This paper is divided into two parts. The first part is a general digression on the pressure angle on cylindrical gears. The pressure angle is a variable that plays an important role in defining the geometry of gears and hobs, yet it is not widely discussed. This introduction serves as a prerequisite for the second part of the paper. The second part will show an application case of hoosing
the most suitable hob to cut a given gear. In this selection process, particular attention will be paid to the pressure angle of the hob for cutting with modified rolling, i.e., with a reduced pressure angle compared to that of the gear.
The Helios team installed a Hera 350 CNC Gear Hobbing Machine at Buffalo Gear in Buffalo, NY. See how Buffalo Gear's capabilities have expanded with the upgrade.
The 67,000 sq. ft. facility occupied by Precision Gears Inc. in Pewaukee, WI, contains a full range of gear manufacturing equipment to meet the varied customer demands of the many industries it serves. Founded in 1919, the company possesses both the technologies and experience to efficiently serve the multiple requirements of manufacturers in fields as varied as agriculture, lawn and garden, foodservice, power transmission construction, pumps, and others.
The Helios Hera 90 CNC gear hobbing machine combines advanced technology, precision components, and economic pricing to enable profitable production of high-quality spur gears, helical gears, straight bevel gears, and other hobbed profiles.
Dayton Gear partnered with Helios Gear Products to install a new Hera 200 CNC gear hobber, followed shortly after by a Hera 500 CNC gear hobber. Helios had a chance to check in with Adam Baird and Brian Baird, 3rd generation at Dayton Gear, to see how their production has changed since the installation, and how they're planning and looking forward to the future.
The Helios team recently installed a Hera 200 and Hera 500 at Dayton Gear in Dayton, OH.
Machining the teeth of a rotor shaft for electric cars has demanding machining requirements. Very few other applications place such high demands as transmission components. The very quiet motor requires the highest surface finishes so that disturbing running noises do not occur. In addition, the number of units in e-mobility is greatly increasing, which is an additional challenge for the mechanical engineering involved. What is needed, therefore, are process-reliable solutions for cost-effective rotor shaft production. EMAG Koepfer HLC 150 H gear hobbing machine demonstrates how this can work, ensuring new productivity in this gear sector.
German Machine Tools of America (GMTA) is now selling Profilator 300-V with linear drives in the North American market.
This modular machine platform used to cut gears, is equipped with one or two workpiece spindles in a compact design. It offers maximum flexibility due to modular design and is individually configurable for various machining processes (i.e. Scudding, hobbing, cycloidal milling, pointing, chamfering and deburring). State-of-the-art linear drives in the x and y axis, as well as a torque drive in the a axis offers high machine dynamics for short cycle times and maximum accuracy/low costs. High machine rigidity is available for Hard Scudding of inner and outer diameters.
During our interactions with customers, we find the common challenge faced by customers about getting incorrect component parameters using corrected lead hobs. To address the challenge, we will talk about what corrected lead hobs are, why it is necessary to design such hobs, and how to set up the hob on the machine depending upon the type of hobbing machine (manual, semiautomatic CNC, or CNC).
When developing the AF160, maximum versatility was the key goal of the Engineering Department of the Swiss family enterprise Affolter Group, a world technology leader in high-precision gear hobbing solutions. Vincent Affolter, Managing Director of the Affolter Group, explains: “The AF160 is designed for high precision manufacturers that need flexibility and efficiency. With its eight axes, sophisticated automation solutions, and an innovative quick-change system, the machine provides exactly that.”
Gear Up for Precision will take place April 12-13, 2023. Both Wenzel and Nidec Machine Tool America, located across from each other in Wixom, Mich., will be open to visitors with displays, technical discussions, presentations, and demonstrations.
State of the Gear Industry Perspectives takes an in-depth look at the challenges and opportunities in gear manufacturing today and in the future. Our fifth installment online is an interview with Adam Gimpert, president, Helios Gear Products.
