The new DNC series from DN Solutions is specialized in the machining of hard-to-machine materials for process consumables.
The term 'DNC' stands for DN Solutions Ceramic and represents the new series of manufacturing machines specifically developed for ceramic processing. The newly introduced machine models particularly target the production of wear components such as focus rings used in the semiconductor wafer process. These components operate in chambers exposed to high temperatures and chemical stress. Therefore, they are made from materials like quartz, ceramics, and silicon carbide (SiC), which are considered extremely difficult to machine. The DNC series enables the precise grinding of these hard-to-machine materials.
Precision machining of quartz and ceramics
Quartz is harder than carbon-based steel, yet it is brittle and prone to breaking, making it difficult to process with conventional tools. Even when using expensive diamond tools, micro-cracks and fractures often occur. Furthermore, quartz is sensitive to contamination, requiring the highest cleanliness during processing.
For the DNC series, DN Solutions has developed a high-performance grinding spindle that reaches 10,000 RPM at 7.5 kW power. Thanks to its combination of power and precision, the spindle is perfectly suited for demanding materials such as quartz and ceramics.
The monolithic, highly rigid machine bed and the precise feed axis guides help suppress vibrations and minimize thermal changes even during longer operating times. While conventional machines lose precision due to spindle drift, the DNC series impresses with long-term dimensional stability and structural integrity, positively affecting the machine's lifespan.
Clean solutions for quartz dust and grinding challenges
Fine quartz dust (grinding sludge) generated during processing can lead to machine failures. To prevent this, DN Solutions uses a fully enclosed sliding cover that shields the inclined bed surface and prevents coolant and dust from entering the machine. For easy maintenance, the easily removable coolant tank allows for effortless sludge removal.
The DNC series also features an internal spindle used for automatic dressing of tools. This is necessary because, during grinding, the surface of the grinding wheel inevitably becomes clogged with chips, requiring periodic dressing to restore shape and cutting performance. Conventional systems typically need to interrupt operation for this. The DNC series is designed to carry out this process automatically and integrated.
The series also combines the multifunctionality of a machining center (milling) with the capabilities of a turning center (lathe), enabling internal and external diameter, drilling, and contour machining in a single setup. The equipment includes an automatic tool changer (ATC), an automatic tool measurement system, and an automatic workpiece measurement system, allowing for fully automated operation, reducing operator workload, and increasing productivity.
Market impacts and strategic positioning
According to the company, DN Solutions holds about 50 percent of the South Korean market for semiconductor material processing equipment, with nearly 80 percent in some processes. 'The DNC series is based on our extensive expertise and field experience and will play a crucial role in enhancing manufacturing competitiveness and the technological capabilities of our customers worldwide,' says DN Solutions.
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