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Imagine the flexibility of having one machine capable of milling, turning, tapping and gear cutting with deburring included for hard and soft material. No, you’re not in gear fantasy land. The technology to manufacture gears on non gear-dedicated, mult-axis machines has existed for a few years in Europe, but has not yet ventured into mainstream manufacturing. Deckel Maho Pfronten, a member of the Gildemeister Group, took the sales plunge this year, making the technology available on most of its 2009 machines.
Sandvik presents the latest in gear milling technologies.
The recently available capability for the free-form milling of gears of various gear types and sizes — all within one manufacturing system — is becoming increasingly recognized as a flexible machining process for gears.
Bevel gear manufacturers live in one of two camps: the face hobbing/lapping camp, and the face milling/grinding camp.
When a customer needed gears delivered in three weeks, here’s how Brevini Wind got it done.
“If it’s broken, bring it on in.” That’s the advice offered by Roy Parker, president and owner of Jones Welding Company Inc.
In co-operation with Voith, a major transmission manufacturer in Germany, Heller has developed a process that significantly enhances the productivity of pre-milling and gear milling operations performed on a single 5-axis machining center.
Look beyond the obvious, and you may well find a better way to machine a part, and serve your customer better. That’s the lesson illustrated in a gear machining application at Allied Specialty Precision Inc. (ASPI), located in Mishawaka, Indiana.
Depo provides all-in-one machining capabilities for the gear industry.
This article is part four of an eight-part series on the tribology aspects of angular gear drives. Each article will be presented first and exclusively by Gear Technology, but the entire series will be included in Dr. Stadtfeld’s upcoming book on the subject, which is scheduled for release in 2011.
In this paper a new method for the introduction of optimal modifications into gear tooth surfaces—based on the optimal corrections of the profile and diameter of the head cutter, and optimal variation of machine tool settings for pinion and gear finishing—is presented. The goal of these tooth modifications is the achievement of a more favorable load distribution and reduced transmission error. The method is applied to face milled and face hobbed hypoid gears.
In this article, the authors calculated the numerical coordinates on the tooth surfaces of spiral bevel gears and then modeled the tooth profiles using a 3-D CAD system. They then manufactured the large-sized spiral bevel gears based on a CAM process using multi-axis control and multi-tasking machine tooling. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. Moreover, the gears were meshed with each other and the tooth contact patterns were investigated. As a result, the validity of this manufacturing method was confirmed.
Klingelnberg's new tool and machine concept allow for precise production.
Hobs, broaches, shaper cutters, shaver cutters, milling cutters, and bevel cutters used in the manufacture of gears are commonly made of high speed steel. These specialized gear cutting tools often require properties, such as toughness or manufacturability, that are difficult to achieve with carbide, despite the developments in carbide cutting tools for end mills, milling cutters, and tool inserts.
I'm a big believer in the value of IMTS as a marketplace where gear manufacturers can go and look at the latest machine tools and processes; compare hobbing machines, gear grinders and inspection equipment; see turning, milling or grinding machines in action; and ask questions of the various vendors all in one place. This year's IMTS promised to be the biggest ever, and I have no doubt that it will be a valuable experience to those who go there looking for ways to improve the way they manufacture products.
Decades ago, technology shifted from HSS to indexable inserts in turning and milling. This movement wasn't immediately realized in gear hobbing because coated PM-HSS hobs and complex gear profiles remained highly effective and productive methods. Only fairly recently have gear manufacturers started to take a serious look at indexable technology to cut gear teeth.
High-speed machining using carbide has been used for some decades for milling and turning operations. The intermittent character of the gear cutting process has delayed the use of carbide tools in gear manufacturing. Carbide was found at first to be too brittle for interrupted cutting actions. In the meantime, however, a number of different carbide grades were developed. The first successful studies in carbide hobbing of cylindrical gears were completed during the mid-80s, but still did not lead to a breakthrough in the use of carbide cutting tools for gear production. Since the carbide was quite expensive and the tool life was too short, a TiN-coated, high-speed steel hob was more economical than an uncoated carbide hob.
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.
Zerol bevel gears are the special case of spiral bevel gears with a spiral angle of 0°. They are manufactured in a single-indexing face milling process with large cutter diameters, an extra deep tooth profile and tapered tooth depth.
