Defined Chamfering Deburrs Gear Teeth in Seconds
Paul Horn GmbH has developed a process for precision deburring of gear teeth that represents a further advance in the world of gear production. Although gear teeth can be deburred relatively easily with brushes and discs, higher levels of precision and quality are being demanded, with the result that there is often no longer any scope for undefined chamfers at the tooth edges. So Horn has developed a technology – together with the associated production process – to enable the production of defined chamfers. It can be used, for example, to create a 45-degree chamfer on both sides of a module 1 gear wheel with 25 teeth in less than five seconds. A turn-mill centre with synchronised axes is required for this production process. However, users do not need any special workholding equipment. The solid carbide tools can be clamped in a standard collet, or in shrink-fit or hydraulic chucks.
The process is particularly suitable for machining gears in high volumes. The milling cutters are special tools and have to be individually designed for each gear tooth. Based on the application, Horn engineers will design the appropriate cutting edge geometry for the module, tip diameter and desired chamfer. Horn supplies the process data required for machining together with the cutter. Tool costs are low and quickly pay for themselves thanks to short machining times. The carbide substrate, tool coating and cutting edge geometry are all specially designed for each gear tooth material. As far as the actual machining process is concerned, the material is irrelevant. Chamfers can be milled into various steels, aluminium and plastics within seconds.
Cost-effective even for Small Batch Production
Paul Horn GmbH is expanding its range of gear cutting products. Horn’s new tool system for milling bevel gear teeth allows the complete machining of bevel gears on universal turn-mill centres. The system was created in cooperation with machine manufacturer INDEX and means that users no longer need any special machines to manufacture gears of this kind. It also allows all functional surfaces to be produced together with the gear teeth in one clamping. This enables high component precision, short lead-times, a very cost-efficient process and short machining times as a result of controlled machining cycles. With a universal turn-mill centre from INDEX, components with bevel gear teeth can be efficiently and flexibly manufactured, including in small quantities. This also makes the process attractive to small and medium-sized companies that would previously have bought in gears or had them manufactured externally.
For the process, Horn relies on its S276 and S279 double-edged indexable inserts, which are screwed on tangentially. This makes it possible to achieve a stable insert seat, which is particularly important during form milling. The tool does not have to be remeasured after the inserts have been turned around or changed because the inserts are precision-ground on the circumference. The milling body can be equipped to allow for different numbers of teeth and outer diameters when cutting gears. The process of developing the complete system (cycle, tool and clamping) called for a great deal of expertise on the part of both the machine manufacturer and the tool manufacturer. To implement the process, various types of INDEX machine with a “bevel gear hobbing” cycle are required. Horn offers the milling cutter bodies with the HSK-T40 and HSK-T63 interfaces. The profiles of the inserts are module-dependent and precision-ground.
Skiving of Large Gear Modules
We present below a Gear Skiving Tool application from HORN for the machining of internal gears from module 3. Featuring interchangeable cutting inserts, the tool system offers high rigidity of the overall system as well as high productivity due to short process times.
Please contact us for more information on Skiving Solutions from Horn.
Complete machining of a Cyclo-Palloid Gear with HORN Tooling:
Horn has developed highly efficient gear machining processes for the Gear Industry. We showcase here an example of machining a Cyclo-Palloid Gear with a HORN tooling solution. The wide profile is opened with a custom multi-row M279 milling cutter, then the flanks are alternately roughed. The root diameter is machined with a DS cutter, the flanks are finished with a DGVZ tool and the sharp edges are chamfered with a DS cutter.
We showcase below another example of Gear Cutting with Horn Tools, from the machining of the Cyclo-Palloid Gear Teeth to the machining of External and Internal Splines by Broaching and Power Skiving.
Click here for the full range of Horn Milling Solutions.
Please contact us for any information you would like to have on any of the products showcased in this video.
For the high-productivity manufacturing of internal gear teeth, splines and other internal profiles, HORN is introducing tools for gear skiving. This machining method has a number of advantages:
- Considerably shorter processing times in comparison to gear tooth broaching
- Can be used on optimised milling centres
- No undercut necessary at the end of the gear tooth
- Turning and gear cutting possible in a single clamping
Depending on the number of gear teeth and the size of the module, a number of different tool interfaces is used. Each tool is designed specifically for the intended application and adapted for the material. Gear skiving tools are therefore used for medium and large batch sizes. On the tooth flanks, typical surfaces are created which differ from the flanks created by broaching. Depending on the geometry of the component, gear skiving may also be a useful alternative to hobbing or broaching for external gear teeth as well.