GEAR CUTTING BY MILLING TECHNOLOGY

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1 Na titulní straně prezentace by vždy měla být fotka, týkající se prezentovaného stroje, nebo odvětví. Na titulní straně by dále měl být uveden její účel a pro koho je připravena. (popisné texty-viz tento, nahraďte tím, co uznáte za vhodné) GEAR CUTTING BY MILLING TECHNOLOGY

2 Core competences: Helical gears Double helical gears Spur gears Internal gears Straight bevel gears All-in-one solution is what we do Drawing Software CAM model Simulation Complete machining Finished components Page 2

3 Productivity & machine price Gear cutting of spur gear sample: diameter = mm, m = 30 mm, z = 186 mm, b = 500 mm Type of machining Machine Total time (hrs) Machine price (%) Hobbing Old conventional hobbing machine from 60s 602 CNC milling (including finishing) CNC milling machine % CNC hobbing CNC Gear hobber % Total time (hrs) Machine price (%) Wider using possibilities CNC hobbing machine Gear cutting CNC milling machine Gear cutting Power industry Railway industry Aerospace industry Construction industry Mining industry Shipbuilding industry Defence industry Other industry areas Page 3

4 Benefits of using the TOS KURIM CNC gear milling machine towards the CNC hobbing machine The same machine can be used for all types of toothing helical, spur, herring-bone, Bevel and internal teeth The machine can be used without any modifications as a standard horizontal boring machine or a machining centre, without any further adjustment»»»»»» wider using possibilities Teeth can be rough with high strength of up to 400 HB Standard tools use exchangeable inserts Standard tools is possible to buy within several days, compared with delivery times of roughening tools for hobbing machines, which are between 12 and 18 weeks Cutting tools are much more cheaper then special cutting tools for hobbing machines Page 4

5 Benefits of using the TOSKURIM CNC gear milling machine The whole gear manufacturing process is managed by a software suite, exclusively developed in partnership with HAVLIK GEAR,that gives control on all phases Page 5

6 3D simulation, easy gear modification, machining time calculation and finally selection the most efficient manufacturing strategy are the main features of the TOS KURIM gear milling solution Page 6

7 TOS KURIM CNC gear milling machine The solution is recommended for gear diameter 4 10 m or more with the below guaranteed accuracy Accuracy per ISO 1328 Accuracy per DIN Accuracy per AGMA Accuracy per JIS Max roughness Ra [nm] Max gear speed [m/s] Max gear speed helical gears [m/s] 0,1 0,2 0,4 0,8 1,6 1,6 3,2 6,3 12, TOS KURIM CNC gear milling machine (Grinding machine) Milling Indicative table for choosing the degree of accuracy by identifying the area of determining the degree of accuracy Area Accuracy ISO Accuracy AGAMA Control gears Measuring Devices Turbine gearboxes Aicraft gearboxes Machine tools Aircraft engines Speed gearboxes Automobiles Industrial gearboxes Light ship engines 7 9 Rolling mills, locomotives Heavy marine engines, tractors Construction and agricultural machinery Textile machinery Page 7

8 Havlik Machinery, Canada Machine: FUQ 150 VR/11 Type: Floor type machining centre Commissioning: 8/2006 Basic parameters: X = mm, Y = mm, Z = mm Power: 30 kw End user: Companies all around the world The Havlik companies have been in the gear manufacturing related business for over 100 years. Main business emphasis is on open gearing, special gearing, replacement gearing, bevel and worm gearing, gear units and gear grinding of all sizes Machine is equipped with automatic interchangeable milling heads: two axis head type VK, universal head type VO, straight head type VA1, customized head type VZ1 Rotary table type CES: table size: x mm, linear axis: v = mm, loading capacity: 25 t Clamping plates: size: x x 400 mm, size: x x 400 mm Z = mm CNC rotary table Page 8

9 Havlik Machinery, Canada Machine: FUQ 150 WR/9 Type: Floor type machining centre Commissioning: 1/2008 Basic parameters: X = mm, Y = mm, Z = mm Power: 30 kw End user: Companies all around the world Machine is equipped with shift-out quill ø 170 mm, W = 400 mm and additional milling head type IPS Two rotary tables type CES: table size: x mm, linear axis: V = mm, loading capacity: 25 t Z = mm CNC rotary table CNC rotary table Page 9

10 Interchangeable milling heads used by Havlik company Two axis head type VK Universal head type VO Straight head type VA1 Max. torque: Nm Spindle speed: rpm Motor output: 30 kw Max. torque: Nm Spindle speed: rpm Motor output: 30 kw Max. torque: Nm Spindle speed: rpm Motor output: 30 kw Special interchangeable milling head VZ1 for internal gear cutting Max. teeth width Type VZ1 Units Max. torque 630 Nm Spindle speed rpm Motor output 30 kw Spindle taper ISO 50 Clamping Cooling automatic Low + high pressure Page 10

