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NC and CNC metal cutting machines are among the most popular machine tools in the business today, There is also a strong trend toward using flexible machining centers and flexible manufacturing systems. The same trend is apparent in gear cutting. Currently the trend toward CNC tools has increased, and sophisticated controls and peripheral equipment for gear cutting machines are now available; however, the investment in a CNC gear machine has to be justified on the basis of economic facts as well as technical advantages.
CNC technology offers new opportunities for the manufacture of bevel gears. While traditionally the purchase of a specific machine at the same time determined a particular production system, CNC technology permits the processing of bevel gears using a wide variety of methods. The ideological dispute between "tapered tooth or parallel depth tooth" and "single indexing or continuous indexing" no longer leads to an irreversible fundamental decision. The systems have instead become penetrable, and with existing CNC machines, it is possible to select this or that system according to factual considerations at a later date.
NC and CNC machines are at the heart of manufacturing today. They are the state-of-the-art equipment everybody has (or is soon going to get) that promise to lower costs, increase production and turn manufacturers into competitive powerhouses. Like many other high tech devices (such as microwaves and VCRs), lots of people have and use them - even successfully - without really knowing much about how they operate. But upgrading to CNC costs a lot of money, so it's crucial to separate the hype from the reality.
Product announcements so often trumpet minor, incremental advances with works like "revolutionary" and "unique" that even the best thesaurus can fail to offer a fresh alternative to alert the reader when something really innovative and important is introduced. In the case of Mitsubishi's new CNC gear shaper, the ST25CNC, both terms apply.
New freedom of motion available with CNC generators make possible improving tooth contact on bevel and hypoid gears. Mechanical machines by their nature are inflexible and require a special mechanism for every desired motion. These mechanisms are generally exotic and expensive. As a result, it was not until the introduction of CNC generators that engineers started exploring motion possibilities and their effect on tooth contact.
Question: When we purchase our first CNC gear hobbing machine, what questions should we ask about the software? What do we need to know to correctly specify the system requirements?
A high-performance, 11-axis CNC system from NUM has enabled machine tool manufacturer Sicmat to create a gear honing machine that sets a new industry standard for post-hardening fine finishing.
These days it's hard to get through breakfast without reading or hearing another story about how the computer is changing the way we live, sleep, eat, breathe, make things and do business. The message is that everything is computerized now, or, if it isn't, it will be by next Tuesday at the latest, Well, maybe.
Analysis of helical involute gears by tooth contact analysis shows that such gears are very sensitive to angular misalignment leading to edge contact and the potential for high vibration. A new topology of tooth surfaces of helical gears that enables a favorable bearing contact and a reduced level of vibration is described. Methods for grinding helical gears with the new topology are proposed. A TCA program simulating the meshing and contact of helical gears with the new topology has been developed. Numerical examples that illustrate the proposed ideas are discussed.
Two major processes used for cutting gears, hobbing and shaping. This article describes advanced machine design and cutter materials for gear shaping.
Grinding in one form or another has been used for more than 50 years to correct distortions in gears caused by the high temperatures and quenching techniques associated with hardening. Grinding improves the lead, involute and spacing characteristics. This makes the gear capable of carrying the high loads and running at the high pitch line velocities required by today's most demanding applications. Gears that must meet or exceed the accuracy requirements specified by AGMA Quality 10-11 or DIN Class 6-7 must be ground or hard finished after hear treatment.
The Shaping Process - A Quick Review of the Working Principle. In the shaping process, cutter and workpiece represent a drive with parallel axes rotating in mesh (generating motion) according to the number of teeth in both cutter and workpiece (Fig. 1), while the cutter reciprocates for the metal removal action (cutting motion).
Over the past few months I've talked with several different gear manufacturers who are in the process of upgrading their gear making equipment with modern CNC machine tools. Each of these manufacturers has come to the realization that in order to stay competitive, he needs to streamline operations and become more efficient...
Question: We are interested in purchasing our first gear hobbing machine. What questions should we ask the manufacturer, and what do we need to know in order to correctly specify the CNC hardware and software system requirements?
Question: We are contemplating purchasing a hobbing machine with dry hobbing capabilities. What do we need to know about the special system requirements for this technology?
Multiple CAM initiatives at Snyder Industries are improving safety, quality and productivity for parts ranging from 50 to 5,000 lbs.
Metrology is a vital component of gear manufacturing. Recent changes in this area, due in large part to the advent of computers, are highlighted in this article by comparison with more traditional methods.
Question: In the January/February issue of your magazine, we came across the term "electronic gearbox." We have seen this term used elsewhere as well. We understand that this EGB eliminates the change gear in the transmission line, but not how exactly this is done. Could you explain in more detail?
