Gear Production

MAR 2014

Gear Production

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10—GEAR Production Supplement F E A T U R E not to offer a tailstock because it would have meant compromising the size and rigidity of the tool spindle. Now, the tool spindle has a large diameter that is ideal for power skiving, but too large to allow for a tailstock. Similarly, the table spindle's use of particularly large and rigid bearings means that it can't operate at the high rpms necessary for smaller pinions, but makes it a very well-suited machine for power skiving larger internal gears. Power skiving produces "V"-shaped chips, which are extremely aggressive because they easily stick to any machine surface or corner and don't slide well on sloped surfaces in the direction of the chip conveyor. Gleason's power skiving machines operate wet to enhance chip evacuation and avoid chip accumulation as much as possible. On the large 400PS and 600PS machines, the vertical machine concept, together with a workholding concept that has been specially designed for improved chip evacuation, helps to move the chips down and away from the gear. In addition, the workholding is fushed with oil to keep it clean from the inside during the entire machining cycle, including loading/unloading. Improving Tooling Previous skiving attempts often proved impractical or failed altogether because of very poor tool life. This was the result of several different factors: Machining conditions were not ideal, there was no effective way to really understand cutting conditions for various process settings, and cutting tool substrates and coatings had not advanced to the levels they are today. Now, engineers from the Gleason Cutting Tool Corp. in Rockford, Ill.—together with application engineering at Gleason Pfauter, Ludwigsburg, Germany—have developed a new generation of power skiving cutting tools that consider the detailed requirements of the power skiving process. During this tool development, the results from the detailed simulations of the entire process along with the results from numerous cutting trials were incorporated into the new cutter design. This resulted in a successful design, generally similar to a shaping cutter, yet different in various important aspects. In many cases, the G50 PM HSS substrate is used which, in combination with Gleason's AlCroNite Pro advanced coatings, delivers the high hardness and toughness A new generation of power skiving cutting tools aims to increase production, extend service life and expand capabilities. 0314_MMS_Gear_RussFeature_EDIT.indd 10 2/13/2014 2:42:56 PM

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