Soft gears turned, hobbed and deburred in one

Gear hobbing centre combines turning, drilling, gear hobbing and deburring of soft gears - up to 240mm diameter - in one machine, so reducing unit costs and overall cycle times.
The VSC 400 Duo WF brings greater productivity to the turning, gear hobbing and deburring of soft gears with up to 240mm diameter. The gear hobbing center combines the different production processes and makes re-chucking between second side turning and gear hobbing and between gear hobbing and pressure deburring unnecessary. The result is absolute concentricity of tooth profile to bore, reduced idle times and lower unit production and servicing costs.

As a combination of two machines of similar design the VSC 400 Duo WF noticeably shortens the machining time of gears.

The manufacturing system combines the operations turning, milling, drilling, gear hobbing and pressure deburring and dispenses with intermediate stages such as re-chucking and interim storage.

The machine accommodates soft gears with up to 240mm diameter.

Dimensional accuracy is ascertained and registered before the next operation commences.

Deviations are fed back to the machine control and corrected.

The VSC 400 Duo WF design is based on that of thousands of successful machines of the VSC series that employ the pick-up principle to automatically load and unload themselves.

The advantages over conventional linked-up systems that employ individual machines for the various processes are: * Greater accuracy in contour and position.

* Tighter tolerances in the production of the tooth profile.

* Less rejects.

* An up to 40% smaller footprint.

* Lower capital outlay at production start-up, * Smaller payroll through integrated automation.

* Reduced servicing costs and a smaller investment in spare part stocks.

EMAG is presently the only company to offer such comprehensively combined gear cutting technologies.

* Trends in automotive transmission technology - there are three major types of automotive transmissions: manual transmission systems;hydraulic converter transmissions and double-clutch transmissions.

Many drivers like to be able to change between manual and automatic, which is why the double-clutch transmission is particularly popular.

What all modern transmissions have in common is that they perform better than ever before, whilst their size has remained the same or even reduced.

They transmit higher torques and work at an improved efficiency level.

Which is why higher demands are made on the combinations.

The preconditions for this are tighter tolerances and a better surface finish than previously achieved.

The tightening of tolerances in the process stream is particularly pronounced when it comes to gear hobbing operations.

Previous practises applied to the process stream Up to now, it has been standard practice in gear production to spread the process over a number of machines.

Re-chucking of the component brought about deviations in contour, dimensions and position as well as longer overall throughput times.

Additional processing requirements, such as pressure deburring, called for considerable extra investment.

Moreover, solutions involving machines from a number of different manufacturers created a considerably greater floor space requirement, frequently necessitated the multiple stockpiling of spare parts and, consequently, demanded the after-sales services of a variety of machine manufacturers.

The VSC DUO WF manufacturing system offers the whole process stream As a combined turning and gear hobbing center the VSC 400 DUO WF offers to soft complete-machine gears.

The integration of a number of individual technologies on a single machine effectively consolidates the process stream.

Moreover, the machine design is based on that of the VSC series, which has been successfully applied in the field over five thousand times.

The worldwide service network of the EMAG Group offers the highest possible degree of machine availability.

The capital outlay for machines at the start-up of transmission production is clear for all to see.

It allows the user to cover production increases with a tighter outlay curve.

The accuracy of the workpieces is checked with measurements taken in the machine.

This is yet another point that shows the difference between this system and the prevalent methods of post-process or manual gauging.

So called 'adaptive' measuring strategies - i e, measured value feedback, the processing and feedback to the machine control of read-off values - ensure that reject rates are kept low.