High-speed finish grinding of hardened gears is performed in a CNC threaded wheel grinding machine using dressable, vitrified-bonded grinding worms as tools.
The 245TWG with a vertical workpiece axis, provides everything required to meet the stringent quality demands placed on productivity and economy. Dressable, vitrified-bonded grinding worms are used as tools. The optimised ratio of the dimensions of the grinding wheel, with a width of 180mm and a maximum diameter of 220mm, permits long tool life and short non-productive times.
A maximum spindle speed of 6,000 rev/min allows the maximum cutting speed of 63m/s for vitrified-bonded wheels to be exploited to the fullest.
To dress these worms, we supply two systems customized to your application.
To achieve short, thread number-independent dressing times, dressing with a diamond-plated dressing gear and roller is optimal for larger production volumes.
In addition, this machine is equipped with a fully-automatic dressing unit (Gleason dresser) with conventional CNC dressing technique to meet high requirements with regard to quality and flexibility.
The machine can be loaded by a fast, solid two-station ring loader.
Standard part storage automation is a pallet ring conveyor, a spin-clean station can be integrated.
The 245TWG is available with the latest Siemens CNC control as standard.
The technology software running on the machine, together with the optimised ergonomics of the user interface for simple data input, support the operator by automatically calculating machine setting and machining data.
The integrated graphics and comprehensive plausibility checks ensure a safe and simple to learn operation of the machine.
Capacities: * Nominal workpiece diameter - 245 (300) mm.
* Nominal module range - 0.5-4 (5) mm.
* Maximum grinding stroke - 400 mm.
Grinding and hobbing done in one machine
Universal CNC gear grinding machine uses high speed, direct drive spindles for different grinding methods such as profile or generating using a worm-type wheel.
Utilising high-speed direct drive spindles for the work head and work spindle the P 90 G provides a universal base for multiple grinding processes. Specific software packages are available for different grinding methods such as profile grinding or generating grinding with a worm type wheel. All processes are based on the use of non-dressable CBN plated grinding wheels.
The diameter of the grinding wheels can be as small as the diameter of the hob used for pre-hobbing, resulting in fast cycle times.
The P 90 G has been designed for exceptional ease of use, reliability and maintainability in even the harshest environments.
It is designed to conserve on precious floor space, and its 3.5m2 footprint is one of the smallest in its class.
The new P 90 G can be equipped with a fast, fully integrated gantry loader system, with buffer storage.
The automation is easily adaptable to different part types, offering the potential for significant improvements in cycle times.
The use of the latest Siemens CNC controller with its Windows-based software interface, and menu-assisted programming make the P 90 G particularly user friendly.
The unique configuration and orientation of its CNC axes create a highly ergonomic work area, and machine components are readily accessible for easy maintenance and servicing.
At the EMO 2005 show, a gear was roughed using the threaded wheel grinding method and then finished using the profile grinding method in one clamping.
Capacities: * Nominal workpiece diameter - 100mm.
* Nominal module - 3mm.
* Maximum axial travel - 320mm.
Utilising high-speed direct drive spindles for the work head and work spindle the P 90 G provides a universal base for multiple grinding processes. Specific software packages are available for different grinding methods such as profile grinding or generating grinding with a worm type wheel. All processes are based on the use of non-dressable CBN plated grinding wheels.
The diameter of the grinding wheels can be as small as the diameter of the hob used for pre-hobbing, resulting in fast cycle times.
The P 90 G has been designed for exceptional ease of use, reliability and maintainability in even the harshest environments.
It is designed to conserve on precious floor space, and its 3.5m2 footprint is one of the smallest in its class.
The new P 90 G can be equipped with a fast, fully integrated gantry loader system, with buffer storage.
The automation is easily adaptable to different part types, offering the potential for significant improvements in cycle times.
The use of the latest Siemens CNC controller with its Windows-based software interface, and menu-assisted programming make the P 90 G particularly user friendly.
The unique configuration and orientation of its CNC axes create a highly ergonomic work area, and machine components are readily accessible for easy maintenance and servicing.
At the EMO 2005 show, a gear was roughed using the threaded wheel grinding method and then finished using the profile grinding method in one clamping.
Capacities: * Nominal workpiece diameter - 100mm.
* Nominal module - 3mm.
* Maximum axial travel - 320mm.
