Case 13 of Industrial Engineering ONLINE Course.
Industrial Engineering Case Studies Collection
https://www.americanmachinist.com/machining-cutting/article/21131995/complex-highprecision-machining-from-profilator-gmta
High productive gear manufacturing with Scudding®
March 26, 2017
In the automotive and commercial vehicle sector, hobbing, shaping and broaching are the dominating processes for soft machining of gears. A highly productive alternative to the methods mentioned before is Scudding® of Profilator. Scudding® combines a high flexibility with a high productivity.
Only Scudding® offers the possibility to produce internal and external and gears with and without interfering contours.
The cutting speed results out of the rotation speeds of tool and workpiece as well as the set cross-axis angle. Today cutting speeds, which are now being implemented with modern machine and tool technology, are up to vc = 250 m/min.
Profilator and Samputensili formed an alliance to offer the market the best tool and machine technology. Together they have many years of experience in SCUDDING® and they successfully supply well-known companies in the gear industry all over the world.
Sandvik Coromant
CNC Machine Offers Versatile, Productive Solution for Gear Chamfer-Deburring
The Helios TM 250-CNC uses a rotary table with twin work spindles to minimize idle machine time.
June 7, 2022
The TM 250-CNC uses a rotary table with twin work spindles to minimize idle machine time, thus maximizing potential productivity. Machining is performed on one work spindle while the other is simultaneously unloaded and loaded manually. The machine can easily adapt in the future to an automatic loading strategy via robot, cobot (collaborative robot), pick-and-place, or other systems. The TM 250 shifts the paradigm from a fully manual deburring process to one equipped with a machine tool that allows next-level quality and productivity.
The TM 250-CNC setup personnel to store all tool spindle parameters. These include radial, axial, and tangential positions, as well as tool speed, direction, and pressure. Crucially, this allows a single setup per part number, which can be consistently and reliably repeated simply by loading a program. With CNC ability, the TM 250 becomes a versatile workhorse for any gear manufacturers with a high mix of part types.
Search for Gear Machining Productivity for more online articles.
Scudding
20 May 2020https://www.americanmachinist.com/machining-cutting/article/21131995/complex-highprecision-machining-from-profilator-gmta
High productive gear manufacturing with Scudding®
March 26, 2017
In the automotive and commercial vehicle sector, hobbing, shaping and broaching are the dominating processes for soft machining of gears. A highly productive alternative to the methods mentioned before is Scudding® of Profilator. Scudding® combines a high flexibility with a high productivity.
Only Scudding® offers the possibility to produce internal and external and gears with and without interfering contours.
The cutting speed results out of the rotation speeds of tool and workpiece as well as the set cross-axis angle. Today cutting speeds, which are now being implemented with modern machine and tool technology, are up to vc = 250 m/min.
Profilator and Samputensili formed an alliance to offer the market the best tool and machine technology. Together they have many years of experience in SCUDDING® and they successfully supply well-known companies in the gear industry all over the world.
https://www.sampspa.com/blog/high-productive-gear-manufacturing-with-scudding/
2015
2015
Scudding - Productivity in Gear Machining - 10 times faster than gear shaping.
An example of the potential speed would be a workpiece that is machined with a 60-tooth scudding cutter at a speed of 4,000 rpm, achieving 240,000 enveloping cuts per minute. This means scudding can be up to 10 times faster than gear shaping.InvoMilling
Increase productivity by as much as 300 percent - new gear machining tools
28 Jul 2012Sandvik Coromant
______________
______________
With the high-speed steel hob, you have to take the hob off and then reset. Today, we can index the hob right on the machine. So we can take an insert and all we have to do is change out the insert.
In an example of a gear wheel that was produced by an HSS hob, which is the usual way of doing it, the time taken was 32 minutes. With our new product line, we are down to four ... going from 32 minutes down to four minutes— a revolution.
Invo-milling process is a great technological event in the gear-milling industry ... And what it does is it gives you the opportunity of taking advantage of the machining technology, which is 5-axis machining and programming, and use standard tools and form a gear out of that combination. Where before you had a special tool on a special machine, now you have a standard tool on a standard machine with special software.
Customers have hands-on access to collaborative insights, training and technologies—including the new Hofler HF1000 gear-milling machine—when they visit the company's Schaumburg, Illinois productivity center.
Coromill® 170 - Rough gear milling with precision
9 Nov 2011
Sandvik Coromant
_______________
_______________
Coromill® 170 is a high performance cutter for machining of large gears in module range 12-22. It will reduce time in your gear machining, leaving minimal and even allowance for subsequent operations. Use it for precision and reliability in roughing of external and internal gears.
CoroMill® 176 - Cost efficient gear milling
9 Nov 2011
Sandvik Coromant
____________
____________
CoroMill® 176 is an innovative indexable insert cutter for productive gear wheel machining. It is a more cost-efficient alternative to regrindable HSS (high speed steel) tools. Its ability to reach higher cutting speeds combined with user-friendly insert changing will reduce cycle times and cost per component, making it the high productivity gear milling choice.
2013
Joining flexibility with high productivity when gear milling.
Imagine a gear milling method where the toolpath—not the tool shape—determines gear characteristics such as diametral pitch or pressure angle. A new concept, involute milling, provides that functionality while delivering machining efficiency and production versatility. The result is a “democratization” of gear milling, moving the process from single-purpose, dedicated machine tools to multipurpose machines that can produce small batches economically because no costly hobs or gashers are needed.
