A new, CNC- based, re-engineering package from Holroyd is enabling existing users of the company's range of mechanical gear hobbing machines to update them and benefit from DIN 5 levels of accuracy in the production of worm wheels and sets, at a cost up to 60% less than that of an equivalent new machine. Holroyd has a long and successful history of producing gear hobbing machines - and of exporting them to all parts of the world. The company manufactured its machines for about 25 years until the late 1970's when the market became saturated and the requirement for new machine stock had started to decline.
At that time the machines produced by Holroyd were mechanically superb.
They were constructed using all cast components and manufactured to a degree of accuracy that compares favourably with the most accurate machines on the market today.
'The highly stable cast base and structure that we routinely provided on our range of gear hobbing machines provides the ideal platform for updating the machines to achieve the highest levels of accuracy at a fraction of the cost of buying new,' says Holroyd Director, Steve Whitehead.
'We have already proved both the effectiveness of the conversion - and the cost savings - by updating one of our own production machines in our own factory.
Previously the machine was referred to as Class B precision, producing product to DIN 7 levels of accuracy.
Following re-engineering, the hobber is now a class A machine, producing to DIN 5 accuracy, a figure that enables the machine to satisfy over 80% of the market for worm wheels.
With most retrofit packages, improved accuracy on its own would more than justify the equipment outlay.
We have gone a step further, however, realising major improvements in set-up times, down from 2 hours to 20mins on the re-engineered hobbing machines.' Holroyd's original production of gear hobbers ran to five sizes of machines with table dimensions of 12in, 24in, 48in, 60in and 72in.
All of these machines were designed using the mechanical, 'multiple differential principle', whereby a single motor drive gives all motion differentials which are coupled mechanically.
In the new re-engineering package this motion is now controlled electronically by a Fanuc 16i CNC machine controller, working in conjunction with four brushless servomotors.
The Fanuc controller was chosen because it offers users the time saving advantages of plain language shopfloor programming.
As an example of this, program features are laid out in simple table formats that allow parameters for the finished worm gear to entered simply and quickly.
Set-up times are much reduced, as a result, leading to real gains in productivity.
The Fanuc CNC co-ordinates the motion of the four machine axes: Hob Spindle, Table Drive, Cross Feed and Infeed, via servomotors equipped with high-resolution encoders; the unit on the Hob spindle being used a reference to synchronise all the remaining axes.
The operation of these servomotors is optimised by the replacement, on the machine's linear axes, of the original plain screws by precision ground ballscrews.
Further mechanical improvement is also realised by the use of precision ballscrew end bearings, which have been adapted to mount worm shafts.
The use of these modified bearings prevents axial 'end wind', or a figure of eight movement encountered as the worm shaft is driven under load.
The complete process of stripping the original Holroyd machine down to its basic structure and then re-engineering with the new CNC package takes on average 26 weeks - saving around 3 months on delivery compared to buying new, and costs approximately GBP 300,000.
'This represents excellent value for money, generally, and especially so when compared to purchasing a new machine,' says Steve Whitehead.
'The buyer who chooses the latter route could be paying anywhere between GBP 500,000 to GBP 750,000 to achieve equivalent levels of quality, and be waiting around 9 months for delivery into the bargain.' At the present time the re-engineering package is available only on the five sizes of hobbing machine produced by Holroyd.
However, the company is prepared to quote for performing similar work on other companies' machines.
Up-to-date system guards CNC gear hobber
Bespoke guarding system combines maximum operator flexibility with highest safeguarding protection on a rebuilt hobbing machine.
Nelsa have designed and manufactured a bespoke guarding system that provides ultimate ease of use and maximum safeguarding on a precision hobbing machine recently rebuilt by precision engineers Holroyd. The Nelsa guarding system is part of a re-engineering package that Holroyd has applied to update the mechanical hobbing machine. CNC based, the package enables DIN 5 levels of precision to be achieved at a cost up to 60% less than that of an equivalent new machine.
Holroyd, based in Rochdale, is a world leader in the design and manufacture of specialist milling and grinding machines for helical components.
The company also has a long and successful history of producing mechanical gear hobbing machines The company manufactured them for approximately 25 years, up until the late 1970's.
At that time the hobbers produced were mechanically superb, they were constructed using all cast components and were manufactured to a degree of accuracy that compares favourably with the most accurate machines currently on the market.
Today, the highly stable cast base and structure that was routinely provided on the mechanical hobbers provides the ideal platform for updating the machines to achieve the highest levels of accuracy at a fraction of the cost of buying new.
Holroyd is exploiting this potential with a re-engineering package that includes servomotors, ball screws and CNC.
Also included, as part of the package is a specially designed machine guarding system from Nelsa, part of EJA.
Nelsa designed the bespoke system, following in-depth discussions both with senior development engineers on the project and also with the machine operators.
As a result, it is easy to use, ensuring minimal disruption to the operator while, at the same time, providing maximum safeguarding against entrapment by moving cutters, chippings, swarf and even coolant.
The guarding system is also interlocked to inhibit machine operation when the operator is setting up or needs to enter the hazardous machining area for any reason.
The increasing complexity and automation of machines means that Nelsa is always being called upon to provide bespoke guarding arrangements which, like the Holroyd system, provide maximum operator protection, without, at the same time, hindering the production process.
These features are essential because experience shows that they are the best possible way to guarantee that when a guard is fitted, it stays fitted.
As evidence of this, the removal of awkward safety guards has been shown to be one of the most common pre-conditions for an industrial accident.
Nelsa have designed and manufactured a bespoke guarding system that provides ultimate ease of use and maximum safeguarding on a precision hobbing machine recently rebuilt by precision engineers Holroyd. The Nelsa guarding system is part of a re-engineering package that Holroyd has applied to update the mechanical hobbing machine. CNC based, the package enables DIN 5 levels of precision to be achieved at a cost up to 60% less than that of an equivalent new machine.
Holroyd, based in Rochdale, is a world leader in the design and manufacture of specialist milling and grinding machines for helical components.
The company also has a long and successful history of producing mechanical gear hobbing machines The company manufactured them for approximately 25 years, up until the late 1970's.
At that time the hobbers produced were mechanically superb, they were constructed using all cast components and were manufactured to a degree of accuracy that compares favourably with the most accurate machines currently on the market.
Today, the highly stable cast base and structure that was routinely provided on the mechanical hobbers provides the ideal platform for updating the machines to achieve the highest levels of accuracy at a fraction of the cost of buying new.
Holroyd is exploiting this potential with a re-engineering package that includes servomotors, ball screws and CNC.
Also included, as part of the package is a specially designed machine guarding system from Nelsa, part of EJA.
Nelsa designed the bespoke system, following in-depth discussions both with senior development engineers on the project and also with the machine operators.
As a result, it is easy to use, ensuring minimal disruption to the operator while, at the same time, providing maximum safeguarding against entrapment by moving cutters, chippings, swarf and even coolant.
