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Heimatec’s custom hobbing tool features a strong bearing structure that helps Gurecky achieve 45-degree helix angles.
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The cluster gear at the left features a 45-degree helix angle and two 23-degree helix angles with both left- and right-hand orientation.
Sales Engineer DMG Mori Seiki Ellison Technologies ( Formerly J&H Machine ) August 2003 – Present 16 years 3 months. Technical Sales Engineer for Delaware, Maryland and Northern Virginia. DMG MORI Technology Excellence: Medical. DMG MORI helps customers in the medical technology sector to achieve efficient production of high-quality parts with groundbreaking technologies. 'Whereby the technological possibilities are not in fact the limiting factor here, instead it is the high demands on the certification requirements. There are 11 companies that go by the name of Dmg Mori Seiki Ellison Technologies. These companies are located in East Lansing MI, Hamilton OH, Indianapolis IN, Parkway IL, Plymouth MN, Santa Fe Springs CA, St Charles MO, St. Charles MO, Warrenville IL, and Wilsonville OR. DMG / Mori Seiki USA Opens Houston Technical Center in partnership with Ellison Technologies. A new joint technical center in Houston will showcase DMG and Mori Seiki machine tools and technology for the energy and oil field industries.
From left to right, John Dorman, president, Bob Lorquet, vice president, and Robert Kight, first-class machinist stand in front of Gurecky’s multifunctional NLX 2500SY/700. The customized machine has the ability to act as a regular CNC lathe and machine helical gears at the same time.
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As the competitive nature within a market increases, so does the need for increased productivity and throughput by handling the parts less. One way to meet this need is to accomplish more operations in one setup. Gurecky Manufacturing Services Inc. of Rosenberg, Texas, decided to enhance its manufacturing operations by purchasing a machine that could act as a regular CNC lathe and machine helical gears at the same time. However, a custom hobbing tool from Heimatec Inc. (Prospect Heights, Ill.) was necessary to achieve a desired 45-degree helix angle.
Gurecky was founded in 1983. Today, the company operates out of a 43,000-square-foot facility, serving the oil, gas and energy industries. The company produces multifaceted precision parts ranging from prototypes to mass production. To remain competitive, Gurecky constantly invests in advanced manufacturing equipment. For example, since buying its first DMU 50 ecoline from DMG Mori (Hoffman Estates, Ill.), the company has moved production from traditional vertical machining centers (VMCs) to the more versatile five-axis DMG Mori machines.
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In late 2012, Gurecky President John Dorman decided it was time to purchase a CNC machine specifically for gear hobbing. The company approached DMG Mori Ellison Technologies and decided to install its customized multifunctional NLX 2500SY/700 with the ability to hob gears. What made this particular application challenging was the fact that Gurecky needed to machine helical gears at a 45-degree angle. This was a problem because standard hobbing units only allow ±30 degrees of helix angle adjustment due to loss of rigidity.
Undaunted by the task, Heimatec said it could design a custom hobbing tool with ±45 degrees of adjustment to use in conjunction with the new machine. According to Preben Hansen, president of Heimatec, lathes and their coordinating controls are more sophisticated these days, so a dedicated hobbing machine isn’t always necessary. “As long as the machines can handle it, we can build a tool to do it.”
After a few months of testing, the tool was complete and ready to be put to work. Rigidity is the key to tackling this difficult machining operation, he says. “It’s a pretty difficult operation, and when you’re twisting that tool, there’s a lot of leverage. You have to be concerned with the rigidity of the tool. When you’re turning at 45 degrees and milling at the same time, you tend to lose rigidity,” he says.
To combat this loss, Mr. Hansen says Heimatec’s hobbing units are designed with a strong bearing structure. In turn, this structure provides the rigidity necessary to reduce backlash and increase tool life. It also increases the performance of the hobs that do the cutting, he says.
The hobbing unit can run at 3,000 rpm and provide 63 Nm of torque. “One of the things we do to help is increase the torque through a gear reduction,” Mr. Hansen says. “Many times, it’s a 1:1 ratio, and we go 2:1. So if its 3,000 rpm into the tool, the tool only rotates at 1,500 rpm. So we increase the torque output by gearing down the tool.”
Heimatec and DMG Mori Ellison Technologies set up the hobbing attachment, wrote the program code and started cutting the 45-degree helical gears in a quarter of the time that it took in the past. Completing more operations in one setup has been a major time saver for Gurecky. Previously, the part would be turned on the lathe, then taken off and set up for a secondary hobbing operation. The hobbing operation alone took one to two hours. Now, the company can machine precision parts on the CNC lathe using the custom hobbing unit in 8 to 10 minutes, start to finish. Another benefit of the single setup is that scrap has been reduced from about 10 percent to 1.6 percent, greatly improving overall efficiency and the company’s bottom line.
Along with the increased adjustment angle, Heimatec designed the custom hobbing tool to be interchangeable, which enables Gurecky to use different arbor sizes. The company can put a different kind of hob in the unit and switch to a different part fairly simply. According to the company, this feature has saved more than $200,000.
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Here are the DMG MORI's world-leading,
advanced machine tool technologies.
advanced machine tool technologies.
No. 1 share in the world through realization of 'Smart Factory'
'Industry 4.0' - a major movement which has swept the industrial world with the notion of IoT (Internet of Things) that everything is connected with the Internet. DMG MORI began to work on the topic early in an effort to improve operation efficiency of machine tools through remote maintenance, operation status management and accurate failure prediction for every machine in motion at DMG MORI factories all over the world by use of networking, software and sensors.
