi-axis turn-mill or mill-turn centers that it became possible to untangle this knot. The interaction of multitasking machining centers with innovative tools and new process and software developments means that even the most complex gear geometries can now be realized economically in small and medium-sized batches.
The NT and NTX series included in the DMG MORI product portfolio are perfect examples of such manufacturing all-rounders that offer up to 5-axis and up to 6-sided complete machining. These turn-mill centers have a flatbed design.
The standard milling spindle achieves speeds of up to 12,000 RPM and the turning spindle up to 6,000 RPM. Other highlights include the stable box-in-box construction of the frame support for maximum rigidity (applies to the NT series), the use of DCG technology or the integrated BMT turret with powerful direct driven tools. In addition, the direct drive of the B-axis with its swivel range of +/- 120 degrees and generously dimensioned travel in the Y-axes provide the necessary degree of freedom in machining.
"The DMG MORI portfolio can accomplish virtually everything that special gear cutting machines can do. They are also more flexible making the cost-effective planning of capacities far easier," said Gregory A. Hyatt Ph.D., Senior Vice President and CTO of Advanced Solutions Development at DMG MORI USA. "Another huge benefit of the machines is that the workpiece can be machined completely, from blank to gear, on a single machine, because this in turn shortens the process chain, prevents errors and boosts both overall productivity and quality." This agility can be applied to helical gears on the economical NHX platform, on the most complex spiral bevel gears on the DMU platform, and on pinions and shaft mounted gears on the NTX and CTX series.
With regard to the relevant gear cutting possibilities, Hyatt first mentions conventional hobbing or gear milling with the respective tools where the rigidity and stability of the CTX and NTX machines come out on top. But what he finds even more impressive are the latest developments such as the InvoMilling method from Sandvik Coromant for spur and helical gears or the DMG gearMILL software from the portfolio of exclusive DMG MORI technologies that are now also available for turn-mill centers.
InvoMilling is a patented process from Sandvik Coromant for the manufacture of spur and helical gears. Even complicated gear geometries are produced exclusively by means of the "intelligent interpolation" of the axes with this method. What is special about the process is the use of InvoMilling milling tools with in part standard indexable inserts that are front fitted into the insert seat of the respective cutter bodies. The inserts are embedded in such a way that the end teeth are positioned at right angles to the rotation axis of the cutter in order to enable true-to-contour orthogonal turn-milling.
The combination of slot milling for roughing and turn-milling for finishing enables the production of any tooth shapes and helix angles. Chamfers on the tip diameter can be realized as well as different protuberance angles, profiles and radii on the tooth root. Each cutter can be used for several module sizes so tooth profiles, for example, can be produced in the module sizes 1 to 4 with a single tool. The largest gear wheel to be milled to date was a module 18 with a diameter of 800 mm (31.5 in), whereby quality 6 gears in compliance with DIN 3962 or higher can be achieved with the InvoMilling method. Surface qualities of smaller than Rz 3 can also be achieved.
For Greg Hyatt, the key benefit of the gearMILL software is that even the most complex gear geometries can be manufactured on standard machines with economical off-the-shelf tools. The software carries out the calculation of the geometries and the automated programming of the tool paths. Special mathematical algorithms in the calculation software make even worm gears with user-defined flanks possible. Due to the new method of calculation this kind of gear manufacturing makes it possible to define gear geometries freely or rather it facilitates easy optimization of flanks and profiles of existing types of gears.
For more information contact:
DMG MORI USA
2400 Huntington Blvd.
Hoffman Estates, IL 60192
847-593-5400
www.us.dmgmori.com
Southwest
DMG MORI - Dallas
9001 Currency Street #200
Irving, TX 75063
972-929-8321
www.us.dmgmori.com
TX, LA
DMG MORI Ellison Technologies - Dallas
9001 Currency Street #200
Irving, TX 75063
972-812-5500
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Houston
3403 N. Sam Houston Pkwy. West #100
Houston, TX 77086
713-365-9500
www.ellisontechnologies.com
OK
DMG MORI - Tulsa
7633 E 63rd Place, Suite 300
Tulsa, OK 74133
918-932-2893
www.us.dmgmori.com
Southeast
DMG MORI - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-940-3380
www.us.dmgmori.com
VA, NC, SC
DMG MORI Ellison Technologies - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-545-7362
www.ellisontechnologies.com
S. AL, GA, MS, TN
DMG MORI Ellison Technologies - Nashville
7118 Crossroads Blvd.
Brentwood, TN 37027
615-661-6800
www.ellisontechnologies.com
FL
DMG MORI - Clearwater
4585 140th Ave. North, Suite H1008
Clearwater, FL 33762
727-530-1490
www.us.dmgmori.com
Northeast
DMG MORI - Newark
1160 Parsippany Blvd, Suite 103
Parsippany, NJ 07054
973-257-9620
www.us.dmgmori.com
DMG MORI Tyler Machine Tool
111 Ledge Rd.
Seabrook, NH 03874
603-474-7730
www.us.dmgmori.com
DMG MORI Tyler Machine Tool
68 Nutmeg Road South
South Windsor, CT 06074
860-528-4010
www.us.dmgmori.com
Boldt Machinery, Inc.
