For Gear, Spline & Rack Manufacturing

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1 For Gear, Spline & Rack Manufacturing METR

2 Advanced Technologies for Gear, Spline and Rack Manufacturing See it in action The VARDEX Gear Milling Concept Advanced milling tools with multi-flute indexable carbide grade inserts for super fast machining. Offering a competitive alternative to the traditional ob system. Tailor-made inserts and holders designed per customer application, with the exact required profile shape (evolvent, involute or any other profile) to be transferred to the component. New Clamping System New stopper technology for guaranteed radial and axial run out s are pre-assembled on the toolholder and remain intact when changing inserts Gear Milling System Advantages Super Fast Machining At least 50% less machining cycle time over other methods Carbide inserts with full profile designed for single pass machining Long Tool Life Tough sub-micron grade coated inserts with up to 3 cutting edges igh Accuracy & Quality Machining No need for additional machining igh quality surface finish Economical Solution Absolute Price/Performance advantage over existing technology igh Precision Machining Gears: Up to Class 7 according to DIN 3962, or Class 11 according to ANSI Involute Splines: According to DIN 5480 or ANSI B92.1 Straight sided Splines: According to ISO Simplified Machining Easy set-up and use on standard 3.5 axis CNC milling machines 2

3 Major Applications GEAR The VARDEX Gear milling tools are suitable for machining both straight and helical teeth covering modules from mm or DP SPLINE The VARDEX Spline milling tools are suitable for machining both involute or straightsided profiles, covering modules from mm or DP 48/96-4/8. RACK The VARDEX Rack milling tools are suitable for covering modules from mm or DP Gears, Splines and Racks can be machined with either Shell Mills, End Mills or Disc Mills. End Mill Shell Mill Disc Mill U Style 3 UT Style 1 Edge 3

4 Gear Milling s Circular Pitch L L Module = Pitch / π DP = 25.4 / Module U Style - 3 UT Style - 1 Edge VARDEX Gear Milling Machining Concept Based on the required customer application, VARDEX designs and supplies tailor-made inserts to suit a specific and single Module / DP as well as the exact number of teeth used on the component. s for Gear, Rack and Spline Applications Application Module Diametrical Pitch (DP) Gear Rack Spline L /4 U /8"U 16 3 Toolholder GME5N 25W U 215/... GM2N D U 215/... GME5N 32W U 215/... GMS6N D U 215/... GMS7N D U 215/... GM2N D U 215/ /2"U 22 3 GMS7N D U 215/ /2"UT 22 1 GMS6S D UT 215/ /8"U 27 3 GMS6N D U 215/ /8"UT 27 1 GMS5S D UT 215/ /96; 40/80; 32/64; 24/48 1/4 U /40; 16/32 3/8"U 16 3 GME5N 25W U 215/... GM2N D U 215/... GME5N 32W U 215/... GMS6N D U 215/... GMS7N D U 215/... GM2N D U 215/ /24; 10/20; 8/16 1/2"U 22 3 GMS7N D U 215/ /12; 5/10 1/2"UT 22 1 GMS6S D UT 215/ /16; 6/12 5/8"U 27 3 GMS6N D U 215/ /10; 4/8 5/8"UT 27 1 GMS5S D UT 215/... 8 Page 5,9 5,6,9 5,9 5,6,9 4

5 Toolholder - Weldon Shank for 1/4 U D L3 L1 L1 L Image for illustration * LP will be only, supplied final with and the inserts. values will Use be the supplied LP* for the with machine the toolholder set-up L L1 D Torx 1/4 U 3 GME5N 25W U 215/ SN2T K2T 5LST SN5LTR K7T Toolholder - Weldon Shank for 3/8 U D L3 L1 L1 L Image for illustration only, final and values will be supplied with the toolholder L L1 D Torx+ 3/8 U 3 GME5N 32W U 215/ SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 Note: Customized toolholders are available upon request. * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 5

6 Toolholder - Shell Mill for 3/8 U d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) older 3/8 U 3 GMS6N D U 215/ SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 M8x1.25x40 Toolholder - Shell Mill for 3/8 U d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) 3/8 U 3 GMS7N D U 215/ SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 M10x1.5x35 older Note: Customized toolholders are available upon request. * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 6

7 Toolholder - Shell Mill for 1/2 U d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) older 1/2 U 3 GMS7N D U 215/ SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8 M12x1.75x40 Toolholder - Shell Mill for 1/2 UT d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) older 1/2 UT 1 GMS6S D UT 215/ SN4T K4T M12x1.75x40 Note: Customized toolholders are available upon request. * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 7