DMG MORI aims to provide customers with support not only for a machine itself, but also hardware and software relating to the machine. DMG MORI’s competitive edge lies in its technologies of the new era that can realize “Smart Factory (thinking factory).” It enables management of every system including the DMG MORI’s new operating system “CELOS” that handles big data inside and outside the company and automation systems essential for unmanned operation via network.
Total Solution that Combines Four Elements
- Complex machining easily completed in a short time -
DMG MORI's Technology Cycles are new solutions integrating four elements: 1. Machine tool body, 2. Cutting tools and peripheral equipment as Open Innovation, 3. Embeddd software, 4. HMI (Human Machine Interface) such as CELOS. Technology Cycles enable easy and quick start of machining operation and high-quality cutting performance. Machining, setups and measurement which used to be done with specialized machines, programs and tools can now be performed with general-purpose machine tools and standard tools & fixtures. DMG MORI provides customers with the total solution that combines machine tools with peripheral equipment & software.
Four Elements of Technology Cycles
DMG MORI's Technology Cycles are new solutions integrating four elements: 1. Machine tool body, 2. Cutting tools and peripheral equipment as Open Innovation, 3. Embeddd software, 4. HMI (Human Machine Interface) such as CELOS.
Machine tool
- 5-axis machines
- Multi-axis machines
- Additive Manufacturing
- Laser machines
- Ultrasonic machines
- etc.
Open innovation
- Cutting tools
- Coolant
- Measuring systems
- Sensors
- Fixtures
- Robots
- Peripherals
- etc.
Embedded software
HMI
Human Machine Interface
List of Technology Cycles
Technology Cycles by category
Handling Cycle
Monitoring Cycle
Measuring Cycle
Shaping Cycle
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Free ideas leading to infinite possibility 'Hybrid machining' changes the world
Additive manufacturing - defined synonymously with 3D printing in general - is the technology that metal power is fused by laser radiation and deposited into an object based on 3D model data.
DMG MORI succeeded in completing a product by machining a workpiece immediately after it is formed by laser metal deposition. This had been impossible to achieve with one machine. We combined years of accumulated cutting-edge machining techniques with additive manufacturing technologies ahead of the times to develop a hybrid machine.
The DMG MORI's hybrid techniques free designers and engineers from the restriction of design, cost and efficiency issues in the conventional 'manufacturing process' and allow them to think outside the box, expanding the possibility of innovation.
Elaborate manual work on a 1/1000 mm scale supports DMG MORI's high precision.
DMG MORI machine tools have metal surfaces called slideways which come in contact with one another and move. The slideways are very important factor for machine accuracy. A slideway surface repeatedly slides over the other surface, which requires smooth movement. What’s essential for such a slideway travel is a technique called “scraping” that a metal surface is scraped with a scraper by a skilled technician. The precisely scraped slideways have smooth surfaces to the limit, and a number of ultra-small pockets made on the surface retain lubricating oil to help protect the slideway surfaces. The smooth and “non-stress” slideways mounted on a machine contributes to bringing out the best in a machine tool performance. The DMG MORI machines are not only equipped with the cutting-edge technologies, but also supported by skilled engineers with years of experience.
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Simpler, smarter and deeper connection between factories and offices via 'CELOS'
The “CELOS,” the DMG MORI-developed next-generation interface, was evolved from an NC control panel. Mac os 9 download free. It is a tool that simplifies and accelerates the process from the idea to the finished product.
The multi-touch monitor of the “CELOS” enables intuitive operation with one-touch to the application menu. It is also possible to establish the network system between machine tools and in-company systems through the “CELOS.” With the Job Manager (Job Assistant) and JOB Scheduler functions, operators can centrally manage production plans, progress status and schedules. The “MAPPS V,” a high performance smart operation system mounted on the “CELOS,” offers various functions: the conversational automatic programming function that enables operators to create the programs easily by simply following guidance and inputting the data; the sensor information function that monitors the sensor information and checks machine information such as temperature of the hydraulic equipment and the oil chiller; the tool management system that supports efficient machining; and other functions that easily controls machine operation.
DMG MORI promotes “Industry 4.0” that connects the production environments via network through the “CELOS.”
'In-production' of units with the highest precision and the industry-leading core technologies
It is a machine tool that produces varieties of parts which are the sources of all products. In the machine tool industry, we are always required to be conscious of the next-generation products in pursuit of product development and production system that meet the market needs.
DMG MORI is working on 'in-company production' with shorter product development times in mind as well as quality improvements and shorter delivery times. For example, the Iga Campus Heat Treatment Plant, the Sheet Metal Plant and the Casting Plant established in 2005 and 2006 are contributing greatly to shortening lead times and prototype development times.
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Moreover, we self-manufacture ball screws, which is uncommon among machine tool manufactures, and built the Spindle Plant where a whole production process from part machining to assembly and inspection can be conducted, in an effort to promote “in-company production” of the main components that have a significant influence on the precision of machine tools.
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We shorten product development times by self-manufacturing prototypes and quickly provide customers with products that meet their needs -- DMG MORI is going to challenge the possibility of 'in-house production' to win the trust from customers and provide them with great satisfaction. https://landclever828.weebly.com/dmg-north-inc.html.