State of the Gear Industry Perspectives takes an in-depth look at the challenges and opportunities in gear manufacturing today and in the future. Our second installment online is an interview with Christof Gorgels, vice president, innovation and technology at Klingelnberg.
State of the Gear Industry Perspectives takes an in-depth look at the challenges and opportunities in gear manufacturing today and in the future. Our first installment online is an interview with Udo Stolz, vice president of sales and marketing at Gleason Corporation.
Nidec Machine Tool Corporation announced today that it has launched Robot Camera SPEED, visual inspection equipment for cutting tools (hobbing machines) to process gears and other components, and Robot Camera MAX, visual inspection equipment for broaching machines.
The Helios team recently delivered custom gear cutting tools to Delta Research in Livonia, MI. This video examines what Delta Research had to say about the process.
Forest City Gear, an industry-leading manufacturer of fine and medium pitch custom gears, is proud to announce the promotion of Kent Blatchford to Gear Hobbing Supervisor.
Electric vehicles or EVs are increasingly popular options for people who want to save money on gas and decrease their reliance on fossil fuels.
IMTS visitors can experience live machining with the WFL M50 MILLTURN/3000 mm. The multifunctional turning-boring-milling center is designed for complete machining of complex chuck and shaft parts up to 670 mm swing over bed. Turning, milling, drilling, hobbing, shaping, gun drilling as well as ID machining can be performed under any angle of the tool.
EMAG will highlight productive, and at the same time, flexible manufacturing solutions for electromobility at IMTS. Among other things, the focus is on the vertical pick-up lathes of the VL series, which EMAG now delivers IoT-Ready.
Helios Gear Products will debut two state-of-the-art gear manufacturing solutions at the International Manufacturing Technology Show in Chicago, September 12–17, 2022.
Nidec Machine Tool (Wixom, Mich.), responding to the needs of the industry, is debuting the new GE15HS gear hobbing machine at IMTS 2022 in Booth #237036. Emphasizing high speed, precision and efficiency, the new machine produces gears for electric and hybrid cars, as well as for robotic and automation applications.
Learn and understand fundamentals of gear manufacturing. Acquire knowledge and understanding of gear nomenclature, hobbing and shaping of spur and helical gears, and splines. Learn and understand hobber and shaper machine set-up, as well as gear tooth element inspection.
Tool-X is a nanofluid that changes the characteristics of existing metalworking fluids by ‘manipulating’ speeds, feeds and metal removal rates using nanotechnology. The science behind Tool-X can potentially change metal cutting dynamics, improve surface finishes and extend tool life. The backstory of this technology is just as fascinating as its production results.
It wasn’t long ago that cylindrical gear chamfering and deburring was almost an afterthought. Now the process ranks as high in importance as hobbing, shaping and grinding. Seemingly every gear manufacturer, particularly those developing transmission gears for e-drive applications, recognizes that anything less than a flawless tooth flank can result in premature transmission failure, less-than-optimal efficiency, and unacceptable noise. Thus, generating a chamfer to precise customer specifications is critical to minimize the potential for sharp, brittle edges after heat treat; avoid edge load situations in the gearbox; and eliminate excessive stock and hardened burrs in the tooth flank prior to the hard finishing operations (conditions which can greatly diminish tool life).
Production demands continue to rise with the burgeoning electrification movement. The desire for high-precision gears and low-cost manufacturing requires versatile and affordable high-efficiency processing to serve the needs of a variety of industries. Gathered here are a few recent hobbing solutions from Affolter Group, Helios Gear Products, and Nidec Machine Tool Corporation.
Bevel gear design is well-established. Flank geometry optimization is used worldwide to ensure satisfactory low-noise emis...
The Digital Manufacturing Revolution Evolves in 2020 IMTS will offer two comprehensive digital programs, IMTS Network and IMTS Sp...
Our company manufactures a range of hardened and ground gears. We are looking into using skiving as part of our finishing process on gears in the 4-12 module range made form 17 CrNiMO6 material and hardened to between 58 and 62 Rc. Can you tell us more about this process?
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