The cutting-edge gear processing technology, brilliant fight!

In order to meet the needs of high-precision and high-efficiency cutting, the development of numerical control tool technology has greatly promoted the rapid development of machine tools towards numerical control, high-speed, high-efficiency and composite direction. In recent years, the research and development of gear NC tools at home and abroad have kept pace with the development of NC efficient machine tools and made great progress. These advances mainly depend on the following aspects: more advanced design technology, more advanced NC special processing technology and precision detection technology, better performance NC tool materials, scientific and advanced surface coating technology, and high-speed steel. The heat treatment technology of gear cutter is also the key. In recent years, the development trend and characteristics of gear cutting tools are mainly manifested in the following aspects.

1. Environmental protection and dry cutting

Environmental protection dry cutting has been applied in gear processing. Compared with traditional wet cutting method, dry cutting method does not need coolant. It is not only environmentally friendly but also reduces the cost of hobbing. Dry cutting method can also adopt higher cutting speed and improve processing efficiency. According to the processing requirements of dry-cutting machine tools, the main tool manufacturers have developed environmentally friendly dry-cutting hobs. The environmentally friendly dry-cutting hobs are divided into integral carbide hobs, carbide indexable hobs and powder metallurgy high-speed steel hobs according to their materials.

Integral carbide hobs are generally used for gears whose modulus is less than 2 mm, the accuracy can reach AAA level and the cutting speed can reach more than 250 m/min; carbide indexable hobs are generally used for gears whose modulus is greater than 6-45 mm, mainly for rough cutting before grinding, and the cutting speed can reach 120-150 m/min; powder metallurgy high-speed steel hobs generally have a wider modulus range and can cover all modulus ranges. They are all made of high performance powder metallurgical high speed steel with good toughness and low processing difficulty. Their structural characteristics are small diameter lengthening structure, reducing the time of feeding and discharging cutters, and stringing cutters to improve tool durability and processing efficiency. Using powder metallurgical materials and high performance coatings, cutting speed can reach 150-200 m/min, precision DINAA level or GBAA level. Environmental protection dry cutting will become the main way of cutting teeth.

2. Cemented Carbide of Gear Cutting Tools

In the traditional sense, gear tool materials are generally high-speed steel (high-performance powder metallurgy high-speed steel has also been widely used). With the development of cemented carbide materials and the progress of processing technology, the proportion of cemented carbide tools has been increasing, which has reached more than 70% in developed countries in Europe. In recent years, various tool manufacturers at home and abroad, such as Gleason, Kennametal, Fette, Ingersoll, Sandvik Coroman, etc. T has developed various carbide indexable gear cutting tools, which greatly improves gear processing efficiency and tool life. The indexable carbide gear hob has 1 or 2 heads, and the blade can be indexated twice or four times. Its modulus range is m5.5-m40. Compared with the high-speed steel hob, the cutting speed of this kind of hob is 100-150 m/min higher (the cutting speed of the same kind of high-speed steel insert hob is only 30 m/min), and the cutting efficiency is increased by 1-3 times. In addition to large modulus indexable alloy hobs, Sandvik Coromant has also developed clamp-type carbide hobs with m5-m8. The difference is that each tooth of the hob uses a blade with assembly accuracy up to DIN B and novel structure.

In the processing of small modulus (m<2) gears, a series of holistic carbide hobs with AAA-A accuracy and cutting speed of more than 250 m/min have been developed. At the same time, the above companies have also developed carbide indexable gear milling cutters, which can be used to process both external gears and internal gears efficiently, especially large inner gear rings in wind power industry, in addition to rough cutting. In addition, the gear can be cut directly and the machining accuracy can reach GB8 level. This also shows the progress of the manufacturing technology of cemented carbide blades. The modulus range is m6~m40, the cutting speed can also reach 100~150 m/min, and the cutting efficiency can be increased by 1~3 times. It is worth mentioning that at home and abroad, CBN, PCD and other super-hard tools have also been more and more applied, and will become the future direction of tool development.

Sandvik Coleman CoroMill 176

High-efficiency replacement scheme for high-speed steel cutting tools

CoroMill 176 is the most cost-effective alternative to regrinding HSS cutters, specializing in the processing of gears with modulus ranging from 4 to 10. This kind of cutter can achieve higher cutting speed, and the user can change the cutter simply and quickly, which shortens the production cycle, thus making it an ideal choice for high efficiency gear milling.

Advantage

· Compared with high speed steel cutting tools, the total cost of a single gear is reduced.

· Higher cutting speed is available

· Longer tool life and reduced downtime

· Easy tool replacement

· No additional cost of re-grinding or re-coating

CoroMill 176 will be on display during CIMT 2015. Welcome to Sandvik Coleman Booth!

Characteristic

· Quality Class B in accordance with DIN 3968

· More effective teeth, shorten the processing time of single gear

· iLock blade interface improves accuracy and tolerance

· Easy blade transposition

application

· Gears for large gearboxes, heavy trucks and wind power

· Rough, Semi-Finish and Finish Machining

· Tooth profile meets DIN 3972-2 requirements

· Modular range: 4-10

· Hobbing Machine Tool, Multi-task Machine Tool, 5-axis Machine Tool

Product scope

· Provide DIN standard class blades, and provide blades for processing special tooth profile as required.

· Modular range: 4-10

· Material: GC1030

· Groove: -PM

· The blade with special tooth profile can also be customized according to the requirements. The body of the cutter can be provided as customized cutter.