I would like some instructions for setting the degrees and minutes on a Liebherr
or Barber Colman hob. Our machines use a Vernier scale to match the lead angle
of the cutter to the part to form straight teeth. There is a dispute on how to do
this task, and I wanted insight from another professional.
Recently, a new type of hob with carbide inserts has been introduced, providing higher cutting speeds, longer tool life and higher feed rates when compared to re-grindable, high-speed steel hobs. But with this kind of hob, new challenges occur due to positional errors of the cutting edges when mounted on the tool. These errors lead to manufacturing errors on the gear teeth which must be controlled. In this paper, the tooth quality of a gear manufactured by hobs with different quality classes is analyzed using a simulation model in combination with Monte Carlo methods.
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.
Investment in advanced new manufacturing technologies is helping to reinvent production processes for bevel gear cutters and coarse-pitch hobs at Gleason - delivering significant benefits downstream to customers seeking shorter deliveries, longer tool life and better results.
Indexable carbide insert (ICI) cutting
tools continue to play a pivotal role
in gear manufacturing. By offering higher cutting speeds, reduced cycle times, enhanced coatings, custom configurations and a diverse range of sizes and capabilities, ICI tools have
proven invaluable for finishing and pre-grind applications. They continue to expand their unique capabilities and worth in the cutting tool market.
In today’s manufacturing environment, shorter and more efficient product
development has become the norm. It is therefore important to consider every
detail of the development process, with a particular emphasis on design. For
green machining of gears, the most productive and important process is hobbing. In order to analyze process design for this paper, a manufacturing simulation was developed capable of calculating chip geometries and process forces based on different models. As an important tool for manufacturing technology engineers, an economic feasibility analysis is implemented as well. The aim of this paper is to show how an efficient process design—as well as an efficient process—can be designed.