In addition to the face milling system, the face hobbing process has been developed and widely employed by the gear industry. However, the mechanism of the face hobbing process is not well known.
News Items About milling
1 Sandvik Introduces Precision Cutter for Gear Milling (November 5, 2010)
Sandvik Coromant has introduced the CoroMill 170 cutter that offers the potential for optimization of milling applications for large gear... Read News
2 Fooke Offers Five-Axis Milling Machines (March 30, 2012)
In the past, various lateral or travelling column milling machines were used for building models and prototypes. Today, the use of Fooke ... Read News
3 ATI Stellram Introduces Milling Cutter (November 18, 2010)
ATI Stellram recently introduced a new chevron-style milling cutter, the Stellram 5230VS12, designed specifically for machining titanium ... Read News
4 Milling and Drilling at Composites 2011 (February 4, 2011)
Seco Tools will be demonstrating a range of tooling solutions for milling and drilling applications at Composites 2011. The company will ... Read News
5 ATI Stellram Releases Milling Products Catalog (June 24, 2011)
ATI Stellram introduces its new catalog featuring indexable milling cutters and inserts specifically designed and manufactured for machin... Read News
6 Koepfers Versatile MZ 130 Provides Same-Setup Gear Hobbing and Worm Milling (January 10, 2007)
Koepfers MZ130 hobbing and worm milling CNC machine from Monnier + Zahner was designed with versatility and ease of use in mind. ... Read News
7 Zimmerman Presents New Milling Machine with Linear Drive (April 14, 2006)
The new FZ 38 from Zimmerman is a CNC portal milling machine driven by linear motors. According to the company's press release, the ... Read News
8 Advent Tool & Manufacturing Debuts New Involute Spline Milling Solution (April 22, 2006)
Advent Tool & Manufacturing released its indexable form milling platform for involute splines, spur gears, "V" shaped gears, and various ... Read News
9 Gear Expo Recap: Sandvik Coromant Demos InvoMilling (September 23, 2013)
The InvoMilling process, a unique approach to milling spur and helical gears using indexable insert cutters was front and center during G... Read News
10 Ingersoll Offers Modular Milling System (September 9, 2013)
Chip-Surfer from Ingersoll provides a modular milling system for NC, Swiss and live tooling applications. Highlights include interchangea... Read News
11 MC Machinery Expands Milling Line (January 31, 2012)
MC Machinery Systems, Inc. expands its product supply chain with the new MC Milling line. The Diamond Cut general milling line is compris... Read News
12 Heller Introduces Gear Manufacturing on Five-Axis Milling Machines (August 2, 2010)
Manufacturers of gear components and bevel gears have been looking for alternatives to traditional manufacturing processes for larger gea... Read News
13 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
14 Iscar Offers Face Milling Solution (February 29, 2012)
Helido S890 FSN is a new family of right-hand indexable face mills with an 88 degree cutting edge angle with eight helical cutt... Read News
15 Sandvik Teams With Star SU for Gear Milling (January 16, 2014)
Sandvik Coromant has teamed up with Star SU on an extended basis. Beginning as an authorized OEM agent, and now a national channel partne... Read News
16 PTG Holroyd Produces Large Helical Profile Milling Machine (March 6, 2014)
Holroyd manufactured one of the world’s biggest high precision screw rotors for a major gas compression project in the Far East usi... Read News
17 Sandvik Expands Gear Milling Family (August 13, 2013)
The CoroMill 176 range of full profile hobs for spur gears, helical gears and splines has now been extended to incorporate module 3-10 ap... Read News
18 Vargus Offers Reliable Gear Milling Tools (March 15, 2013)
A well-known gear manufacturer in the United States had an application they were currently using conventional hobbing methods on. They ha... Read News
19 Seco to Offer Milling Solutions at Windpower 2012 (March 22, 2012)
Seco will be highlighting a range of solutions for wind power machining applications at Windpower 2012, including the North American... Read News
20 Index Releases Turning Milling Center (May 14, 2012)
Index Corporation, IMTS Booth S-8450, will introduce a new concept machine tool featuring two independent 5-axis subsystems, each with on... Read News
21 Sandvik Introduces InvoMilling 1.0 During IMTS (September 15, 2014)
Sandvik Coromant introduced InvoMilling 1.0 during IMTS in Chicago. The InvoMilling solution was released as software supported by dedica... Read News