The perfect symbiosis between high-performance 5-axis machining centres and special software is opening up completely new opportunities for the manufacturers of gearwheels and gear-cutting components. Modern milling technology is conquering ever broader application areas.
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Optimised machines at Hermle The 5-axis technology allows the simultaneous precision machining of extremely complex 3D contours. The motor spindles allow torque-optimised and therefore efficient use of the particular mini-milling or drilling tool for superfinish machining, or of the cutter head for power roughing. The static and dynamic stability of modern machining centres means that even rationalised hard machining is possible today.
Middle size parts in small batches The German Maschinenfabrik Berthold Hermle AG presents what is really feasible in the impressive manufacturing area of gear-cutting components and bevel gear sets. It is obvious that the symbiosis between 5-axis high-performance machining centres and 3D special software is able to substitute conventional tooth machining and offer a technically and economical highly interesting alternative.
Innovative modelling The sequence is designed as follows: The gearwheel geometry data, such as module, diameter, tooth width and height, crowning etc. is transmitted via an online link to the licenser HPG. On the basis of this data the software performs the mathematical calculation for the exact tooth shape. The tooth shape is additionally developed as a point cloud with X, Y and Z coordinates and translated into an NC program. Globally HPG is the only company which performs tooth shape modelling in the stated mathematical manner and thus obtains a much higher resolution than is ever possible based on the modelling of CAD data.
Intelligent process As a consequence, coordinated NC programs are produced for rationalised roughing and finishing. Basically the production of gear-cutting components still consists of the two operating sequences pre-milling and finishing (hardening in between) or fine machining, gauging and very fine finishing. After hardening, the workpiece is returned to the machine for fine machining where it is measured. This data is re-evaluated online at HPG and is returned to the machine in a very short time (a few minutes) as a very fine finishing program (nominal/actual comparison with the 3D data). After fine finishing, a gear-cutting component is available with high precision and surface quality, but produced at low cost.
Other kind of parts? No problem! Gear-cutting machines can be used for cutting teeth only, whereas 5-axis machining centres can be used universally and flexibly for a wide range of cutting tasks. Finally the new gear-cutting component milling process also offers the prospect that particularly the relevant branches of transport systems (ship and train drives), power engineering (hydro-power and wind-power stations), mining and construction machines (stone crushers, cement works) as well as plant manufacturers and manufacturers of special drives are less affected by the recession and that the suppliers as well as cutting technology service providers can therefore make themselves more independent of critical industries.
We will go in further detail about this powerful way to mill teeth in Eurotec 369 published in April. If you want to receive a copy of the article as soon as ready, ask your personal copy to [email protected]
For more information Maschinenfabrik Berthold Hermle AG Udi Hipp marketing Director Industriestraße 8-12 D-78559 Gosheim Phone +49 (0)7426 95-6238 Fax +49 (0)7426 95-6110 [email protected] www.hermle.de
