The German group Schaeffler Technologies, which manufactures roller bearings for automotive, aerospace and industrial applications — and owns the INA and FAG brands, among others — is co-operating with global machine tool manufacturer DMG Mori, which has a UK subsidiary in Coventry (
www.dmgmori.com).
They are testing suitable metals to advance the development of additively manufactured roller-bearing components, with the aim of “producing optimised products that offer greater added value for customers”.
Since May, Schaeffler has been using a DMG Mori Lasertec 65 3D hybrid machine to produce one-offs and small batches of bearing components, as well as spare parts in metallic functionally graded materials (FGM) to finished-part quality.
The rapid one-hit process combines the flexibility of additive manufacturing by laser deposition welding with five-axis subtractive milling.
The machine is equipped with a twin powder feed that accommodates change-over from one material to another, allowing the toughness and hardness of the material to be regulated during the build and optimally tailored to the specific requirements of each application.
Schaeffler has been active in Formula E for many years and is working on further improvements in electric drives. Material ‘gradation’ offers exciting opportunities for development; for example, magnetic and non-magnetic materials could be combined in a component using FGM, with the properties adjusted as required.
Patrick Diederich — managing director of Sauer GmbH, which is responsible for promoting DMG Mori’s advanced technologies — said: “We are very pleased that Schaeffler has decided on a Lasertec 65 3D hybrid.
"Our strong partnership brings about a fascinating synergy in the production of additively manufactured components. Schaeffler was awarded the accolade of overall winner in
DMG Mori’s Partner Award 2017.”