CNC bevel gear cutter has small footprint
CNC bevel gear cutting machine has a design that permits the shortest possible structural overhang of both cutter and work for maximum stiffness and thermal stability.
Gleasons new CNC Bevel Gear Cutting Machine Phoenix II 600HC features the unique monolithic column design. It is particularly well-suited for dry machining, but can accommodate wet cutting processes. Based on the highly successful Gleason Phoenix II 275HC, but designed for workpiece diameters as large as 600mm, the concept of the new 600HC occupies 35% less floor space than comparable models in its class.
The cutter spindle and work spindle are mounted directly to the column, and the cutter spindle pivots to create the root angle, rather than mounting the work spindle on a rotating base.
This permits the shortest possible structural overhang of both cutter and work for maximum stiffness and thermal stability.
The 600HC also features direct-drive spindle motors, which further reduces set-up and machining times by eliminating the need for mechanical adjustments and change gears.
Higher acceleration/deceleration rates and increased torque, combined with shorter, faster axis motions reduce non-cutting time between cycles and increase overall productivity during machining.
The 600HC is available with latest Fanuc CNC controls, and can be furnished with Gleason Machine Manager software to simplify set-up and operation in a Windows environment.
Capacities: * Extreme ratio - 10:1.
* Maximum full depth - 21.5mm.
* Maximum face width - 110 mm.
* Maximum workpiece diameter - 500-600mm.
* Minimum/maximum cutter size - 76/210mm.
Gleasons new CNC Bevel Gear Cutting Machine Phoenix II 600HC features the unique monolithic column design. It is particularly well-suited for dry machining, but can accommodate wet cutting processes. Based on the highly successful Gleason Phoenix II 275HC, but designed for workpiece diameters as large as 600mm, the concept of the new 600HC occupies 35% less floor space than comparable models in its class.
The cutter spindle and work spindle are mounted directly to the column, and the cutter spindle pivots to create the root angle, rather than mounting the work spindle on a rotating base.
This permits the shortest possible structural overhang of both cutter and work for maximum stiffness and thermal stability.
The 600HC also features direct-drive spindle motors, which further reduces set-up and machining times by eliminating the need for mechanical adjustments and change gears.
Higher acceleration/deceleration rates and increased torque, combined with shorter, faster axis motions reduce non-cutting time between cycles and increase overall productivity during machining.
The 600HC is available with latest Fanuc CNC controls, and can be furnished with Gleason Machine Manager software to simplify set-up and operation in a Windows environment.
Capacities: * Extreme ratio - 10:1.
* Maximum full depth - 21.5mm.
* Maximum face width - 110 mm.
* Maximum workpiece diameter - 500-600mm.
* Minimum/maximum cutter size - 76/210mm.
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.
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.
Raise quality and reduce transmission part costs
Power honing system hones hardened gears of between 20 and 160mm diameter and uses the in-process feedback of measured values to maintain tolerances and records the results.
The VSC 400 PH Manufacturing System - PH stands for Power Honing - hones hardened gears of between 20 and 160mm diameter, uses the in-process feedback of measured values to maintain tolerances and records the results. The EMAG pick-up system - tried and tested on more than 5,000 machines in the field - loads and unloads the components. The result: shorter throughput times, and a reduction in unit production costs.
As the design is based on that of the well-established VSC series, the VSC 400 PH is also a vertical machine that loads and unloads itself with the help of its pick-up system.
This allows for the integration of the VSC 400 PH into production lines and its optimal combination with upstream processes.
The advantages of the new machine: * Tighter manufacturing tolerances on gear profiles.
* Less rejects.
* Up to 40% smaller footprint.
* Lower labour costs through integrated automation.
* A reduction in the cost of spare-part stockholdings and service calls.
EMAG is the only supplier of manufacturing systems for the whole range of metal-cutting processes employed in the production of gears - from raw-part to honed, ready-to-install component.
The VSC 250/400 DUO WF (see Press Release 3/2005) turns and gear hobs the raw-parts.
The VSC 250/400 DS hard turns the hardened gears and grinds the bore (and cone).
The VSC 400 PH subsequently hard precision-machines the tooth profile.
* Trends in automotive transmission technology - all modern transmissions have one thing in common.
The power transfer capacity they offer is greater than ever before, while the spatial limits it is subjected to remain the same or have become even tighter.
They transfer higher torques and work on an improved efficiency level.
It is the reason why much greater demands are made on the pairing.