The guarding system is also interlocked to inhibit machine operation when the operator is setting up or needs to enter the hazardous machining area for any reason.
The increasing complexity and automation of machines means that Nelsa is always being called upon to provide bespoke guarding arrangements which, like the Holroyd system, provide maximum operator protection, without, at the same time, hindering the production process.
These features are essential because experience shows that they are the best possible way to guarantee that when a guard is fitted, it stays fitted.
As evidence of this, the removal of awkward safety guards has been shown to be one of the most common pre-conditions for an industrial accident.
Gear grinder is easier to set up
Gear grinding machine is equipped with a mobile operator panel that makes machine set-up easier and includes dialogue software based on MS Windows operating systems for dressing cycles.
The new S 250 G gear grinding machine completes the Samputensili range of gear grinding machines for economical mass production. Particular attention has been paid to the choice of components used on this machine which have all been thoroughly tried and tested on Samputensili hobbing machines, grinding machines and in automation systems, guaranteeing high performance and reliable results. The cast iron machine bed ensures excellent vibration damping even when large amounts of stock are removed and it was in fact designed for our new S 150 - S 400 series of hobbing machines.
This rigid structure enhances the performance of the direct-drive motors both of which power the tool spindle (rotation speed of 0 - 10.000 rpm) and the workpiece table (rotation speed 0 - 1000 rpm).
The grinding wheel head has been thoroughly tested on the Samputensili S 400 GT grinding machine and is well-managed thanks to the safe tool clamping system.
The tool work area is spaciously designed and the cooling liquid release system is PLC-controlled so that the jet of oil is aimed directly at the tool and workpiece contact zone.
This system also keeps the whole work area much cleaner.
The radial, axial and tangential movements of the axes are performed with the aid of backlash-free, pre-loaded re-circulating ball screws together with a synchronous servo-motor on roller guide ways.
Ceramic worm wheels can be dressed by the diamond dressing roller.
The fully automated system loads and unloads the dressing tool depositing it and collecting it from a specific on-machine tool storage area.
CBN grinding wheels should be used as form wheels.
In terms of automation, the machine is equipped with a fast, innovative, 3-axes CN telescopic loader.
It moves along the longitudinal axis and passes through the machine counter-column so that the loader is always outside the work area during the actual grinding phase.
The control system is the Siemens 840 D with linear and circular interpolation of up to 5 axes and high-performance geometric programming for easy profile and helix generation and relative congruity testing.
The machine is also equipped with a mobile operator panel which makes machine set-up easier as well as dialogue software based on MS Windows operating systems to facilitate the management of data, grinding and dressing cycles and data storage without the need for an external PC.
Other notable safety features of this machine are the interpolated tool withdrawal system in the event of power failure or emergencies which prevents tools from being damaged and the automatic fire extinguishing system which combats the risk of damage to the machine and its surroundings in the event of fire.
The new S 250 G gear grinding machine completes the Samputensili range of gear grinding machines for economical mass production. Particular attention has been paid to the choice of components used on this machine which have all been thoroughly tried and tested on Samputensili hobbing machines, grinding machines and in automation systems, guaranteeing high performance and reliable results. The cast iron machine bed ensures excellent vibration damping even when large amounts of stock are removed and it was in fact designed for our new S 150 - S 400 series of hobbing machines.
This rigid structure enhances the performance of the direct-drive motors both of which power the tool spindle (rotation speed of 0 - 10.000 rpm) and the workpiece table (rotation speed 0 - 1000 rpm).
The grinding wheel head has been thoroughly tested on the Samputensili S 400 GT grinding machine and is well-managed thanks to the safe tool clamping system.
The tool work area is spaciously designed and the cooling liquid release system is PLC-controlled so that the jet of oil is aimed directly at the tool and workpiece contact zone.
This system also keeps the whole work area much cleaner.
The radial, axial and tangential movements of the axes are performed with the aid of backlash-free, pre-loaded re-circulating ball screws together with a synchronous servo-motor on roller guide ways.
Ceramic worm wheels can be dressed by the diamond dressing roller.
The fully automated system loads and unloads the dressing tool depositing it and collecting it from a specific on-machine tool storage area.
CBN grinding wheels should be used as form wheels.
In terms of automation, the machine is equipped with a fast, innovative, 3-axes CN telescopic loader.
It moves along the longitudinal axis and passes through the machine counter-column so that the loader is always outside the work area during the actual grinding phase.
The control system is the Siemens 840 D with linear and circular interpolation of up to 5 axes and high-performance geometric programming for easy profile and helix generation and relative congruity testing.
The machine is also equipped with a mobile operator panel which makes machine set-up easier as well as dialogue software based on MS Windows operating systems to facilitate the management of data, grinding and dressing cycles and data storage without the need for an external PC.
Other notable safety features of this machine are the interpolated tool withdrawal system in the event of power failure or emergencies which prevents tools from being damaged and the automatic fire extinguishing system which combats the risk of damage to the machine and its surroundings in the event of fire.
Range of hobs suits SME batch gear production
Delivery ranges of hobs for small to medium batch production have been especially studied to meet the needs of small to medium sized batch and prototype gear manufacturers.
Samputensili X2 and X4 delivery ranges of hobs have been especially studied to meet the needs of small to medium sized batch and prototype gear manufacturers. Samputensili comprehends the present day need for increasingly rapid delivery of your purchase orders and thanks to our modern and sophisticated manufacturing cells, we now pre-machine hob blanks and finish them to your specifications, including coating, in just two weeks. All manufacturing phases of standard hob production are carried out in house so we are not reliant on sub suppliers.
Time is money and reducing your delivery time reduces your manufacturing costs.
Try out the advantages of this range yourselves and fill out one of our order forms.
You will be amazed by the speed with which your finished tools arrive.
Samputensili X2 and X4 delivery ranges of hobs have been especially studied to meet the needs of small to medium sized batch and prototype gear manufacturers. Samputensili comprehends the present day need for increasingly rapid delivery of your purchase orders and thanks to our modern and sophisticated manufacturing cells, we now pre-machine hob blanks and finish them to your specifications, including coating, in just two weeks. All manufacturing phases of standard hob production are carried out in house so we are not reliant on sub suppliers.
Time is money and reducing your delivery time reduces your manufacturing costs.
Try out the advantages of this range yourselves and fill out one of our order forms.
You will be amazed by the speed with which your finished tools arrive.
Consortium investigates face gear grinding
An Estonian-led consortium with partners from Italy and the Czech Republic is performing research into the development af a cost-effective technology for face gear grinding.
A consortium led by Feanor, including partners from Italy and the Czech Republic is performing a research for the development af a cost-effective technology for face gear grinding. Face gears have been known and studied for many years, but since they were used for low power and low speed, the requirement for a constant speed ratio was not very important. With the advent of high power and speed requirements, face gears have been driven out by conventional bevel gears, which are easier to be manufactured.
