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12/22/2023|Machining Transformation (MX): Part 1

Process Integration for holistic performance

Every company must face up to the challenges of ever faster, more efficient and more sustainable manufacturing. Every ten years, societal needs experience a drastic change. DMG MORI has continuously developed its business model to meet these needs through new products and services. Machining Transformation (MX) combines four pillars that drive Process Integration, Automation and the Digital Transformation (DX) and Green Transformation (GX) of machine tools. Through the new concept, DMG MORI is responding to changes in the business environment. Workpieces that were previously machined by several machines one after the other can now be produced by one process-integrated machine.

Machining Transformation (MX)
With the four pillars of Machining Transformation (MX), DMG MORI provides an answer to the challenges of ever faster, more efficient and more sustainable manufacturing.

Process Integration

Process integration
Over the past decades, DMG MORI has integrated more and more technologies and processes into its machines – such as grinding and gear hobbing.

The first step of the transformation combines the intelligent mechatronics of machine tools with the far-reaching possibilities of process integration. DMG MORI is thus opening up a holistic new perspective for its customers. The company has already repeatedly set innovative standards over decades with the integral mill 6 turn combination of 5-axis milling and turning technology. With the integration of further complementary processes (such as grinding, Lasertec DED or Ultrasonic) and supplementary processes, for example for measuring or gear machining, DMG MORI is going even further.

In-process measuring
In-process measuring complements the complete machining of demanding workpieces and ensures consistent precision.

Compared to step-by-step machining over several machine tools and stations, the customer gains holistic productivity and performance. Among other things, setup times are extremely reduced. In addition, idle times and errors during reclamping from one machining station to the next are eliminated. Cycle times are reduced and the precision of the components is ensured thanks to in-process measuring. Furthermore, the integrated measuring routines in interaction with the CNC control open up the future field of adaptive machining processes.

Direct customer added value of Process Integration at a glance

  • Holistic performance: Combining multiple machining processes in one setup increases overall efficiency and productivity.
  • Reduced setup times: Process Integration significantly reduces the time required to switch between different machining processes.
  • Elimination of idle time and errors: The integration of all required machining processes in one setup eliminates the need for reclamping, which minimizes downtime and potential errors.
  • Shortened process chain: Integrating multiple processes into one setup simplifies the production process and reduces the number of steps and machines required.
  • Faster cycle time: Reduced setup and idle times shorten the overall production time, enabling faster delivery of customized products.
  • Improved energy balance: By combining several processes in one plant, the energy efficiency of the machines is improved.
  • Increased precision: Process Integration ensures that components are machined accurately and consistently, resulting in higher quality products.
  • Real-time monitoring and quality control: In-process measurements and adaptive machining operations enable continuous monitoring of the machining process so that any deviations can be quickly detected and corrected.

Moreover, Process Integration with its decisively higher productivity compared to step-by-step processing on individual machines naturally reduces the number of individual machines required. This reduces the complexity of job planning and control and directly reduces the financial burden of further automation. Above all, however, the ecological footprint of metal-cutting workshops is reduced as a result of the higher efficiency of the resources used in terms of energy, space, operating effort and internal logistics.

Process integration
Process integration reduces the effort involved in designing holistic manufacturing solutions. 

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