In the last two years, DMG Mori has expanded their gear milling portfolio to include more machine platforms that produce more types of gears. The highlight of the show will be the power skiving technology displayed on a multi-tasking machine platform that combines turning operations with milling operations and gear production.  DMG Mori’s DMC 80 FD duoBLOCK machine will demonstrate machining of an ID gear using a power skiving process (Booth S-8900). As compared to conventional shaping processes, the power skiving process is a highly productive process for machining of ID and OD gears. The demonstration will show that the machine and process is suitable for even automotive volume production. The same machine will also demonstrate the machining of a spiral bevel gear using the flankmilling process. In addition, it will measure the spiral bevel gear using the onboard standard measurement probe and a point cloud generated by the DMG gearMILL software. Using the data gathered by the probe, the Gear Pro involute software from Zeiss will prepare the flank charts for the gear. This in-machine checking of gears is a unique feature and can be extremely useful for quick check measurement of large gears before removing them/unloading them from the machine. This feature is available for measurement of all types of gears.

DMG Mori is also launching its new horizontal machining center NHX 4000 2nd Generation. This machine provides a very cost effective way to produce large diameter cylindrical gears. The super accurate B-axis (rotary table) ensures machining of excellent quality gears and a pallet changer (standard feature) eliminates the setup time altogether. The fast tool changes will reduce the cycle time and a large tool magazine will keep the machine running overnight. This machine will show a 19 in. diameter spur gear machined using the InvoMilling process and a 26 in. diameter herringbone gear machined using the flankmilling process.

In addition to this diverse gear portfolio, DMG Mori will demonstrate its technological expertise with their hybrid manufacturing machine. This machine combines the additive (3-D printing in metals) and subtractive processes into one machine to produce a finished part from just powder. It uses a powder spray technique that gives 20x to 40x deposition rates for depositing material and then conventional milling turning processes to remove material from any unwanted areas. The combination of these two processes on a single platform and the ability to execute them sequentially provides unparalleled freedom to design engineers – enabling them to design parts in ways they have not even imagined.