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January 2018

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Schaeffler and DMG MORI Develop AM Processes for Roller Bearing Components



The LASERTEC 65 3D hybrid combines the flexibility of additive component manufacturing with the precision of machining thus enabling the generative manufacture of complete components in finished part quality.

In their latest cooperation project, DMG MORI and Schaeffler are developing AM processes for roller bearing components made of graded materials in small batch sizes using laser deposition welding.

For many years Schaeffler and DMG MORI have cooperated closely in a long-term partnership. In their latest cooperation project, the partners are developing additive manufacturing (AM) processes for roller bearing components made of graded materials in small batch sizes using laser deposition welding. The LASERTEC 65 3D hybrid from DMG MORI has served here as the mechanical basis since May 2017.

Schaeffler is expanding its own in-house area of AM to include the powder bed process for the first time with the LASERTEC 65 3D hybrid from DMG MORI, which it uses for the production of components made of metallic materials. The high build-up rate and high degree of flexibility of materials were aspects that influenced the decision. In addition, integrated 5-axis simultaneous machining enables the production of components in finished part quality in a single set-up, a feature for which Schaeffer sees potential in serial production.

Added Value Through Graded Materials

The LASERTEC 65 3D hybrid is equipped with two powder feeders and enables targeted control of the changeover from one material to another during laser deposition welding. This results in graded materials with a smooth transition between the different material properties. The toughness and hardness of the material can be regulated in the build-up process and optimally aligned to the specific requirements of each application.

Schaeffler and DMG MORI are testing suitable materials in the cooperation project, with the aim of advancing the development of additively manufactured roller bearing components in small batch sizes using laser deposition welding. Schaeffer's focus of attention here is on realizing optimized products that offer added value for end customers.

"We are very pleased that Schaeffler has decided on a LASERTEC 65 3D hybrid from DMG MORI. This partnership brings about fascinating synergy effects in the production of additively manufactured components," said Patrick Diederich, responsible for Advanced Technologies at DMG MORI and Managing Director of SAUER GmbH.

Integration in the Production Process

Schaeffler has expanded its capacities in AM processes to include laser deposition welding. The LASERTEC 65 3D hybrid will also be integrated in the production process at Schaeffler in order to optimize the production of spare parts, small series and single parts. Immediate production of such parts allows the speedy provision of spare parts while at the same time eliminating storage costs for large workpieces.

For more information contact:

DMG MORI - Americas Headquarters

2400 Huntington Blvd.

Hoffman Estates, IL 60192

847-593-5400

www.us.dmgmori.com

Schaeffler Group USA Inc.

308 Springhill Farm Road

Fort Mill, SC 29715

803-548-8500

info.us@schaeffler.com

www.schaeffler.us

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