Liebherr has optimized chamfering with the ChamferCut technology and opened it up for completely new applications. The chamfering process can now be performed during the machining process, which represents a huge customer benefit. The established method is based on tried-and-tested Liebherr machine technology and was further developed from the classic process with the ChamferCut tools on the hob arbor. Milling machines with integrated ChamferCut unit, as well as stand-alone chamfering machines, are especially adapted to the requirements.
Liebherr-Verzahntechnik GmbH optimized its gear hobbing machine portfolio for the ChamferCut process and offers the customer enhanced technologies with increased cost-efficiency. Additional machining is now no longer required following chamfering in the Liebherr ChamferCut unit. As a result, chamfering can be performed more precisely, reliably and economically than with competing processes, such as press deburring. The ChamferCut process enables a complete and even chamfer right down to the tooth root. There is no need for a second cut, which is often required during the deformation-based deburring process for the removal of build-up material. As the exact chamfer shape is generated during chamfering, there is no effect on the material structure, unlike with deformation-based processes. An optimal starting point is created for the downstream hard gear finishing, through grinding or, in particular, honing. The quality of the chamfer defines a new standard, as not only very precise chamfer geometry, but also high chamfer quality and reproducibility are achieved. The tool costs are also lowered, which in turn leads to a low amortization period of the machine.
In contrast to press deburring, the advantages for the customer during chamfering include fast retooling and simple adaptation in the case of varying flank modifications, in addition to user-friendly software. Simple adjustments or corrections are also possible via the CNC axes. In general, dry and wet machining are possible with the optimized machines. The machine tools are flexibly automated - for instance, via a plastic chain conveyor or a palletizing cell. The automatic loading is effected by the flexible ringloader principle. Alternatively, the loading can also be done using a robot or gantry. The following machine types are equipped with the integrated ChamferCut unit.
The established LC 180 DC with integrated ChamferCut unit is a very compact gear hobbing machine. This integrated automation solution enables hobbing and simultaneous chamfering of workpieces with a maximum diameter of 180 mm and a module of 3.5 mm.
With the LC 300 DC gear hobbing machine workpieces with a maximum diameter of 300 mm can be produced very economically, with a high gear cutting quality and precise chamfer quality. Workpieces up to module 6.5 mm can be hobbed and simultaneously chamfered.
The LD 180 C and LD 300 C are compact stand-alone machines whose main task is the chamfering of gears. They can be integrated easily, quickly and cost-effectively into all existing production/manufacturing lines.
The classic ChamferCut process with the chamfer cutters on the hob arbor can be retrofitted on all existing Liebherr gear hobbing machines with Siemens 840 D control and higher.