4803 Pittsburgh Ave.
Erie, PA 16509
814-833-9836
www.boldtmachinery.com
Boldt Machinery, Inc.
104 Boss Rd.
Mattydale, NY 13211
315-463-5754
www.boldtmachinery.com
MD, DE
DMG MORI - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-940-3380
www.us.dmgmori.com
DMG MORI Ellison Technologies - Charlotte
4345 Morris Park Drive
Charlotte, NC 28227
704-545-7362
www.ellisontechnologies.com
Midwest
DMG MORI - Chicago
2400 Huntington Boulevard
Hoffman Estates, IL 60192
847-593-5400
www.us.dmgmori.com
DMG MORI Ellison Technologies - Chicago
4630 Weaver Parkway
Warrenville, IL 60555
630-393-8900
www.ellisontechnologies.com
DMG MORI - Cincinnati
5333 Mulhauser Road
Hamilton, OH 45011
513-874-2736
www.us.dmgmori.com
DMG MORI Ellison Technologies - Cincinnati
5333 Mulhauser Road
Hamilton, OH 45011
513-874-2736
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Cleveland
6955 Treeline Drive
Brecksville, OH 44141
440-546-1920
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Davenport
145 West 76th Street
Davenport, IA 52806
563-388-0800
www.ellisontechnologies.com
DMG MORI Ellison Technologies - St. Louis
16 MB Corporate Park Ct.
St. Charles, MO 63301
636-946-7077
www.ellisontechnologies.com
DMG MORI - Detroit
29050 Cabot Drive
Novi, MI 48377
248-324-1928
www.us.dmgmori.com
DMG MORI Ellison Technologies - Detroit
29050 Cabot Drive
Novi, MI 48377
248-324-1928
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Grand Rapids
1550 Gezon Parkway SW, Suite B
Wyoming, MI 49509
616-261-8665
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Indianapolis
8930 Bash Road, Suite A
Indianapolis, IN 46256
317-577-3723
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Milwaukee
N27 W23750 Paul Road
Pewaukee, WI 53072
262-523-3400
www.ellisontechnologies.com
DMG MORI Ellison Technologies - Minneapolis
13400 10th Avenue North
Plymouth, MN 55441
763-545-9699
www.ellisontechnologies.com
DMG MORI - Kansas City
7500 College Blvd, 5th Floor
Suites 520/521/522/524
Overland Park, KS 66210
913-871-1373
www.us.dmgmori.com
DMG MORI - Wichita
3450 N Rock Rd
Building 500, Suite 505
Wichita, KS 67266
316-425-7993
www.us.dmgmori.com
West
DMG MORI - Los Angeles
5740 Warland Drive
Cypress, CA 90630
562-430-3800
www.us.dmgmori.com
Southern CA
DMG MORI Ellison Technologies - Los Angeles
9890 Pioneer Blvd.
Santa Fe Springs, CA 90670
562-949-8311
www.ellisontechnologies.com
Northern CA
DMG MORI Ellison Technologies - San Francisco
2607 7th St. Suite C
Berkeley, CA 94710
866-814-7238
www.ellisontechnologies.com
WA, ID, MT
DMG MORI Ellison Technologies - Seattle
19625 62nd Ave. South, Suite A109
Kent, WA 98032
253-872-1661
www.ellisontechnologies.com
OR
DMG MORI Ellison Technologies - Portland
10159 SW Commerce Circle #K
Wilsonville, OR 97070
503-682-3280
www.ellisontechnologies.com
AZ
Ellison Machinery
1610 S. Priest Dr. #101
Tempe, AZ 85281
480-968-5335
www.ellisonaz.com
CO
Triad Machine Tool Co., Inc.
7885 West 48th Avenue
Wheat Ridge, CO 80033
303-424-0268
www.triadmt.com
UT, ID, MT, WY
New West Machine Tool Technologies
7990 South 1530 West
West Jordan, UT 84088
801-561-2001
www.newwestmachine.com