Adaptive drilling control for smarter deep-hole machining

Deep-hole drilling remains one of the most demanding machining operations in automotive manufacturing, where chip congestion, tool breakage and bore deviation can quickly lead to scrap and costly production delays. To address these challenges, DMG MORI has developed Adaptive Drilling Control (ADC), a new technology cycle that transforms drilling from a parameter-driven process into an adaptive, sensor-controlled operation.

Unlike conventional drilling cycles that rely on fixed settings, ADC continuously monitors machining conditions using sensors that track coolant pressure, flow rate and machine load. The system automatically adjusts coolant delivery and machining parameters in real time, enabling stable drilling performance even when material conditions, tool wear or drilling depth change during the process.

The technology integrates standard drilling, deep-hole drilling and gun drilling into a single software cycle with three operating modes. For standard drilling, operators only need to enter basic machining parameters, while the system optimizes coolant flow automatically. Additional functions for deep-hole drilling and advanced gun drilling support applications such as cross-holes, pilot-hole offsets and adaptive feed-rate control through an intuitive dialog-based interface.

For automotive manufacturers, the technology is particularly relevant when machining high-value components such as crankshafts, fuel injection systems, transmission parts and EV powertrain components, where drilling accuracy and process stability are critical. By maintaining optimal coolant flow throughout the machining cycle, ADC helps reduce chip accumulation, minimize thermal loading and improve bore quality, resulting in more consistent machining outcomes.

DMG MORI reports that the adaptive control strategy can extend tool life by up to 30% while reducing energy consumption by as much as 30% through optimized coolant management. The system also records machining data for process monitoring, quality documentation and integration with CELOS X and factory IT systems, supporting manufacturers' digital production and traceability initiatives.

Developed in collaboration with partners including botek Präzisionsbohrtechnik, Gühring, Kennametal, Walter and FUCHS Lubricants, ADC combines tooling, coolant and machine control expertise into a unified drilling solution. The technology is initially available on selected DMG MORI machining centres with Siemens and HEIDENHAIN controls and forms part of the company's broader Machining Transformation (MX) strategy, which focuses on increasing automation, process reliability and machining intelligence.