Face gears have important applications in helicopter transmission systems.
They proved to be effective also with insufficient lubrication, thus increasing the reliability of the aircraft, and they work also with bad alignment between pinion and the rotor gear.
Helicopters using transmission systems based on face gears have a higher safety and survivability.
The target of the Facegear project is to study a cost-effective method for the manufacturing of face gears, thus increasing their application in the helicopter industry.
Face gears have some other natural advantages, compared to bevel gears, such as: 1.
the pinion is a normal spur gear which axial position has no influence on the meshing zone provided its face is adequate (see point 2 of the proposal summary).
2.
assembly time is reduced because only the axial position of the face gears needs to be set.
3.
Lapping is not necessary because all gears irrespective of their tooth numbers or shaft angles may be interchangeably meshed with the common pinion upon which the particular generating hob geometry is based.
4.
There is no axial load on a pinion with straight spur teeth.
5.
The meshing is smoother due to oblique contact lines and high contact ratio.
6.
Face gears provide high transmission ratios in one stage.
7.
Cost effective manufacture on conventional CNC gear hobbing machines straddle mounted pinions, provided that the calculation is correct.
8.
Zero backlash transmission for positioning or measuring machines can be easily obtained.
9.
Face gears have high strength teeth and good contact geometry, which give high torque capability.
Objectives of the proposed EU project are a calculation software for face gear geometry, a cost-effective gear cutting technology for face gears and a measuring system for the geometry of face gears.
A consortium led by Feanor, including partners from Italy and the Czech Republic is performing a research for the development af a cost-effective technology for face gear grinding. Face gears have been known and studied for many years, but since they were used for low power and low speed, the requirement for a constant speed ratio was not very important. With the advent of high power and speed requirements, face gears have been driven out by conventional bevel gears, which are easier to be manufactured.
Face gears have important applications in helicopter transmission systems.
They proved to be effective also with insufficient lubrication, thus increasing the reliability of the aircraft, and they work also with bad alignment between pinion and the rotor gear.
Helicopters using transmission systems based on face gears have a higher safety and survivability.
The target of the Facegear project is to study a cost-effective method for the manufacturing of face gears, thus increasing their application in the helicopter industry.
Face gears have some other natural advantages, compared to bevel gears, such as: 1.
the pinion is a normal spur gear which axial position has no influence on the meshing zone provided its face is adequate (see point 2 of the proposal summary).
2.
assembly time is reduced because only the axial position of the face gears needs to be set.
3.
Lapping is not necessary because all gears irrespective of their tooth numbers or shaft angles may be interchangeably meshed with the common pinion upon which the particular generating hob geometry is based.
4.
There is no axial load on a pinion with straight spur teeth.
5.
The meshing is smoother due to oblique contact lines and high contact ratio.
6.
Face gears provide high transmission ratios in one stage.
7.
Cost effective manufacture on conventional CNC gear hobbing machines straddle mounted pinions, provided that the calculation is correct.
8.
Zero backlash transmission for positioning or measuring machines can be easily obtained.
9.
Face gears have high strength teeth and good contact geometry, which give high torque capability.
Objectives of the proposed EU project are a calculation software for face gear geometry, a cost-effective gear cutting technology for face gears and a measuring system for the geometry of face gears.
Low cost centre grinds gears to better than DIN 2
Although easy to set and operate, a grinding centre uses a novel machining system to achieve better than DIN 2 accuracy for the form grinding of high precision helical, spur and worm gears.
Holroyd's new Smart GTG2 grinding centre employs a unique (patent applied for) machining system to achieve DIN 2 levels of accuracy - and beyond - in the form grinding of high precision helical, spur and worm gears. Designed with high levels of onboard intelligence, the GTG2 is extremely easy to set-up and operate. It also benefits users with onboard CMM and an automatic, in cycle wheel dressing feature that enables closed loop profile control to be achieved.
'Our design aim was to produce the lowest cost, highest accuracy grinding machine for helical and worm gears in the world, and I am sure that we have succeeded,' says Dr Tony Bannan, Holroyd's Engineering Director, who led the design and manufacturing team that produced the machine.
'Although the GTG2 is designed to provide DIN 2 levels of accuracy, generally, it has exceeded this level under optimum operating conditions, producing its 'best ground' performance with a tooth profile of DIN 1, considered by many to be pinnacle of grinding performance.' The GTG2 is an extremely versatile gear grinding centre, developed for one-off or batch production of high precision helical, spur and worm gears in sizes up to 350mm diameter and 160mm gear face width.
The machine's exceptional performance is the result of a design synergy that combines a 'patent- pending' machining method, with high levels of machine intelligence and onboard features such as automatic co-ordinate adjustment, in-cycle wheel dressing, integrated profile management and CMM.
Holroyd's patent-pending machining method has been developed to compensate for helical twist, an unwelcome condition that occurs when helical gears are 'lead crowned' to improve meshing and reduce noise and wear.
Lead crowning varies the amount of material removed from the flank of a tooth across the face width, by causing the tool motion to deviate from a true helix.
However, in form grinding this has the undesirable effect of causing the profile of the tooth flank to vary across the face.
In many applications this 'error' is not of concern, but in high precision and low noise applications it affects gear wheel performance by concentrating loads on particular areas of the teeth during meshing.
Correction of this problem is achieved on the CNC controlled GTG2 machine by calculating additional motions of the grinding wheel and by then controlling them during the grinding operation using bespoke software written by Holroyd engineers.
In the machining process, the workpiece is rotated about its axis and translated parallel to its axis relative to the tool, and the tool is also moved so as to vary continuously the angle of inclination of its axis relative to the axis of the workpiece.
In this way the generating errors (i.e the deviation of the groove surfaces actually produced from those desired and specified) are reduced along each line of instantaneous contact between the tool envelope and the groove surface being machined.
The resultant benefits are better tooth contact during meshing and improvements in torque transfer efficiency.
Although it performs a highly complex operation, the technology that underpins Holroyd's new machining method is not unwieldy for the user.
Neither does it mean that the machine is difficult to program and use.
On the contrary: the GTG2 is referred to as a 'Smart' machine because of its high levels of onboard intelligence, which make it easy to set-up and operate.
The machine is equipped with Holroyd's own HTG8, 8 axis CNC with facilities such as an Advanced Touch Screen Interface and Integrated Profile Management System.
The touch screen interface enables an operator to take a typical design drawing and enter the specification directly into the machine; leaving high levels of inbuilt intelligence do the rest.
What this means in practical terms is that the machine, by integrating facilities such as automatic co-ordinate adjustment, in-cycle wheel dressing, profile management and automatic programmable cycles, replaces the variable of operator skill in precision machine set-ups and operations with machine intelligence.
By distilling operator knowledge and experience into the GTG2's CNC controller, the machine is able to take data from its (optional) on-board probing system and predict the minute alterations to the profile of the grinding wheel required to achieve any desired profile and make these alterations 'on the fly'.