Question: We just received permission to purchase our first CNC gear inspection system. With capital approvals so hard to come by, especially for inspection equipment, I want to be sure to purchase a system I can count of for years to come. My past experience with purchasing CNC equipment has shown me that serviceability of the computer and the CNC controller portion of the system can be a problem in just a few years because of the obsolescence factor. What information do I need to look for when selecting a supplier to reduce the risk of obsolescence, as well as to reduce the long-term servicing costs in the computer and controls portion of the system?
Traditionally, profile and lead inspections have been indispensable portions of a standard inspection of an involute gear. This also holds true for the worm of a worm gear drive (Ref. 1). But the inspection of the profile and the lead is rarely performed on a worm wheel. One of the main reasons is our inability to make good definitions of these two elements (profile and lead) for the worm wheel. Several researchers have proposed methods for profile and lead inspections of a worm wheel using CNC machines or regular involute and lead inspections of a worm wheel using CNC machines or regular involute measuring machines. Hu and Pennell measured a worm wheel's profile in an "involute" section and the lead on the "pitch" cylinder (Ref. 2). This method is applicable to a convolute helicoid worm drive with a crossing angle of 90 degrees because the wheel profile in one of the offset axial planes is rectilinear. This straight profile generates an involute on the generated worm wheel. Unfortunately, because of the hob oversize, the crossing angle between the hob and the worm wheel always deviates from 90 degrees by the swivel angle. Thus, this method can be implemented only approximately by ignoring the swivel angle. Another shortcoming of this method is that there is only one profile and one lead on each flank. If the scanned points deviated from this curve, it produced unreal profile deviation. Octrue discussed profile inspection using a profile checking machine (Ref. 3).
In today's economy, when purchasing a new state-of-the-art gear shaper means a significant capital investment, common sense alone dictates that you develop strategies to get the most for your money. One of the best ways to do this is to take advantage of the sophistication of the machine to make it more than just a single-purpose tool.
Borazon is a superabrasive material originally developed by General Electric in 1969. It is a high performance material for machining of high alloy ferrous and super alloy materials. Borazon CBN - Cubic Born Nitride - is manufactured with a high temperature, high pressure process similar to that utilized with man-made diamond. Borazon is, next to diamond, the hardest abrasive known; it is more than twice as hard as aluminum oxide. It has an extremely high thermal strength compared to diamond. It is also much less chemically reactive with iron, cobalt or nickel alloys.
Up until approximately 1968-69, pinion cutter-type gear shaping machines had changed very little since their conception in the early 1900's.
Gear gashing is a gear machining process, very much like gear milling, utilizing the principle of cutting one or more tooth (or tooth space) at a time. The term "GASHING" today applies to the roughing, or roughing and finishing, of coarse diametral pitch gears and sprockets. Manufacturing these large coarse gears by conventional methods of rough and finish hobbing can lead to very long machining cycles and uneconomical machine utilization.
Most anyone that has been in the gear industry—or any machining and tooling oriented business, for that matter—is probably at least somewhat familiar with the Roto-Flo workhorse line of hydraulic-actuated spline and thread rolling machines. After all, they’ve been at it for decade
Okay. You've been convinced. You've gritted your teeth and decided to spend the money to launch a company Web site. Everybody from your teenage propeller-head to the girl in the mail room and the salesman in the flashy suit who gave you "such a deal" on Web site services has promised that your site will be the best thing that's happened to your business since the advent of CNC machines.
The goal of gear drive design is to transit power and motion with constant angular velocity. Current trends in gear drive design require greater load carrying capacity and increased service life in smaller, quieter, more efficient gearboxes. Generally, these goals are met by specifying more accurate gears. This, combined with the availability of user-friendly CNC gear grinding equipment, has increased the use of ground gears.
It isn't for everyone, but... Within the installed base of modern CNC gear profile grinding machines (approximately 542 machines worldwide), grinding from the solid isn't frequent, but a growing number of gear profile grinder users are applying it successfully using CBN-plated wheels.
This paper presents a new approach in roll testing technology of spiral bevel and hypoid gear sets on a CNC roll tester applying analytical tools, such as vibration noise and single-flank testing technology.
The modern day requirement for precision finished hobbed gears, coupled with the high accuracy characteristics of modern CNC hobbing machines, demands high tool accuracy.
The art of gear hobbing has advanced dramatically since the development and introduction of unique machine and tool features such as no backlash, super rigidity, automatic loading of cutting tools, CNC controls, additional machine power and improved cutter materials and coatings. It is essential to utilize all these features to run the machine economically.
Hard Gear Finishing (HGF), a relatively new technology, represents an advance in gear process engineering. The use of Computer Numerical Controlled (CNC) equipment ensures a high precision synchronous relationship between the tool spindle and the work spindle as well as other motions, thereby eliminating the need for gear trains. A hard gear finishing machine eliminates problems encountered in two conventional methods - gear shaving, which cannot completely correct gear errors in gear teeth, and gear rolling, which lacks the ability to remove stock and also drives the workpiece without a geared relationship to the master rolling gear. Such a machine provides greater accuracy, reducing the need for conventional gear crowning, which results in gears of greater face width than necessary.