8 Toolholder - Shell Mill for 5/8 U d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) older 5/8 U 3 GMS6N D U 215/ SN2T K5T 3ST SN3TM K3T M12x1.75x40 Toolholder - Shell Mill for 5/8 UT d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) older 5/8 UT 1 GMS5S D UT 215/ SN5TM K5T M12x1.75x40 Note: Customized toolholders are available upon request. * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 8

9 Gear Milling Toolholder - Disc Mill for 1/4 U d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) 1/4 U 3 GM2N D U 215/ SN2T K2T 5LST SN5LTR K7T Gear Milling Toolholder - Disc Mill for 3/8 U d(6) Image for illustration only, final and values will be supplied with the toolholder d (6) 3/8 U 3 GM2N D U 215/ SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8 Note: Customized toolholders are available upon request. * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 9

10 Recommended Grades, Speeds Vc [m/min] and Feed f [mm/tooth] Material Group P Steel M Stainless Steel K Cast Iron N(K) Non-Ferrous Metals S(M) eat Resistant Material (K) ardened Material Vardex No. 1 Material ardness Brinell B Vc [m/min] VBX Feed f [mm/tooth] Low carbon (C= %) Unalloyed steel Medium carbon (C= %) igh Carbon (C= %) Non hardened Low alloy steel (alloying elements 5%) ardened ardened igh alloy steel Annealed (alloying elements>5%) ardened Low alloy (alloying elements <5%) Cast steel 10 igh alloy (alloying elements >5%) Stainless steel Non hardened Ferritic ardened Stainless steel Austenitic Austenitic Super Austenitic Stainless steel Non hardened Cast Ferritic ardened Stainless steel Austenitic Cast austenitic ardened Malleable Ferritic (short chips) Cast iron Pearlitic (long chips) Low tensile strength Grey cast iron 31 igh tensile strength Ferritic Nodular SG iron 33 Pearlitic Aluminium alloys Non aging Wrought Aged Cast Aluminium alloys 37 Cast & aged Aluminium alloys Cast Si 13-22% Copper and Brass Copper alloys Bronze and non leaded copper Annealed (Iron based ) igh temperature Aged (Iron based) alloys Annealed (Nickel or Cobalt based) Aged (Nickel or Cobalt based) Titanium alloys Pure 99.5 Ti 400Rm α+β alloys 1050Rm Rc Extra hard steel ardened & tempered Rc* * Note: Special tools, which are not listed in this catalog, are required for extra hard steel (51-60Rc). Grades U Style UT Style Grade VBX Application TiCN coated carbide grade. Excellent grade for general use. Other grades are available upon request. 10

11 Distributor Name N E U M O E h r e n b e r g G r o u p ENQUIRY No. Request Form* * Please submit a completed version of this form with each request (a drawing is recommended). For Rack, Straight Spline, Worm or other special forms, a drawing must be supplied with all relevant dimensions! Basic Dimensions 1 Gear / Spline Standard 2 Class of Accuracy 3 Module (M) / Diametrical Pitch (DP) 4 Number of Teeth 5 Pressure Angle 6 elix Angle 7 Direction of elix (R/L) 8 Pitch Diameter (REF) 9 Major Diameter 10 Minor Diameter 11 Form Diameter (For Spline only) 12 Fillet Radius Additional Information 15 For Tool Exit Limitation, a detailed component drawing must be supplied! 16 Exit Arc Radius (R) 17 Material ardness (During machining) 18 Material Designation Max: Max: 13 Root Type (For Spline only) One of the following must be supplied: 14a Measurement Over Pins 14b Tangent Length Over (N) Teeth 14c Actual - Tooth Thickness Min: Min: Fillet Root Ø: N: Flat Root Max: Max: Max: Min: Min: Min: Tool Radius (R) < Exit Arc Pin Diameter R (/2) Tool Radius (R) < Tool Exit Limitation R (/2) Exit Arc Limitation Pressure Angle Flat Root Spline Form Diameter Involute Fillet Radius Major (Outside) Diameter Minor (Root) Diameter Pitch Diameter Measurement Over Pins Fillet Root Spline Involute Tooth Thickness Fillet Radius Form Diameter Fillet Radius Tangent length over (N) teeth

12 For Gear, Spline & Rack Manufacturing Visit VARGUS VARGUS Ltd METR EE 0 7 / EDITION 03

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