An example highlighting the proficiency of this system is a workpiece that does not meet tolerance requirements after a first grinding pass.
Following on-machine measurement, the GTG2 calculates the necessary adjustments to grinding wheel form or axis position and then passes the data to a 2-axis CNC wheel dressing system to achieve on machine dressing of the grinding wheel.
All of these operations are achieved automatically and rarely does the machine need to make further corrections after the first pass.
Holroyd's integration of the in-cycle wheel dressing system into the GTG2 is not a one off, rather it is part of an overall design strategy that takes a number of functions crucial to precise and effective gear grinding and integrates them into the machine as Automatic Programmable Cycles.
The GTG2 offers users eight of these cycles to simplify and improve gear production.
In addition to automatic wheel dressing they include: * Gear Tooth Grinding, with Optional Probing and Form Measurement.
* Repeat Cycles with Nesting up to 99 Times.
* Fillet Radius or Trochoid Root Form.
* Gear Crowning Cycle for Modified Tooth Forms.
* Lead Crowning by Bob Crowning, or by Adjusting the Lead or Combination of Both.
* Programmable Constant Peripheral Grinding Wheel Speed, Based on Actual Wheel Diameter.
* Optional Programmable Component Taper Correction.
Optimising the performance of the GTG2 in all of its bespoke and automatic operating cycles is a highly effective measurement system, provided by an inbuilt CMM.
This is designed, manufactured and calibrated to the same specifications and tolerances as standalone CMM, and also uses the same high level 3D scanning probes.
The CMM function is used at the start of each scan cycle to provide a validated reference point for commencement of the grinding operation.
Importantly, the probing operation, which is integral to this process, takes place without any machining forces and is therefore dynamically and kinematically stable.
In addition, as the workpiece is held in the same fixture used for machining, there is no requirement for off- machine measurement, and no consequent loss of position for corrective rework.
As a result the measuring process, overall, is that much more accurate and reliable.
* GTG2 Technology recognised for Queens's Award for Innovation - even before its major market launch, the technology that underpins the GTG2 grinding centre has been recognised by the prestigious Queen's Award For Innovation 2004.
'This award is an early recognition and a validation of all that we were trying to achieve with our design,' said Bannan.
'We have produced a highly cost competitive machine with grinding technology that literally leads the world, demonstrating our continuing ability to produce winners in the increasingly competitive global market for high precision machine tools.
Holroyd's new Smart GTG2 grinding centre employs a unique (patent applied for) machining system to achieve DIN 2 levels of accuracy - and beyond - in the form grinding of high precision helical, spur and worm gears. Designed with high levels of onboard intelligence, the GTG2 is extremely easy to set-up and operate. It also benefits users with onboard CMM and an automatic, in cycle wheel dressing feature that enables closed loop profile control to be achieved.
'Our design aim was to produce the lowest cost, highest accuracy grinding machine for helical and worm gears in the world, and I am sure that we have succeeded,' says Dr Tony Bannan, Holroyd's Engineering Director, who led the design and manufacturing team that produced the machine.
'Although the GTG2 is designed to provide DIN 2 levels of accuracy, generally, it has exceeded this level under optimum operating conditions, producing its 'best ground' performance with a tooth profile of DIN 1, considered by many to be pinnacle of grinding performance.' The GTG2 is an extremely versatile gear grinding centre, developed for one-off or batch production of high precision helical, spur and worm gears in sizes up to 350mm diameter and 160mm gear face width.
The machine's exceptional performance is the result of a design synergy that combines a 'patent- pending' machining method, with high levels of machine intelligence and onboard features such as automatic co-ordinate adjustment, in-cycle wheel dressing, integrated profile management and CMM.
Holroyd's patent-pending machining method has been developed to compensate for helical twist, an unwelcome condition that occurs when helical gears are 'lead crowned' to improve meshing and reduce noise and wear.
Lead crowning varies the amount of material removed from the flank of a tooth across the face width, by causing the tool motion to deviate from a true helix.
However, in form grinding this has the undesirable effect of causing the profile of the tooth flank to vary across the face.
In many applications this 'error' is not of concern, but in high precision and low noise applications it affects gear wheel performance by concentrating loads on particular areas of the teeth during meshing.
Correction of this problem is achieved on the CNC controlled GTG2 machine by calculating additional motions of the grinding wheel and by then controlling them during the grinding operation using bespoke software written by Holroyd engineers.
In the machining process, the workpiece is rotated about its axis and translated parallel to its axis relative to the tool, and the tool is also moved so as to vary continuously the angle of inclination of its axis relative to the axis of the workpiece.
In this way the generating errors (i.e the deviation of the groove surfaces actually produced from those desired and specified) are reduced along each line of instantaneous contact between the tool envelope and the groove surface being machined.
The resultant benefits are better tooth contact during meshing and improvements in torque transfer efficiency.
Although it performs a highly complex operation, the technology that underpins Holroyd's new machining method is not unwieldy for the user.
Neither does it mean that the machine is difficult to program and use.
On the contrary: the GTG2 is referred to as a 'Smart' machine because of its high levels of onboard intelligence, which make it easy to set-up and operate.
The machine is equipped with Holroyd's own HTG8, 8 axis CNC with facilities such as an Advanced Touch Screen Interface and Integrated Profile Management System.
The touch screen interface enables an operator to take a typical design drawing and enter the specification directly into the machine; leaving high levels of inbuilt intelligence do the rest.
What this means in practical terms is that the machine, by integrating facilities such as automatic co-ordinate adjustment, in-cycle wheel dressing, profile management and automatic programmable cycles, replaces the variable of operator skill in precision machine set-ups and operations with machine intelligence.
By distilling operator knowledge and experience into the GTG2's CNC controller, the machine is able to take data from its (optional) on-board probing system and predict the minute alterations to the profile of the grinding wheel required to achieve any desired profile and make these alterations 'on the fly'.
An example highlighting the proficiency of this system is a workpiece that does not meet tolerance requirements after a first grinding pass.
Following on-machine measurement, the GTG2 calculates the necessary adjustments to grinding wheel form or axis position and then passes the data to a 2-axis CNC wheel dressing system to achieve on machine dressing of the grinding wheel.
All of these operations are achieved automatically and rarely does the machine need to make further corrections after the first pass.
Holroyd's integration of the in-cycle wheel dressing system into the GTG2 is not a one off, rather it is part of an overall design strategy that takes a number of functions crucial to precise and effective gear grinding and integrates them into the machine as Automatic Programmable Cycles.
The GTG2 offers users eight of these cycles to simplify and improve gear production.
In addition to automatic wheel dressing they include: * Gear Tooth Grinding, with Optional Probing and Form Measurement.
* Repeat Cycles with Nesting up to 99 Times.
* Fillet Radius or Trochoid Root Form.
* Gear Crowning Cycle for Modified Tooth Forms.