11 Vítkovice Gearworks, Czech Republic Machine: FUQ 150 VR/14 Type: Floor type machining centre Commissioning: 11/2007 Basic parameters: X = mm, Y = mm, Z = mm Power: 30 kw End user: Companies all around the world Machine is equipped with automatic interchangeable milling head: universal milling head type VO Clamping area: two clamping plates: x x 400 mm, rotary table type ISN Page 11

12 External gear cutting double helical gears Double helical gears, overcome the problem of axial thrust presented by "single" helical gears, by having two sets of teeth that are set in a V shape. A double helical gear can be thought of as left hand and right helical gears joined together. This arrangement cancels out the net axial thrust, since each half of the gear thrusts in the opposite direction. Big advantage of milling machines is the possibility of machining both sides (left and right hand) at once. Double helical gears are more difficult to manufacture due to their more complicated shape. The teeth can be aligned at an apex or they can be staggered. The machine controls the alignment of teeth accurately. Minimization of idle times For watching movie use the QR Code Page 12

13 External gear cutting single helical gears Helical gears can be meshed in a parallel or crossed orientations. The former refers to when the shafts are parallel to each other; this is the most common orientation. In the latter, the shafts are non-parallel, and in this configuration are sometimes known as "skew gears". For watching movie use the QR Code Page 13

14 External gear cutting spur gear The spur gear profile is the most commonly used system for gearing today. In an involute gear, the profiles of the teeth are involutes of a circle. (The involute of a circle is the spiraling curve traced by the end of an imaginary taut string unwinding itself from that stationary circle called the base circle). For watching movie use the QR Code Page 14

15 Internal gear cutting internal gear These have a similar tooth design to that of a spur and helical gears, except that the teeth are formed on the inner surface of a cylinder or cone, and they are more concave in shaped, whereas the teeth of a spur gear are more convex in shape. In fact, the teeth on a annular gear are basically the same shape as the space between the teeth of a spur gear. Page 15

16 Floor type machining centres The floor type machining centres have vertical travel of up to 6,000 mm and maximum motor output of 70 kw and are offered with shift-out boring spindle or with automatic interchangeable milling heads; dual configuration is available on request. The production program also includes technological workplaces tailor-made to the customer s needs. Automatic interchangeable milling heads Shift-out quill W Basic feature of the floor type machining centres - FU(Q) is its build-up configuration. Clamping area can executed accordingly to the customer request. This machining centres are designed for swarfmachining of materials with a wide range of technological use in operations such as milling, drilling, roughing out, reaming, and threading including thread cutting by chaser. In the basic execution this machine is delivered with control system HEIDENHAIN itnc 530, digital drives BOSCH-REXROTH and hand measuring HEIDENHAIN. The machine FUQ is equipped with a chain-type tool magazine with code position. Searching and moving of tool into holding position is executed during working operation of the machine. The machine is equipped with automatic interchangeable milling heads, which can be designed according to customers requests. Benefits: Various working areas: movable rotary tables / movable rotary tables with hydrostatics /movable rotary tables with VTL ability / clamping plates Automatic pick-up tool exchange (PICK-UP) Automatic spindle head exchange Two ball screws with measuring in vertical axis enable elimination of deformation when headstock is being removed out of work Three-step gearbox enables optimum use of motor output within full range of speed Active inspection Hydraulically balanced weight of machine parts moving in vertical direction (knee, headstock, spindle head) Thermal stabilization of three-step gearboxes and spindle drive chains at spindle heads Finishing operation possible using 5-axis machining Axial tool cooling in all types of spindle heads Axial tool cooling depending on spindle head up to 100 bars Spindle head exchange for customer s special technological applications Possibility of two independent machines sharing one working area Vertically adjustable operator s working platform Page 16

17 Various working areas Clamping plates Rotary tables Fixed Clamping plate width / length [mm] / Table clamping area dimensions [mm] X Load capacity [t/m 2 ] Load capacity [t] 6-60 Torque (S1) [Nm] Movable Table clamping area dimensions [mm] X Load capacity [t] Torque (S1) [Nm] Linear axis travel [mm] Rotary tables with VTL ability VTL tables Fixed Table clamping area dimensions [mm] X Carousel table clamping area diameter [mm] Load capacity [t] Load capacity [t] Torque (S1) [Nm] Torque (S1) [Nm] Max. speed [rpm] Max. speed rpm] Movable Table clamping area dimensions [mm] X Load capacity [t] Torque (S1) [Nm] Linear axis travel [mm] Max. speed [rpm] Page 17

18 TRADITION - RELIABILITY - INNOVATION Turn-key delivery of technology Guaranteed performance with adjusted technology Tailor-made customer s solutions Gantry type machining centres Column to column distance up to mm Execution: fixed table / movable table Motor output kw Multi-purpose machining centres Gantry type machining centres with carousel or grinding function Floor type machining centres Motor output kw Vertical turning lathes Execution: single / double column Max. turning diameter mm Max. turning height up to mm Max. workpiece weight up to 450 t Optional with Y axis Page 18