Gear Production

SEP 2015

Gear Production

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September 2015—15 features run true to the gear teeth. Plus, the same multitasking machine that power skives a gear one day can machine completely different, non- geared components the next. The Power Skiving Process Dedicated skiving systems are fast, but multitasking machines are much more cost- effective in comparison, especially when they eliminate the need to farm out occasional gear work. By keeping gear cutting in-house, shops also gain complete control over part processing, as well as delivery times, because outside vendor turnaround times are no longer an issue. Prior to its power skiving applications development, Mazak showed how larger sized fve-axis multitasking vertical machining centers could cost-effectively and quickly produce those occasional, low-volume spiral bevel gear sets in- house. Mazak machined a spiral bevel gear set that included a 29-tooth, 22"-diameter pinion gear and a 114-tooth, 6-foot-diameter ring gear on one of its Integrex e-1550V/10 multitasking fve-axis machining centers. This gear set was completed in days as opposed to months, and using only the one machine. Power skiving is a gear shaping process in which cutting tools are shaped like gear teeth. The tools spin and mesh with workpieces to generate the gear teeth geometry, and it is this meshing that creates the gear teeth profles. For its skiving process development, Mazak also used Integrex series multitasking machines. The models included the e-420 and i-200, both with B-axis milling spindles and C-axis turning spindles, and the Integrex i-630 with a B-axis milling spindle and C-axis table. The machines successfully power skived gears of all sizes and types, including standard and ID splines in both straight and angled teeth patterns. These machines could also power skive spur gears or helical gears. Seeking Synchronicity Synchronization and proper cutting ratio are key in power skiving. During the operation, the workpiece—whether mounted on a table or in a turning spindle—rotates in synchronization with that of the skiving tool. Rotation of the two also happens at a specifc ratio dictated by the Multitasking machines are more cost-effective than dedicated skiving systems, eliminating the need for some shops to subcontract their gear work while providing complete control over pro- cessing, delivery and quality.

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