* Lead Crowning by Bob Crowning, or by Adjusting the Lead or Combination of Both.
* Programmable Constant Peripheral Grinding Wheel Speed, Based on Actual Wheel Diameter.
* Optional Programmable Component Taper Correction.
Optimising the performance of the GTG2 in all of its bespoke and automatic operating cycles is a highly effective measurement system, provided by an inbuilt CMM.
This is designed, manufactured and calibrated to the same specifications and tolerances as standalone CMM, and also uses the same high level 3D scanning probes.
The CMM function is used at the start of each scan cycle to provide a validated reference point for commencement of the grinding operation.
Importantly, the probing operation, which is integral to this process, takes place without any machining forces and is therefore dynamically and kinematically stable.
In addition, as the workpiece is held in the same fixture used for machining, there is no requirement for off- machine measurement, and no consequent loss of position for corrective rework.
As a result the measuring process, overall, is that much more accurate and reliable.
* GTG2 Technology recognised for Queens's Award for Innovation - even before its major market launch, the technology that underpins the GTG2 grinding centre has been recognised by the prestigious Queen's Award For Innovation 2004.
'This award is an early recognition and a validation of all that we were trying to achieve with our design,' said Bannan.
'We have produced a highly cost competitive machine with grinding technology that literally leads the world, demonstrating our continuing ability to produce winners in the increasingly competitive global market for high precision machine tools.
CNC covers all gear machining aspects
Configured with a very flexible and cost effective combination of hardware and software, Num's Axium Power CNC system is particularly well suited to address all aspects of gear manufacturing. This is an 'off the shelf solution', with embedded conversational/graphical operator interface and machining cycles for gear hobbing or grinding and automatic gear/tool alignment. The Num gear system saves years of software development and re-development, while shortening the machine operator's learning curve.
The PC or CNC based user-friendly interactive conversational/graphical interface (HMI) allows the operator to program the machine without knowledge of ISO code programming.
The operator is guided by pictorial information and questions presented on the screen.
Entry screens provide the machine operator with a comprehensive graphical approach that depicts the hob or grinding wheel, the gear, and associated setup data in a clear and concise manner.
He or she simply fills in the data fields presented in the screen.
After this data entry session, the program is automatically generated, stored, and it is ready for execution.
On-line step-by-step video tutorials and graphical simulation further facilitates the operation.
In addition, the operator is allowed to combine conversational/graphical programming with ISO programming or use one or the other individually, if desired.
NUM application engineers familiar with gear manufacturing are available to help with system integration and technical support.
* Two system packages are available - with the basic package, the CNC synchronises cutter rotation and axial tool motion (Z axis) with the rotation of the work piece (C axis).
This configuration is principally designed for the simplest machines with three axes (X, Z and C) and a spindle.
With the advanced package, the CNC adds tangential tool movement (Y axis) to the synchronization of the Z and C axes.
This configuration is designed for applications with up to 6 axes (X, Y, Z, A, C, and W) and a spindle, allowing for manufacturing of bevel and helical gears with straight or conical cutting tools.
The gear alignment option provides cutting tool and gear re-synchronisation, via a non-contact sensor, allowing for automatic 'tool-work piece' timing pickup, when reintroducing a precut or hardened gear into the machine.
The PC or CNC based user-friendly interactive conversational/graphical interface (HMI) allows the operator to program the machine without knowledge of ISO code programming.
The operator is guided by pictorial information and questions presented on the screen.
Entry screens provide the machine operator with a comprehensive graphical approach that depicts the hob or grinding wheel, the gear, and associated setup data in a clear and concise manner.
He or she simply fills in the data fields presented in the screen.
After this data entry session, the program is automatically generated, stored, and it is ready for execution.
On-line step-by-step video tutorials and graphical simulation further facilitates the operation.
In addition, the operator is allowed to combine conversational/graphical programming with ISO programming or use one or the other individually, if desired.
NUM application engineers familiar with gear manufacturing are available to help with system integration and technical support.
* Two system packages are available - with the basic package, the CNC synchronises cutter rotation and axial tool motion (Z axis) with the rotation of the work piece (C axis).
This configuration is principally designed for the simplest machines with three axes (X, Z and C) and a spindle.
With the advanced package, the CNC adds tangential tool movement (Y axis) to the synchronization of the Z and C axes.
This configuration is designed for applications with up to 6 axes (X, Y, Z, A, C, and W) and a spindle, allowing for manufacturing of bevel and helical gears with straight or conical cutting tools.
The gear alignment option provides cutting tool and gear re-synchronisation, via a non-contact sensor, allowing for automatic 'tool-work piece' timing pickup, when reintroducing a precut or hardened gear into the machine.
CNC retrofit raises gear grinder output, accuracy
A Pfauter Kapp gear grinder has been successfully retrofitted with a Siemens Sinumerik 840D CNC to improve productivity by 40% and raise the machine's accuracy.
In early 2005 CNC Design performed a retrofit on a Pfauter Kapp PE1000G gear grinder at David Brown Gear Industries' Woolongong plant. The heat treatment process used to harden gears and pinions distorts them slightly, so before being fitted to a gearbox these workpieces must be ground to eliminate this distortion. The Pfauter Kapp grinding machine, originally built in 1988 performs this critical final step in the production process.
However the hardware and software used on the machine was becoming obsolete and hard to maintain while the user interface was difficult to learn and inflexible.
The retrofit involved the installation of Siemens 1FT6 digital servo motors to all feed axes.
These motors are controlled by Simodrive 611D digital drives which allow the use of feedforward control.
This provides extremely stiff control and fast machine response which is evident in the smooth surface finish on the gear teeth being ground.
The existing spindle motor was retained and connected to a new 611U drive.
The drives are controlled by a Sinumerik 840D CNC.
This is the only product on the market offering integrated safety features.
Sinumerik Safety Integrated is now responsible for monitoring the working space and ensuring the safety of the operator during workpiece set-up and while checking results.
Safe Standstill monitoring, Safe Speeds and Safe External Stops are implemented to create maximum operator safety at all times.
A new user interface was developed in consultation with the machine operators to allow flexible and intuitive control of the grinding process.
The interface runs on a PCU50 control panel which allows grinding and setup data to be saved to the internal hard disk.
Not only did the upgrade provide an easy to understand and intuitive interface, it also allowed greater flexibility during the grinding process.
Any further machine upgrades or diagnosis are also made easier by incorporating a modem which allows secure remote access to the machine software.
The entire commissioning process, including the rewiring of the entire machine, the refurbishment of all ancillary systems, tuning of all axes and the testing of all grinding cycles, was performed in a six week period of down-time.
Full production was able to begin immediately after this commissioning period.
Reductions in grinding time of up to 40% have been experienced on the refurbished machine.
And importantly, operator interaction has been reduced, increasing efficiency and allowing the operators more time to perform other tasks.