The advent of CNC technology as applied to gear shaping machines has, in the last 10 years, led to an astonishing improvement in both productivity and quality. As is usual when developments such as this take place, the technology of the machine tool suddenly jumps ahead of that of the cutting tool, and the machine is then capable of producing faster than the cutting tool can withstand.
You're already a veteran of the computer revolution. Only you and your controller know how much money you've spent and only your spouse knows how many sleepless nights you've had in the last ten years trying to carve out a place in the brave new world of computerized gear manufacturing. PC's, CNCs, CAD, CAM, DNC, SPC, CMM: You've got a whole bowl of alphabet soup out there on the shop floor. Overall these machines have lived up to their promises. Production time is down, quality is up. You have fewer scrapped parts and better, more efficient machine usage.
News Items About CNC
1 Techno Offers CNC Teaching Aid (June 14, 2010)
Techno, Inc.'s Educational CNC Division recently introduced a new "Basic Manufacturing Skills: An Introduction to CNC Machining&... Read News
2 CNC Shapers Machine Multiple Surfaces Quickly (August 27, 2009)
Ohio Broach and Machine Company introduces a line of CNC Shaper machines that machine multiple surfaces in seconds, and various parts... Read News
3 Sunnen Delivers Vertical CNC Honing System (April 28, 2010)
Sunnen's new SV-400 Series vertical CNC honing system combines a wide choice of tooling options, large work envelope, and up to 1524 ... Read News
4 Mitsubishi Integrates Advanced CNC Control in All Product Lines (December 8, 2008)
The M700 Series CNC Control provides advanced programming for high-precision machining and productivity using nano technology. Mitsubishi... Read News
5 Cincinnati Machine Introduces CNC Tape Layer Technology (February 6, 2007)
Cincinnati Machine's new CHARGER Series of machines were designed to improve upon the technology and productivity of CNC composite ta... Read News
6 Hexagon Metrology Debuts CNC Measuring Arm at Fabtech (January 19, 2005)
Hexagon Metrology introduced a new CNC articulated measuring arm at Fabtech that president and CEO William Gruber calls ?our version of a... Read News
7 Weilers New Brochure Details In-Machine CNC Deburring on Flat Surfaces (April 11, 2006)
Weiler Corp.s newest brochure details its in-machine CNC deburring of flat surfaces and highlights the companys Nylox disc br... Read News
8 Koepfer America Launches Large Capacity CNC Hob Sharpening Machine (August 7, 2007)
Koepfer America developed the new KFS250 CNC hob sharpening machine, which is based on its KFS100 series. The KFS250 series h... Read News
9 INDEX Releases Six-Spindle CNC Bar/Chucker (October 7, 2010)
INDEX Corporation's MS52 six-spindle CNC Bar/Chucker with 52 mm/2-inch bar capacity and 100 mm/4-inch chuck capacity brings productiv... Read News
10 ANCA to Demonstrate CNC Tool and Cutter Grinder (March 25, 2013)
The new, affordable ANCA MX5 CNC tool and cutter grinder will be demonstrated at EASTEC Booth 1152. Designed with the volume end-mill pro... Read News
11 NUM Offers CNC Solution for Gear Production (December 10, 2013)
NUM has announced a high performance CNC solution for gear production machines that fully automates threaded wheel grinding. Incorporatin... Read News
12 Heidenhain Releases CNC Training Tools (February 18, 2013)
Heidenhain Corporation has released a unique online interactive training tool for CNC instruction called Heidenhain Interactive Training ... Read News
13 Okuma Highlights CNC Lathe at IMTS (August 15, 2012)
Okuma America Corporation recently announced that the new LT-3000EX, a high-powered CNC lathe, will be shown for the first time in the Un... Read News
14 Index Introduces Multi-Spindle CNC Lathe (August 19, 2011)
The new Index MS40P CNC multi-spindle automatic lathe includes a quillstock with six tool carriers and one counter spindle opposite the m... Read News
15 China Spends 2.5 Million on CNC Helical Profile Milling System (April 14, 2011)
A major Chinese compressor manufacturer recently ordered a machine from Holroyd Precision of Milnrow, Lancashire to be used for the rough... Read News
16 Mastercams Latest CNC Software Enhanced to Provide Multi-Axis Toolpaths (April 20, 2006)
The new Maintenance Release 2 (MR2) software from Mastercam introduces new capabilities including multi-axis toolpaths and Mastercam X a... Read News
17 H 400 CNC Hobs Small or Large Batches (May 9, 2012)
Run small lots or mass produce straight and helical gears; crowned and tapered gears; worm gears; chain sprockets and toothed belt discs;... Read News
18 CNC Technology Expands with Sinumerik from Siemens (December 19, 2013)
Industrial corporations are facing deep-rooted changes in the world of manufacturing. These changes are taking place alongs... Read News