en.Wedoany.com Reported - DMG MORI, a German-Japanese joint venture, demonstrates through its processing transformation technology framework how to economically and sustainably meet the stringent requirements of the semiconductor industry for precision parts and cleanroom quality. The key lies in achieving reliable, repeatable, and scalable precision under industrial production conditions.
The semiconductor industry opens up highly attractive opportunity areas for contract manufacturers, while simultaneously imposing increasingly stringent requirements for precision parts and cleanroom-compliant quality. Components in the semiconductor industry, such as housings involving numerous production steps, require consistent machining processes due to long cycle times, micron-level tolerances, and strict demands for high surface quality and cleanliness. Traditional manufacturing, involving multiple separate processes and manual handling, is approaching its limits in effectiveness. An integrated approach is crucial, combining milling, turning, grinding, and measurement on a single machine tool to reduce setup times and minimize error sources, thereby achieving high part quality, reducing scrap, and shortening delivery times.
Automation is another key success factor. Automatic pallet handling systems and automated guided vehicles form the foundation for unmanned shifts and flexible production of different part variants, significantly increasing machine tool runtime without additional personnel, improving capacity utilization and planning reliability while reducing costs. As process integration and automation advance, digital transformation becomes increasingly important. End-to-end data chains, simulation, and digital twins enable proactive planning and continuous optimization of manufacturing processes. Real-time data from the shop floor provides transparency into capacity utilization, delivery times, and quality.
In addition to precision, the cleanroom quality of parts is also important. DMG MORI integrates these quality requirements into machine tool design and process solutions. Coolant plays a key role, ensuring thermal and tribological stability during machining. As a DMG MORI qualified product partner, coolant developer FUCHS SE integrates its technology into the machine tool manufacturer's solutions.
As a practical application example of this manufacturing concept, DMG MORI cites the production of a housing for the semiconductor industry. This housing is machined on a DMG MORI DMC 125 FDS μPrecision five-axis horizontal mill-turn machining center. First, the part is centered and aligned using the easycenterSET system, achieving centering accuracy within 5µm. This is followed by two deep flange turning operations, feature inspection using a touch probe, and then turning the top face end groove to a mirror finish. Subsequently, extensive deburring and chamfering are performed, and specialized tools are used to achieve an ultra-smooth, reflective surface finish on the external vertical faces of the housing. Forming operations then open and finish a slot on each of the eight faces. Finally, holes are drilled on the vertical side of the face openings using a drill in a 90-degree angle head. A high-pressure internal coolant supply flushes out fine chips and controls heat in the cutting area.
In-process inspection is carried out throughout the machining cycle, followed by GD&T (Geometric Dimensioning and Tolerancing) inspection of the part on a Zeiss coordinate measuring machine. Results show flatness and perpendicularity tolerances in single-digit microns, and positional tolerances of 15µm (total tolerance). The machining process of the EN AW-5083 aluminum alloy part with a diameter of 800mm can be viewed on YouTube.