Overall, both management and operators at the David Brown plant are extremely happy with the result of the project.
Not only have productivity and usability been improved, but the future viability of the Pfauter Kapp is assured at a fraction of the price of a new machine
In early 2005 CNC Design performed a retrofit on a Pfauter Kapp PE1000G gear grinder at David Brown Gear Industries' Woolongong plant. The heat treatment process used to harden gears and pinions distorts them slightly, so before being fitted to a gearbox these workpieces must be ground to eliminate this distortion. The Pfauter Kapp grinding machine, originally built in 1988 performs this critical final step in the production process.
However the hardware and software used on the machine was becoming obsolete and hard to maintain while the user interface was difficult to learn and inflexible.
The retrofit involved the installation of Siemens 1FT6 digital servo motors to all feed axes.
These motors are controlled by Simodrive 611D digital drives which allow the use of feedforward control.
This provides extremely stiff control and fast machine response which is evident in the smooth surface finish on the gear teeth being ground.
The existing spindle motor was retained and connected to a new 611U drive.
The drives are controlled by a Sinumerik 840D CNC.
This is the only product on the market offering integrated safety features.
Sinumerik Safety Integrated is now responsible for monitoring the working space and ensuring the safety of the operator during workpiece set-up and while checking results.
Safe Standstill monitoring, Safe Speeds and Safe External Stops are implemented to create maximum operator safety at all times.
A new user interface was developed in consultation with the machine operators to allow flexible and intuitive control of the grinding process.
The interface runs on a PCU50 control panel which allows grinding and setup data to be saved to the internal hard disk.
Not only did the upgrade provide an easy to understand and intuitive interface, it also allowed greater flexibility during the grinding process.
Any further machine upgrades or diagnosis are also made easier by incorporating a modem which allows secure remote access to the machine software.
The entire commissioning process, including the rewiring of the entire machine, the refurbishment of all ancillary systems, tuning of all axes and the testing of all grinding cycles, was performed in a six week period of down-time.
Full production was able to begin immediately after this commissioning period.
Reductions in grinding time of up to 40% have been experienced on the refurbished machine.
And importantly, operator interaction has been reduced, increasing efficiency and allowing the operators more time to perform other tasks.
Overall, both management and operators at the David Brown plant are extremely happy with the result of the project.
Not only have productivity and usability been improved, but the future viability of the Pfauter Kapp is assured at a fraction of the price of a new machine
'Smart' grinding achieves best gear performance
Bespoke helical gear production service uses a combination of stress prediction software and DIN 2 'smart' grinding to achieve maximum gear performance.
Holroyd is harnessing the DIN 2 capabilities of its new 'Smart' GTG2 gear grinder to provide a bespoke service for high precision helical/spur gears in diameters up to 350mm and 160mm gear face width. The new service meets the market need for ever increasing accuracy of small volume, high precision gears in aerospace and high performance automotive applications, industrial optics and custom designed industrial products. 'The helical service is a complement to our existing and well proven high precision wormgear business,' says Paul Hannah, Holroyd Sales Director.
'Using the newly introduced GTG2 machine, we can grind even small batches of helical/spur gears to DIN 2 levels of quality with some features achieving DIN 1'.
'This sort of performance means that our service is ideal for providing items such as master gears for prototyping, timing gears for use in aerospace applications and helical gears for use in high performance automotive gearboxes and oil pumps.' Hannah continues: 'What differentiates our service in a competitive market is that we provide a package of design advice and manufacturing which not only ensures the highest levels of precision, but also optimises gear performance'.
' One of the major problems in helical gear manufacture is predicting actual stresses'.
'This is important because the more pressure on the gear teeth, the more risk there is of pitting (macro or micro) and eventual gear failure'.
'We address this problem with unique stress prediction software, which was developed by Holroyd engineers, and enables us to optimise gear design, with profile and lead modifications to achieve the optimum contact conditions for low noise and high strength'.
'The software, however, is only one part of the package'.
'Crucially, we must be able to replicate the profile derived from software on a gear grinding machine'.
'On conventional machines this can be difficult, but the GTG2 is designed with just this capability'.
'It is on-board scanning probe and dresser compensation enables us to replicate, faithfully, any lead and profile modification from our prediction software to minimise contact stress and pitting.' In addition to profile modification, users of Holroyd's new gear service also benefit from the additional features of the GTG2 machine, which uses form grinding rather than the generation method.
Besides higher productivity from single wheels, form grinding offers improved flexibility for flank and root profiles, and produces a better (quieter) surface texture, with reduced risk of thermal damage.
The machine also has a unique method of compensating for 'helical twist', an unwelcome condition that occurs when helical gears are 'lead crowned' to reduce transmission errors which often occur when the gears experience misalignments or deflections under load.
Lead crowning varies the amount of material removed from the flank of a tooth across the face width, by causing the tool motion to deviate from a true helix.
Besides giving the desirable 'relief' to the helix, this gives an undesirable 'lean' to the profile where the crowning is greatest.
In many applications.
this deviation is not of concern, but in high precision and low noise applications it affects gear wheel performance by concentrating loads on particular areas of the teeth during meshing.
Correction of this problem is possible with the GTG2.
It is achieved by calculating additional motions of the grinding wheel and controlling them during the grinding operation using Holroyd's unique software.
This modifies the angle of inclination of the grinding wheel during the grinding operation, either alone or in combination with other axis deviations.
The result is better tooth contact during meshing, giving improvements in load bearing and transmission accuracy, i e, smoother, more durable gears.
Developed in collaboration with the respected Gear Design Unit at Newcastle University, Holroyd's machine is the first CNC gear grinder to be designed, produced and marketed in the UK, and is believed to be the only gear grinding system available which uses a continuously variable wheel angle in this way.
Patents are pending, and the machine is now available for sale.
Summing-up the benefits of the new service, Hannah stressed Holroyd's unrivalled experience in designing and manufacturing grinding machines for the global market - the same machines that Holroyd uses for its own bespoke gear production'.
''Holroyd is unique, in that we not only manufacture bespoke worm and helical gears and rotors, but also make the machine tools, which produce these components'.
'This complementary operating strategy means that we are, in essence, always our own customer, a situation that provides an ongoing database of manufacturing experience, benefiting users of Holroyd products worldwide.
Holroyd is harnessing the DIN 2 capabilities of its new 'Smart' GTG2 gear grinder to provide a bespoke service for high precision helical/spur gears in diameters up to 350mm and 160mm gear face width. The new service meets the market need for ever increasing accuracy of small volume, high precision gears in aerospace and high performance automotive applications, industrial optics and custom designed industrial products. 'The helical service is a complement to our existing and well proven high precision wormgear business,' says Paul Hannah, Holroyd Sales Director.
'Using the newly introduced GTG2 machine, we can grind even small batches of helical/spur gears to DIN 2 levels of quality with some features achieving DIN 1'.