A precondition for this is tighter manufacturing tolerances than hitherto customary.
How gearwheels have been hard precision-machined up to now - up to now, it has been standard procedure to spread the precisionmachining process of hardened gearwheels over a number of machines.
This made it inevitable that the frequent re-chucking should lead to deviations in contour, dimension and position of the workpiece and also result in comparatively long throughput times.
In addition, solutions involving machines from different manufacturers mean considerably larger floor space requirements, as well as multiple spare part stockholdings and, consequently, correspondingly higher costs for the services that are being provided by the various suppliers.
* Process stream with the VSC 400 PH Manufacturing System - as a honing center the VSC 400 PH delivers finish-machined, ready-to-install gears with a first-rate surface finish.
The dimensional accuracy of the workpieces is ascertained through in-process gauging.
This is yet another advantage the new system has over the widely used post-process gauging technique or the manual check.
Adaptive measuring strategies, i e, measured value feedback - the processing and feedback of measured values to the machine control - ensure lower reject rates.
As the VSC 400 PH is based on the VSC series of machines - of which more than 5,000 are well-established in the field - and its individual elements are therefore similar to, for instance, those of the VSC 250/400 DUO WF Gear Hobbing Center - the headstocks for turning, gear hobbing, internal grinding and power honing are of the same construction, as they are part of the same modular design - maintenance costs are much reduced.
The worldwide service network of the EMAG Group offers a high degree of machine availability.
The VSC 400 PH Manufacturing System - PH stands for Power Honing - hones hardened gears of between 20 and 160mm diameter, uses the in-process feedback of measured values to maintain tolerances and records the results. The EMAG pick-up system - tried and tested on more than 5,000 machines in the field - loads and unloads the components. The result: shorter throughput times, and a reduction in unit production costs.
As the design is based on that of the well-established VSC series, the VSC 400 PH is also a vertical machine that loads and unloads itself with the help of its pick-up system.
This allows for the integration of the VSC 400 PH into production lines and its optimal combination with upstream processes.
The advantages of the new machine: * Tighter manufacturing tolerances on gear profiles.
* Less rejects.
* Up to 40% smaller footprint.
* Lower labour costs through integrated automation.
* A reduction in the cost of spare-part stockholdings and service calls.
EMAG is the only supplier of manufacturing systems for the whole range of metal-cutting processes employed in the production of gears - from raw-part to honed, ready-to-install component.
The VSC 250/400 DUO WF (see Press Release 3/2005) turns and gear hobs the raw-parts.
The VSC 250/400 DS hard turns the hardened gears and grinds the bore (and cone).
The VSC 400 PH subsequently hard precision-machines the tooth profile.
* Trends in automotive transmission technology - all modern transmissions have one thing in common.
The power transfer capacity they offer is greater than ever before, while the spatial limits it is subjected to remain the same or have become even tighter.
They transfer higher torques and work on an improved efficiency level.
It is the reason why much greater demands are made on the pairing.
A precondition for this is tighter manufacturing tolerances than hitherto customary.
How gearwheels have been hard precision-machined up to now - up to now, it has been standard procedure to spread the precisionmachining process of hardened gearwheels over a number of machines.
This made it inevitable that the frequent re-chucking should lead to deviations in contour, dimension and position of the workpiece and also result in comparatively long throughput times.
In addition, solutions involving machines from different manufacturers mean considerably larger floor space requirements, as well as multiple spare part stockholdings and, consequently, correspondingly higher costs for the services that are being provided by the various suppliers.
* Process stream with the VSC 400 PH Manufacturing System - as a honing center the VSC 400 PH delivers finish-machined, ready-to-install gears with a first-rate surface finish.
The dimensional accuracy of the workpieces is ascertained through in-process gauging.
This is yet another advantage the new system has over the widely used post-process gauging technique or the manual check.
Adaptive measuring strategies, i e, measured value feedback - the processing and feedback of measured values to the machine control - ensure lower reject rates.
As the VSC 400 PH is based on the VSC series of machines - of which more than 5,000 are well-established in the field - and its individual elements are therefore similar to, for instance, those of the VSC 250/400 DUO WF Gear Hobbing Center - the headstocks for turning, gear hobbing, internal grinding and power honing are of the same construction, as they are part of the same modular design - maintenance costs are much reduced.
The worldwide service network of the EMAG Group offers a high degree of machine availability.
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