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What is the best tooling to use when hard milling a gear tooth on a 5-axis machining center? And what makes it the best? We have just bought a DMG Mori mono-block and are not getting the finishes at the cycle times we require.
Exciting new machine, cutting tool and software technologies are compelling many manufacturers to take a fresh look at producing their larger gears on machining centers. They're faster than ever, more flexible, easy to operate, highly affordable - and for any type of gear.
Free form milling of gears becomes more and more important as a flexible machining process for gears. Reasons for that are high degrees of freedom as the usage of universal tool geometry and machine tools is possible. This allows flexible machining of various gear types and sizes with one manufacturing system. This paper deals with manufacturing, quality and performance of gears made by free form milling. The focus is set on specific process properties of the parts. The potential of free form milling is investigated in cutting tests of a common standard gear. The component properties are analyzed and flank load-carrying capacity of the gears is derived by running trials on back-to-back test benches. Hereby the characteristics of gears made by free form milling and capability in comparison with conventionally manufactured gears will be shown.
At first sight the appearance of 5-axis milling for bevel gears opens new possibilities in flank form design. Since in comparison to existing machining methods applying cutter heads no kinematic restrictions exist for 5-axis milling technology, any flank form can be machined. Nevertheless the basic requirements for bevel gears did not change. Specifications and functional requirements like load carrying capacity and running behavior are still increasing demands for design and manufacturing. This paper describes the demands for gear design and gives an overview about different design principles in the context of the surrounding periphery of the gear set.
Developed here is a new method to automatically find the optimal topological modification from the predetermined measurement grid points for bevel gears. Employing this method enables the duplication of any flank form of a bevel gear given by the measurement points and the creation of a 3-D model for CAM machining in a very short time. This method not only allows the user to model existing flank forms into 3-D models, but also can be applied for various other purposes, such as compensating for hardening distortions and manufacturing deviations which are very important issues but not yet solved in the practical milling process.
Higher productivity, faster setup times and single unattended operations are just a few of the capabilities gear manufacturers seek in the multifunctional machine tool market.
The complete product news section from the June 2009 issue of Gear Technology.
Big Data Expands Process Capabilities for Multi-Axis Machining.
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.
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.
The latest in big gear machining with DMG/Mori Seiki.
The geometry of the bevel gear is quite complicated to describe mathematically, and much of the overall surface topology of the tooth flank is dependent on the machine settings and cutting method employed. AGMA 929-A06 — Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius — lays out a practical approach for predicting the approximate top-land thicknesses at certain points of interest — regardless of the exact machine settings that will generate the tooth form. The points of interest that AGMA 929-A06 address consist of toe, mean, heel, and point of involute lengthwise curvature. The following method expands upon the concepts described in AGMA 929-A06 to allow the user to calculate not only the top-land thickness, but the more general case as well, i.e. — normal tooth thickness anywhere along the face and profile of the bevel gear tooth. This method does not rely on any additional machine settings; only basic geometry of the cutter, blank, and teeth are required to calculate fairly accurate tooth thicknesses. The tooth thicknesses are then transformed into a point cloud describing both the convex and concave flanks in a global, Cartesian coordinate system. These points can be utilized in any modern computer-aided design software package to assist in the generation of a 3D solid model; all pertinent tooth macrogeometry can be closely simulated using this technique. A case study will be presented evaluating the accuracy of the point cloud data compared to a physical part.
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.
News Items About 5-axis
1 Heller HF Series 5-axis Machining Center Designed for Machining Complex Prismatic Parts (May 5, 2017)
Heller Machine Tools introduces its versatile HF Series 5-axis horizontal machining centers to North America for machining complex prisma... Read News
2 Hardinge Develops Latest 5-Axis Vertical Machining Center (August 9, 2016)
Hardinge Inc. has announced the release of their newest 5-axis vertical machining center, the Bridgeport XT 630 5-Axis. Bridgeport's... Read News
3 Heller FP 4000 5-axis Horizontal Machining Center Features Z-axis Twin Drives (December 6, 2016)
Heller offers new levels of flexibility and precision with its FP 4000 5-axis horizontal machining center with twin drives in the Z-axis.... Read News
4 Hardinge Releases New Bridgeport 5-Axis VMC (September 7, 2012)
Hardinge Inc., an international provider of advanced metal-cutting solutions, announces the release of the all-new Bridgeport GX-250 5AX ... Read News
5 EMCO Umill 1800 5-Axis Milling-Turning Machine (June 8, 2016)
The Umill 1800 from Mecof, part of EMCO Group, offers milling and turning solutions designed to meet the needs of mold makers and aerospa... Read News
6 Heller 5-axis Machining Center Provides Reduced Setups, High Precision (November 2, 2015)
The recently introduced CP 4000 series horizontal machining centers accomplish horizontal, vertical and tilted turning with A and B axis ... Read News