'This sort of performance means that our service is ideal for providing items such as master gears for prototyping, timing gears for use in aerospace applications and helical gears for use in high performance automotive gearboxes and oil pumps.' Hannah continues: 'What differentiates our service in a competitive market is that we provide a package of design advice and manufacturing which not only ensures the highest levels of precision, but also optimises gear performance'.
' One of the major problems in helical gear manufacture is predicting actual stresses'.
'This is important because the more pressure on the gear teeth, the more risk there is of pitting (macro or micro) and eventual gear failure'.
'We address this problem with unique stress prediction software, which was developed by Holroyd engineers, and enables us to optimise gear design, with profile and lead modifications to achieve the optimum contact conditions for low noise and high strength'.
'The software, however, is only one part of the package'.
'Crucially, we must be able to replicate the profile derived from software on a gear grinding machine'.
'On conventional machines this can be difficult, but the GTG2 is designed with just this capability'.
'It is on-board scanning probe and dresser compensation enables us to replicate, faithfully, any lead and profile modification from our prediction software to minimise contact stress and pitting.' In addition to profile modification, users of Holroyd's new gear service also benefit from the additional features of the GTG2 machine, which uses form grinding rather than the generation method.
Besides higher productivity from single wheels, form grinding offers improved flexibility for flank and root profiles, and produces a better (quieter) surface texture, with reduced risk of thermal damage.
The machine also has a unique method of compensating for 'helical twist', an unwelcome condition that occurs when helical gears are 'lead crowned' to reduce transmission errors which often occur when the gears experience misalignments or deflections under load.
Lead crowning varies the amount of material removed from the flank of a tooth across the face width, by causing the tool motion to deviate from a true helix.
Besides giving the desirable 'relief' to the helix, this gives an undesirable 'lean' to the profile where the crowning is greatest.
In many applications.
this deviation is not of concern, but in high precision and low noise applications it affects gear wheel performance by concentrating loads on particular areas of the teeth during meshing.
Correction of this problem is possible with the GTG2.
It is achieved by calculating additional motions of the grinding wheel and controlling them during the grinding operation using Holroyd's unique software.
This modifies the angle of inclination of the grinding wheel during the grinding operation, either alone or in combination with other axis deviations.
The result is better tooth contact during meshing, giving improvements in load bearing and transmission accuracy, i e, smoother, more durable gears.
Developed in collaboration with the respected Gear Design Unit at Newcastle University, Holroyd's machine is the first CNC gear grinder to be designed, produced and marketed in the UK, and is believed to be the only gear grinding system available which uses a continuously variable wheel angle in this way.
Patents are pending, and the machine is now available for sale.
Summing-up the benefits of the new service, Hannah stressed Holroyd's unrivalled experience in designing and manufacturing grinding machines for the global market - the same machines that Holroyd uses for its own bespoke gear production'.
''Holroyd is unique, in that we not only manufacture bespoke worm and helical gears and rotors, but also make the machine tools, which produce these components'.
'This complementary operating strategy means that we are, in essence, always our own customer, a situation that provides an ongoing database of manufacturing experience, benefiting users of Holroyd products worldwide.
Gear cutting tools and workholding offered
Gleason offers a broad array of cutting tools for soft and hard machining of bevel and cylindrical gears from Rockford/USA, Plymouth/UK, Munich/Germany and Bangalore/India.
Gleason offers a broad array of cutting tools for soft and hard machining of both bevel and cylindrical gears from our facilities in Rockford/USA, Plymouth/UK, Munich/Germany and Bangalore/India. Complete workholding designs and systems are available for all machine tools. At Gleason-Hurth in Munich we have expanded and rebuilt the tool production area so that we can supply shaper cutters of all kinds with maximum precision and consistent quality - as well as honing, shaving and deburring tools.
Particular emphasis is placed on the best possible design of shaper cutters to suit the pro-duction task in question.
We are also pleased to provide a resharpening service for these tools.
Gleason offers a broad array of cutting tools for soft and hard machining of both bevel and cylindrical gears from our facilities in Rockford/USA, Plymouth/UK, Munich/Germany and Bangalore/India. Complete workholding designs and systems are available for all machine tools. At Gleason-Hurth in Munich we have expanded and rebuilt the tool production area so that we can supply shaper cutters of all kinds with maximum precision and consistent quality - as well as honing, shaving and deburring tools.
Particular emphasis is placed on the best possible design of shaper cutters to suit the pro-duction task in question.
We are also pleased to provide a resharpening service for these tools.
Gear tester also checks tooling
CNC gear tester with 3D probe head provides high accuracy and flexibility for measuring bevel gears and cylindrical gears as well as gear cutting tools.
The Gleason-M and M CNC Gear Tester Sigma 5 with 3D probe head provides high accuracy and flexibility for bevel gears and cylindrical gears as well as gear cutting tools. A complete library of software exists to comply with special evaluation methods and international standards. Further more the Sigma series is capable to inspect shaft dimensions, cam shafts, and crank shafts.
The easy to handle user interface ensures effective use in the lab as well as on the shop floor.
Capacities: * Maximum OD - 475mm.
* Module range - 0.5-18mm.
* Distance between centers - 30-650mm.
The Gleason-M and M CNC Gear Tester Sigma 5 with 3D probe head provides high accuracy and flexibility for bevel gears and cylindrical gears as well as gear cutting tools. A complete library of software exists to comply with special evaluation methods and international standards. Further more the Sigma series is capable to inspect shaft dimensions, cam shafts, and crank shafts.
The easy to handle user interface ensures effective use in the lab as well as on the shop floor.
Capacities: * Maximum OD - 475mm.
* Module range - 0.5-18mm.
* Distance between centers - 30-650mm.
Gear shaper reduces changeover times
For gear-shaping, 'Electronic helical guide technology' eliminates time consuming procurement and changeover of mechanical guides from the production of helical gears.
The 'Electronic helical guide technology' in the Gleason GP 200 ES gear shaping machine eliminates completely the expensive, time consuming procurement and changeover of mechanical guides from the production of helical gears. The shaping head has been completely redesigned with a backlash-free direct drive for the cutter spindle in order to deliver highest precision and dynamics for the required additional motion of the shaper cutter. The ES technology provides the user with huge potential for flexibility and savings: * No investment in mechanical helical guides required.
* Elimination of the lengthy lead times and cost required to purchase mechanical guides.
* No time-consuming and, in some cases, difficult changeover of guides.
* Even helix angles above 45 deg (extremely short leads) for external and internal gears can be produced.
* Lead angle corrections can be easily made from one part to the next (e g, lead angle errors due to hardening).
* Using tandem tools, multiple gears with left and right hand helix angles can be produced in one set-up.
Capacities: * Nominal workpiece diameter - 200mm.
* Nominal module - 6mm.
* Maximum face width - 100mm.
