With the development and progress of cemented carbide gear tool materials, the proportion of cemented carbide tools used in gear processing is also increasing year by year, especially in developed countries in Europe, which has reached more than 70%. Solid carbide hobs are widely used in the processing of small modulus gears, and have the characteristics of good versatility, high efficiency, and high precision. However, with the increase of the gear modulus, the cost of using the integral carbide hob will also increase significantly, which is especially not conducive to the selection of small and medium-sized gear customers. Today, I will introduce several high-quality gear processing blades to solve the problem of gear processing in small and medium batches.
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Sandvik Coromant full tooth blade hobs
Sandvik Coromant's CoroMill® 176 is an innovative blade-type gear hob, which is used for rough hobbing, semi-finishing and fine hobbing of gears or splines with modulus m3~m9. The cutter body of the hob supports a variety of interface designs, and can be applied to traditional gear hobbing machines, machining centers with gear hobbing programs, and multi-task machine tools.
CoroMill® 176 hob
Features
1) The full tooth shape design makes the number of effective teeth more;
2) Using iLockTM positioning technology and wedge clamping design, the repeat positioning accuracy of the tool is higher;
3) The blade adopts the GC1130 material manufactured by ZertivoTM coating technology, which greatly improves the safety of the edge line, is suitable for higher line speeds, and supports dry processing.
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CoroMill® 176 hob inserts
Applications
1) Workpiece name: construction machinery gear
2) Gear parameters: M5, Z73, B108 (HB220)
3) Machine tool: gear hobbing machine
4) Cutting conditions: dry cutting, down milling
5) Cutting parameters: vc1=200 m/min, fv1=5 mm/rev, ap1=10 mm
vc2=300m/min, fv1=3mm/rev, ap2=1.5mm
6) Cutting effect: 28% higher efficiency than the double-head integral hob, and the precision of the parts is 8~9, fully meeting the production needs.
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CoroMill® 176 hob and gear machining surfaces
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Zhengzuan special tool series - rotary blade
1. Company introduction
Zhengzhou Diamond Precision Manufacturing Co., Ltd., since its establishment in 1997, has focused on the development and application services of high-end precision tools, providing high-quality tool products and supporting technical solutions for the global cutting manufacturing industry. The products cover more than 5,000 categories and are widely used in the fields of automobile industry, civil aviation industry, ultra-precision machining, general machinery and energy and wind power. The company is committed to providing superhard material (PCD/PCBN) tool products, cemented carbide products and precision cutting technology solutions for the global manufacturing market. The products comprehensively cover turning, milling, boring, drilling, reaming and honing. processing technology.
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2. Processing technology and solution introduction
Rotary blades are suitable for internal and external gears of automobile transmissions, synchronizer hubs and jaw clutches, etc. The synchronizer is the main part of the car transmission: through the synchronizer, the gears to be meshed will reach a consistent speed and mesh smoothly.
3. Difficulties in workpiece processing
In the old process, the inverted cone surface is realized by cold extrusion. The disadvantages of this process are: poor precision and many burrs, which greatly affect the accuracy of the synchronizer. (Gear cold extrusion is formed by rolling against the extrusion wheel and the workpiece under a certain pressure).
4. Processing method
Through the different speed ratios of the cutter shaft and the workpiece, the high-speed machining of the inverted cone surface and the slider surface is realized, and continuous indexing is realized during the high-speed rotation process, which greatly improves the processing efficiency!
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Workpiece name: synchronizer gear sleeve material (steel)
Processing method: gear special machine composite milling
Cutting parameters: vc =120 m/min, Feed=0.15 mm/teeth
Tool life: slider blade 4000 pieces/tip;
Back-tapered blades: 1000 pieces
6. Tool advantages and effects
Rotary turning instead of traditional extrusion processing greatly improves processing efficiency, reduces workpiece burrs, and greatly improves surface quality;
Using the cycloid rotary machining method, the blade structure design of the shape of the tooth groove, combined with the appropriate rotational processing parameters, can realize the tooth groove machining in one feed;
Tool accuracy reaches ±0.005mm;
The workpiece roughness is controlled below Ra0.4μm;
Tool holders and blades are available as a complete solution.
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Aussie locomotive gear cutter
Founded in March 1938, OSG is a world-renowned comprehensive cutting tool manufacturer, providing services for many industrial fields such as automobiles, moulds, 3C, medical and aerospace, focusing on thread processing, milling, drilling Precision tools such as hole processing and rolling processing. Since its inception, OSG has been anticipating, listening to and actively responding to the needs of the market, providing customers with overall processing solutions through innovative technical capabilities, excellent technical services, and innovative ways of thinking.