The new gear milling approach is based on using a multiaxis mill/turn machine. Sandvik Coromant Co. developed involute milling and it is being offered in collaboration with DMG / Mori Seiki USA Inc. Involute milling, or InvoMilling, is an alternative to the specialized hobbing process traditionally used to make gears. For gears with 25 to 30 teeth, InvoMilling’s cycle time is comparable to single-start hobbing with HSS tools. However, the possibility to integrate many operations in one setup and on one machine can reduce overall cycle times. Also, the wait time for a new gear hob can be weeks, while acquiring a new CNC InvoMilling code takes a matter of hours.
https://www.ctemag.com/news/articles/shifting-gears (Detailed article)
2013 - InvoMilling - Sandvik Video
______________
______________
Brochure on Invo-milling
https://www.sandvik.coromant.com/sitecollectiondocuments/downloads/global/brochures/en-gb/c-1140-547.pdf
2017
Cutting of one tooth with multiple tools - InvoMilling
______________
______________
Performance of Gears Manufactured by 5-Axis Milling
The article "Performance of Gears Manufactured by 5-Axis Milling" appeared in the March/April 2017 issue of Gear Technology.
https://www.geartechnology.com/articles/0317/Performance_of_Gears_Manufactured_by_5-Axis_Milling/
Research article: 2018 https://www.mdpi.com/2504-4494/2/3/44/pdf
2019
https://www.sandvik.coromant.com/en-us/news/press_releases/pages/power-skiving-solution-2-3-times-faster-than-gear-shaping.aspx
With the high-speed steel hob, you have to take the hob off and then reset. Today, we can index the hob right on the machine. So we can take an insert and all we have to do is change out the insert.
In an example of a gear wheel that was produced by an HSS hob, which is the usual way of doing it, the time taken was 32 minutes. With our new product line, we are down to four ... going from 32 minutes down to four minutes— a revolution.
Invo-milling process is a great technological event in the gear-milling industry ... And what it does is it gives you the opportunity of taking advantage of the machining technology, which is 5-axis machining and programming, and use standard tools and form a gear out of that combination. Where before you had a special tool on a special machine, now you have a standard tool on a standard machine with special software.
Customers have hands-on access to collaborative insights, training and technologies—including the new Hofler HF1000 gear-milling machine—when they visit the company's Schaumburg, Illinois productivity center.
Coromill® 170 - Rough gear milling with precision
9 Nov 2011
Sandvik Coromant
_______________
_______________
Coromill® 170 is a high performance cutter for machining of large gears in module range 12-22. It will reduce time in your gear machining, leaving minimal and even allowance for subsequent operations. Use it for precision and reliability in roughing of external and internal gears.
CoroMill® 176 - Cost efficient gear milling
9 Nov 2011
Sandvik Coromant
____________
____________
CoroMill® 176 is an innovative indexable insert cutter for productive gear wheel machining. It is a more cost-efficient alternative to regrindable HSS (high speed steel) tools. Its ability to reach higher cutting speeds combined with user-friendly insert changing will reduce cycle times and cost per component, making it the high productivity gear milling choice.
2013
Joining flexibility with high productivity when gear milling.
Imagine a gear milling method where the toolpath—not the tool shape—determines gear characteristics such as diametral pitch or pressure angle. A new concept, involute milling, provides that functionality while delivering machining efficiency and production versatility. The result is a “democratization” of gear milling, moving the process from single-purpose, dedicated machine tools to multipurpose machines that can produce small batches economically because no costly hobs or gashers are needed.
The new gear milling approach is based on using a multiaxis mill/turn machine. Sandvik Coromant Co. developed involute milling and it is being offered in collaboration with DMG / Mori Seiki USA Inc. Involute milling, or InvoMilling, is an alternative to the specialized hobbing process traditionally used to make gears. For gears with 25 to 30 teeth, InvoMilling’s cycle time is comparable to single-start hobbing with HSS tools. However, the possibility to integrate many operations in one setup and on one machine can reduce overall cycle times. Also, the wait time for a new gear hob can be weeks, while acquiring a new CNC InvoMilling code takes a matter of hours.
https://www.ctemag.com/news/articles/shifting-gears (Detailed article)
2013 - InvoMilling - Sandvik Video
______________
______________
Brochure on Invo-milling
https://www.sandvik.coromant.com/sitecollectiondocuments/downloads/global/brochures/en-gb/c-1140-547.pdf
2017
Cutting of one tooth with multiple tools - InvoMilling
______________
______________
Performance of Gears Manufactured by 5-Axis Milling
The article "Performance of Gears Manufactured by 5-Axis Milling" appeared in the March/April 2017 issue of Gear Technology.
https://www.geartechnology.com/articles/0317/Performance_of_Gears_Manufactured_by_5-Axis_Milling/
Research article: 2018 https://www.mdpi.com/2504-4494/2/3/44/pdf
Power Skiving
2019
https://www.sandvik.coromant.com/en-us/news/press_releases/pages/power-skiving-solution-2-3-times-faster-than-gear-shaping.aspx
Gear Grinding
Grinding Gears for EV Powertrains
https://gearsolutions.com/features/the-advantages-of-shifting-from-machining-to-grinding-gears-for-ev/
Contacting specialist manufacturers and finding whether they can offer items at lower cost is an important activity for industrial engineers.
https://www.minigears.co.uk/products/gears/
Gear Manufacturers
Contacting specialist manufacturers and finding whether they can offer items at lower cost is an important activity for industrial engineers.
https://www.minigears.co.uk/products/gears/
Updated 23.7.2022, 17 July 2022, 10 May 2021
First pub: 20 May 2020
No comments:
Post a Comment