The 'Electronic helical guide technology' in the Gleason GP 200 ES gear shaping machine eliminates completely the expensive, time consuming procurement and changeover of mechanical guides from the production of helical gears. The shaping head has been completely redesigned with a backlash-free direct drive for the cutter spindle in order to deliver highest precision and dynamics for the required additional motion of the shaper cutter. The ES technology provides the user with huge potential for flexibility and savings: * No investment in mechanical helical guides required.
* Elimination of the lengthy lead times and cost required to purchase mechanical guides.
* No time-consuming and, in some cases, difficult changeover of guides.
* Even helix angles above 45 deg (extremely short leads) for external and internal gears can be produced.
* Lead angle corrections can be easily made from one part to the next (e g, lead angle errors due to hardening).
* Using tandem tools, multiple gears with left and right hand helix angles can be produced in one set-up.
Capacities: * Nominal workpiece diameter - 200mm.
* Nominal module - 6mm.
* Maximum face width - 100mm.
Hardened gears finish ground at high speed
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.
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.
Volkswagen Passat 2005: Body and Chassis for Volkswagen Parts at Parts Train
The Volkswagen Passat 2005 features a powerful design. The new VW face with its chrome radiator represents the greatest design progression since the creation of the series.
The new Passat is 4.77 metres long (+ 62mm), 1.82 metres wide (+ 74mm) and 1.47 metres tall (+ 10 mm). The wheelbase measures 2.71 metres. One real indicator of outstanding quality is the static torsional stiffness. .
Volkswagen is using the FSI engines with homogeneous direct injection for the first time in the Passat. They deliver 85kW / 115hp, 110kW / 150hp and 147kW / 200hp (Turbo FSI).
The Passat TDI will also be available with a diesel particulate filter. The most powerful TDI features the innovative Piezo high-pressure unit-injector system. The petrol engines with outputs of 85kW / 115hp, 110kW / 150hp and 147kW / 200hp can be optionally combined with a driver-friendly six-speed automatic gearbox
Using aluminum components (weight: -13.3 kilogrammes) guarantee a maximum level of agility, comfort and safety, it has new four-link rear axle, which has been decoupled from the body to reduce noise, along with the McPherson front.
The chassis technology has been perfected with the ESP + Trailer Stabilizations that comes as standard on all vehicles with a tow bar. All Passats have 16-inch brakes with an integrated “wiper” function. The brake pads are applied lightly at specific intervals. This “wipes away” any water film that may have formed while driving on wet surfaces and thus shortens the braking distance.
Standard for the first time is the electronic parking brakes at the push of a button. It has new Starting and Locking System, New Automatic Adaptive Cruise Control, Sound System from Dynaudi, Draught-free Climatronic, Bi-Xenon Headlights with Cornering Function. Hands-free telephone system with a Bluetooth interface is available as an option.
Equally impressive and highly durable Volkswagen auto body parts, performance parts, replacement parts, discount parts are available at Parts train's online store. When you need Volkswagen Hood, first class quality is available at Partstrain. Volkswagen Grille and Volkswagen fenders for example are put you on top of the race due to its strict quality control measures.
The Potent 2006 BMW M6 Complimented Perfectly By Top-notch BMW Replacement Parts
The BMW M6 is the most sophisticated and powerful BMW 6 Series Coupé ever. Under the lightweight body of this luxurious 2+2 lurks a thoroughbred super sports car boasting a V10, 507bhp power unit, providing 520Nm of torque. A seven-speed sequential manual gearbox and a superior chassis and suspension compliments its engine.
The all-new M6 features weight-saving technologies such as a carbon-fiber roof and 19-inch forged aluminum wheels that are almost four pounds lighter than regular cast wheels. With almost 500 horsepower available, BMW claims the M6 will hit 60 mph in under 4.6 seconds, and it will run to 20 5mph without the traditional 155-mph speed limiter.
The suspension, though similar to that of the M5, is specially tuned to take advantage of the M6's shorter wheelbase and lower center of gravity. Massive cross-drilled brakes enable the M6 to pull up from 60 mph in less than 118 feet. The new M6 also uses BMW's new third-generation seven speed Sequential Manual Gearbox (SMG) with Drivelogic. Drivelogic offers the choice of 11 different change patterns, depending on the speed of change required.
The new SMG gearbox also offers safety benefits when downshifting on slippery surfaces. If it detects the rear wheels locking up, the clutch opens for a fraction of a second to ensure traction is maintained. In automatic mode, the SMG gearbox recognizes that the car is traveling on an incline and holds gears uphill to maintain acceleration and selects lower gears when progressing downhill to make the most of the available engine braking.
The BMW M6 has deeper front valance with air intakes for the engine and brakes, more contoured sills and rear valance that includes a diffuser to increase aerodynamic efficiency. Driving dynamics, motoring comfort and generous space inside redefines the new BMW series. Featuring more powerful and fuel efficient four and six cylinder engines, innovative assistance systems, a wide range of safety features, as well as a superior standard of equipment, the new BMW series of today need no less than superior BMW replacement parts when the need arises.
BMW 2006: BMW Performance Parts, Aftermarket Parts
The BMW M6 is the most sophisticated and powerful BMW 6 Series Coupe ever. Under the lightweight body of this luxurious 2+2 lurks a thoroughbred super sports car boasting a V10, 507bhp power unit, providing 520Nm of torque. A seven-speed sequential manual gearbox and a superior chassis and suspension compliment its engine.
The all-new M6 features weight-saving technologies such as a carbon-fiber roof and 19-inch forged aluminum wheels that are almost four pounds lighter than regular cast wheels. With almost 500 horsepower available, BMW claims the M6 will hit 60 mph in under 4.6 seconds, and it will run to 20 5mph without the traditional 155-mph speed limiter.
The suspension, though similar to that of the M5, is specially tuned to take advantage of the M6's shorter wheelbase and lower center of gravity. Massive cross-drilled brakes enable the M6 to pull up from 60 mph in less than 118 feet. The new M6 also uses BMW's new third-generation seven speed Sequential Manual Gearbox (SMG) with Drivelogic. Drivelogic offers the choice of 11 different change patterns, depending on the speed of change required.
The new SMG gearbox also offers safety benefits when downshifting on slippery surfaces. If it detects the rear wheels locking up, the clutch opens for a fraction of a second to ensure traction is maintained. In automatic mode, the SMG gearbox recognizes that the car is traveling on an incline and holds gears uphill to maintain acceleration and selects lower gears when progressing downhill to make the most of the available engine braking.
The BMW M6 has deeper front valance with air intakes for the engine and brakes, more contoured sills and rear valance that includes a diffuser to increase aerodynamic efficiency. If you want to maintain the superior performance of your BMW, then Partstrain is the store for you. Partstrain is the leading supplier of BMW discount- priced finest quality BMW Auto Parts. For your performance demands, Partstrain offers electrical parts, exhaust, catalytic converters, grille, head panel, engine parts, spoiler, radiator support, rear body panel, turn signal lights and a whole lot more.
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