Additive Manufacturing and Machine Tool 4.0

The "Machine Tool 4.0" joint project between DMG MORI and Schaeffler on the DMC 80 FD duoBLOCK turning and milling machining center. (Image courtesy of DMG MORI.)

DMG MORI, a manufacturer of machine tools, and Schaeffler Technologies AG & Co. KG, a supplier for rolling bearings, linear guides and drive technology, have signed a cooperation agreement to develop additive manufacturing processes for rolling bearing components.

“Both partners complement each other perfectly to drive the future of machine tools as well as the continuing development of rolling bearing technology,” said Dr. Stefan Spindler, CEO Industrial of Schaeffler AG. “Our joint ‘Machine Tool 4.0’ development project has already demonstrated this with great success. Our cooperation in additive manufacturing means another very important strategic area for the future.”

Laser Deposition Welding for Rolling Bearing Components

The basis for the joint development work will be a Lasertec 65 3D made by DMG MORI, a five-axis machining center including a laser metal deposition welding unit. The machine will be used at Schaeffler.

The goal of the project is to develop laser metal deposition welding so that it can be used for the flexible manufacture of rolling bearing components for prototypes and for small batch sizes. Its focus is on process issues as well as on the materials used and their suitability for the process.

Laser Deposition on the Lasertec 65 3D. (Image courtesy of DMG MORI.)

In laser metal deposition welding, a material is simultaneously melted and applied to a surface. In this case, the material is metal powder. The heat source is a high-performance laser.

This additive manufacturing process is combined with conventional five-axis machining in the hybrid facilities developed by DMG MORI so that the resulting components can be finished immediately afterwards.

The “Machine Tool 4.0” Innovation Project

Schaeffler and DMG MORI also presented the “Machine Tool 4.0” innovation project jointly with other partners at JIMTOF. The project uses new digitalized components to link existing technology with the cloud via sensors.

Two prototypes were set up at the show based on the fourth-generation DMC 80 FD duoBLOCK universal milling and turning machining center. According to Schaeffler, additional sensors for measuring vibrations, forces, temperatures and pressures were integrated in nearly all bearing positions relevant for the machining process in the prototypes of the innovation project in order to obtain information about the machines’ conditions.

Continuing Machine Tool Partnership

The two companies have also extended their marketing partnership to 2017. As part of this cooperation, Schaeffler is DMG MORI’s marketing partner worldwide for bearings and linear guides. When the partnership begun this year, Schaeffler participated in in-house exhibitions, technology symposia and training courses held by DMG MORI.

DMG MORI and Schaeffler expect to cooperate even more next year. According to Schaeffler, the operators of machine tools in particular will benefit from this cooperation in two ways:

It will help to demonstrate bearings, linear technology and direct drive technology as well as new ideas in sensor systems and linking components.
It will help to show how these can be used for predictive maintenance, increasing efficiency and process optimization.

For more information, visit the websites for DMG MORI and Schaeffler.