Many gears
“Many of the gears we process are manufactured according to the customer's specific requirements. Customers can only process one gear with specific requirements, or a batch of gears, or they can request a set of transmission solutions. We often deal with small batches. Production, that is, processing 1-100 parts, but there are also orders for producing thousands of gears throughout the year. According to industry regulations, some products (especially those related to automotive gearboxes) need to be delivered on time. We are specialized in production. Manufacturers of helical and spur gears, providing gear processing products for a variety of industries."
This is the positioning of a gear manufacturing company. They use unique gear processing tools tailored for applications in a variety of industries. Using the process manufacturing reverse method, it is possible to accurately determine how the worn unknown gear is designed and then quickly manufacture it. Flexibility is part of the business philosophy. However, versatility in production has always been difficult to combine with high productivity. The necessary flexibility means that every time you need to machine different gears, you need to use new tools , and each time you need to program the gear machine according to the new gear.
new method
The flexibility of gear machining is based on the innovative milling method of multi-axis turning and milling machines : InvoMilling. This is a unique process developed by Sandvik Coromant (patent pending and registered trademark) and is being used in cooperation with Mori Seiki. Mori Seiki needed a specialized, relatively slow flexible gear manufacturing process that would replace the major applications on the market today. This innovative multi-axis solution is based on an advanced but simple cutting strategy. The strategy is to work directly on standard multi-function machines with off-the-shelf cutting tools that machine spur and helical gears instead of hobbing.
The InvoMilling method combines slot milling and turning and milling operations. The same tool can be used to machine gears with any helix angle.
Includes involute and non-involute profiles. The exact number of cuts depends on the gear size and the size of the tool used.
The new InvoMilling multi-axis machining method is a flexible production method for spur and helical gears using standard disc milling cutters and standard special face milling cutters. By cutting the X-axis and the B-axis or the Y-axis and the B-axis, the cutting tool can be machined along the involute path. Therefore, the tooth profile change will coincide with the tool path (rather than the tool shape). For this purpose, the car-milling machine is the ideal machine .
This new method can be used on the DMG Mori Seiki NT machine . This multi-axis milling center is capable of simultaneous milling and turning. The flexible B-axis has a rotation range of ±120°, and the direct drive motor can achieve high speed and high precision with an indexing capacity of 0.0001°. This method has been proven to significantly reduce machining time, especially with 5-axis machining. Better results with complex parts. Hobbing is a machining process performed on a machine tool , and it can also process parts related to the transmission parts. However, hobbing is not the best solution when producing many different types and small batches of gears.
At present, if a processing shop is or intends to invest in CNC machine tools , then InvoMilling software is a convenient option. Car-milling machines can be used directly to machine gears.
We offer gear processing packages for a wide range of moduli, each with three tools for several different moduli. With these tool kits, it is easy to produce gears in a large modulo range with great flexibility and to meet particularly stringent accuracy standards.
InvoMilling method
The InvoMilling method combines the slot milling and turning and milling processes together. The same tool can be used to machine gears with any helix angle, including involute and non-involute profiles. The number of cuts depends on the gear size and the size of the tool used. InvoMilling can take advantage of the high precision of modern machine control and CNC machines , as well as the precision of cutting tools , so that precision gears and semi-finished gears for fine grinding can be machined. The use of newly developed insert materials also allows for higher cutting parameters for optimum efficiency.
In this way, it is also possible to chamfer the outer diameter of the tooth teeth and to machine different lobes, tooth profiles and radii at the root. The chip cross-section produced by each cut is small and there is no such side pressure, so that the tendency to vibrate is minimized.
For example, when machining the cogging of the outer spur gear, the groove should first be milled along the axial direction of the workpiece. For subsequent cutting, the gears need to be rotated slightly to coordinate with the tool 's simultaneous radial plunge milling. The result is an involute curve shape by turning and milling.
For larger moduli, more cuts may be required. For wider gears, the tool is offset in the axial direction and the cutting steps are repeated.
Since each InvoMilling tool covers several modulo sizes, InvoMilling reduces processing costs in small to medium volume production. For example, a gear with a modulus of 2 to 4 uses the same tool , and three tools can cover all gears with a modulus of 2-12. To date, the InvoMilling method has a maximum gear modulus of 18 and a diameter of 800 mm, which has the obvious advantage of shortening gear delivery and reducing costs.
Modern indexable insert technology
Modern indexable insert technology has made the new method a success. With the InvoMilling method, the quality of the gear teeth can reach DIN 3962 level 6 or above. In addition, on machines with sufficient rigidity, the correct use of the tool can achieve better surface accuracy than Rz 3 microns. The InvoMilling method, which uses precise tool paths and precision tools , produces competitively high quality gears. With this method, various gear grinding allowances can be generated. The low cutting force of this method allows for higher cutting parameters during cutting while ensuring the precise profile required for small tolerances. These advantages, combined with the flexibility of this gear processing method, have been a success factor in gear machining.
The InvoMilling method can use dedicated milling cutters CoroMill 161 and CoroMill 162
The standard carbide inserts used in the milling tools are easily rotated outside the machine and are easily stored in the knife box. The InvoMilling of gears with a machining modulus of 4-10 and a number of teeth of less than 30 can be compared to the use of single-head high speed steel hobbing. Since many processes can be incorporated into multitasking, the gears can be machined in a single machine setup, resulting in shorter lead times and product replacement times, with the advantage of being able to temporarily insert products during the production process, facilitating a single piece. Flexible production of small and medium batch gears.
Therefore, even if the cycle time for manufacturing the gear itself is longer than the time for using the hobbing, the overall manufacturing time is shortened. Finally, since there is no need to wait for the special tool to be manufactured, production can be started after a new setup. With the introduction of InvoMilling, Sandvik Coromant has upgraded its technology to produce high-quality gears using standard-purpose machines , significantly reducing machining costs, increasing flexibility and significantly reducing lead times.
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