Gear machining is an extremely complex process, only the use of the right technology to make efficient production is possible, each part of the production process must also be extremely accurate dimensions.
The gear machining cycle includes:
ordinary turning → gear hobbing → shaping → shaving → hard turning → gear-grinding machining → honing → drilling → bore grinding → welding → measurement
It is important to have the right clamping system for this process, and we will introduce the gear clamping system for each process.
1. Ordinary turning
In normal turning, the gear blank is usually clamped on a vertical or horizontal turning machine.
For automatic clamping fixtures, most of them do not require an additional stabilizer on the other side of the spindle.
2. Gear hobbing
Because of its outstanding economy, gear hobbing is a cutting process used for the production of external and cylindrical gears.
Gear hobbing is widely used not only in the automotive industry, but also in the manufacture of large industrial transmissions, but the premise is that it will not be restricted by the outer contour of the workpiece.
Shaping is a process of machining gears, which is mainly used in cases where hobbing is not possible.
This method is mainly used for internal gears and some external gears that are structurally disturbed.
Shaving is a finishing process for gears, where the cutting is performed with a cutter body corresponding to the tooth shape of the gear.
This process has been widely used in industry due to its high productivity and economy.
5. Hard turning
Hard turning makes it possible to replace expensive grinding processes.
In order to function properly, the various parts of the system are connected to the machining part accordingly.
The selection of the correct machine tool, fixture and cutting tools determines the effectiveness of the turning process.
6. Gear-grinding machining
In order to successfully achieve the precision required in gear production today, hard finishing of the tooth flanks is essential in many cases.
It is a very economical and efficient machining way in mass production.
On the other hand, similar to sample machining, grinding is more flexible when adjustable grinding tools are used.
Honing is the process of the final finishing of hard gears by applying an amorphous cutting angle.
Honing is not only economical but also results in a smooth surface with low noise level of the machined gears.
Honing has a low cutting speed (0,5 to 10 m/s) compared to grinding, eliminates the damage to gear machining caused by cutting heat.
More specifically, the internal stresses generated on the machined tooth surface have a positive effect on the load capacity of the equipment.
Examples of honing with flanged fixtures:
Drilling is a rotary cutting process.
The axis of the cutting tool and the center of the drilled hole is identical in the axial direction, and the feed direction is the same as that of the cutting tool in the axial direction.
The spindle of the cutting motion should be aligned with the cutting tool, which is independent of the feed motion direction.
Example of drilling with the SG clamping system:
9. Bore grinding
Bore grinding is a machining process with an amorphous cutting angle.
Compared to other cutting processes, grinding offers the advantages of high dimensional and forming accuracy, dimensional accuracy (IT 5-6), and high surface accuracy (Rz = 1-3μm) with very low chatter marks on hard metals.
Example of bore grinding with the film clamping SM system:
10. Capacitive discharge welding
Capacitive discharge welding is a resistance welding process.
Capacitive discharge welding is achieved by a rapid increase in current, a relatively short welding time and a high welding current.
Thus, capacitive discharge welding offers many advantages.
The economy and efficiency of capacitive discharge welding are particularly important because of increasing energy prices.
Example of capacitive discharge welding using a welding fixture system:
The testing of gears is very extensive and must be adjusted to the different forms of gears.
In the measurement of gears, the different important parameters of the gear are determined by measuring the length, the angles and the special gearing techniques.
Examples of measurements with flanged SP clamping systems:
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