Gear Production

MAR 2014

Gear Production

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March 2014—19 Once the correct M dK or M dR values are achieved, compensate for tool defection with the tool defection adjustment formula (Figure 2). Disc Cutters at Work in Spline Operations: A Case in Point Let's compare an inserted disc cutter, in this case, the CoroMill 172 mentioned earlier, with a HSS tool when roughing and fnishing an external spline on a low alloy steel (16MnCr5) shaft. Spline data for this operation was at DIN 5480 using module 5 (similar in size to an ANSI 5/10) at 26 teeth (z). To achieve the desired result, the HSS tool required two roughing passes and one fnishing pass at 165 fpm cutting speed at a 0.003-inch programmed feed per tooth. The second roughing pass was needed because the hob was supported on only one end. The inserted disc cutter, however, completed the same operation with a single, much faster roughing pass of 540 fpm at 0.008-inch feed per tooth and a fnishing pass of 640 fpm at 0.007-inch per tooth. The resulting cycle time for the HSS tool was 250 minutes, compared with 20 minutes for the CoroMill 172. This disc cutter generates gear profles in accordance with DIN 5480 for splines (DIN 867 for gears), and executes both internal and external machining of splines, gears and racks. In addition to applications on multitasking machines, this cutter can be used on machining centers and turning centers, as well as applications on traditional hobbing machines. The CoroMill 172 covers a range of modules from 3 to 10 (DP 8/16 – 2.5/5). A new, smaller version covers modules 0.8 to 3 Different disc cutter styles are available for various spline applications and different spindle interfaces. Whatever style cutter body is chosen, the ability to swap out different indexable insert profles on a single cutter body enables it to achieve different depths, root confgurations and tip chamfers. (DP 32/64 – 8/16). This smaller cutter accommodates the smallest feasible inserts, so it is suitable for a range of splines used on the lighter side of heavy vehicles, such as buses and large trucks. However, splines can be found in almost any industry for which gearboxes or transmissions are needed. The world of heavy vehicle manufacturing is increasingly subject to the same pressures bearing down on the automotive industry, most notably the push for fexibility and more short runs for small- to medium-batch sizes. This trend is compelling more shop owners to bring spline manufacturing back in-house. The opportunity to use disc cutting technology on traditional CNC machines—lathes, machining centers and multitasking machines—is attractive because long-standing barriers have been broken. About the author: Aaron Habeck is a marketing project manager at Sandvik Coromant in the United States. 0314_MMS_Gear_MarkFeature.indd 19 2/13/2014 2:45:07 PM

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