(Gear skiving package)

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Stuart Small
5 years ago
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1 Gear production by compact type general purpose machine e500h-gs (Gear skiving package)

2 e500h GS (gear skiving package) Integrated gear machining process into machining center Improved productivity by high peripheral speed machining Reduced size and weight Automatic programming function NCSFC & simple input Pursuing high reliability and ease of use Evolution of skiving technology

3 Machining principle of skiving method What is the skiving method? A method implementing gear machining by using the relative speed generated by inclining the tool relative to the workpiece and rotating them synchronously Cross angle φ Tool Workpiece Cutting speed V 2 Actual cutting speed V 3 Tool cutting speed V 1 Feed direction Tool cutting speed: V1 200 m/min Workpiece cutting speed: V2 170 m/min Index angle (cross angle): φ 30 Workpiece torsion angle: β 0 Workpiece Actual cutting speed : V3 100 m/min V3=V1 SINφ/COSβ This principle was proposed in Europe in the 1960 era, however the level of engineering at the time was low, and practical use was difficult.

Comparison of each gear cutting method Hob cutting Shaper cutting Broach cutting Skiving cutting Machining method Principle Meshes the workpieces through

gear by withdrawing a tool with gear-shaped blades arranged like a saw.

4 Comparison of each gear cutting method Hob cutting Shaper cutting Broach cutting Skiving cutting Machining method Principle Meshes the workpieces through rotation and feeds the tool to create the gear Creates gear by rotating the pinion cutter and workpiece at the specified speed, then reciprocating Creates gear by withdrawing a tool with gear-shaped blades arranged like a saw. Creates gear by inclining the cutter and workpiece axis and rotating synchronously at high speed. Shape Outer gear Inner gear 〇〇〇〇〇〇 Cutting performance Accuracy Cost CT 5 12 grades 5 12 grades 5 12 grades 5 12 grades (Special tool)

Incomplete gear shape Incomplete gear shape Hobbing

5 Merit of skiving Size reduction of product Shortening of incomplete gear shape section Size reduction Incomplete gear shape Incomplete gear shape Hobbing Skiving Contributes to size and weight reduction of the product

Merits of skiving Improved productivity Improved product strength Gear shaper V: 40-60 m/min

Gear shaper Recess section 3 5 mm Low product strength Skiving V: 100-300 m/min Depends on

6 Merits of skiving Improved productivity Improved product strength Gear shaper V: m/min Depends on feed axis. Gear shaper Recess section 3 5 mm Low product strength Skiving V: m/min Depends on rotating axis. 5 times the cutting speed with high machining ability Skiving No need for recess section High product strength Contributes to improved product strength

7 Integrated gear machining processes to machining center Merits of gear machining by machining center Machining process Lathe Hobbing Shaper Chamfering Drilling Conventional Machining equipment Lathe Hobbing machine Gear shaper Chamfering machine Machining center New technology Machining process Machining equipment Lathe + Skiving (gear cutting) + Chamfering + Drilling Machining center One chuck machining from lathing to gear cutting and drilling

Internal gear 30,000 sets/m Established element/control/tool/machining technology

8 JTEKT initiatives in skiving History of engineering development 2005 Began skiving engineering development 2006 Began production of gear parts Production results Internal gear 30,000 sets/m Established element/control/tool/machining technology Coupling 25,000 sets/m 2013 Skiving machining unit e500h-gs released Sun gear 25,000 sets/m

by high speed synchronization Simple programming function Machining engineering Optimum machining conditions Selects the optimum machining conditions according to the customer s

9 Necessary engineering for skiving method Element engineering High speed/high rigidity workpiece axis N=3,000 min -1 spec. Compaction by built-in motor Compatible with automatic hydraulic fixture Control engineering High speed/high accuracy gear cutting control TOYOPUC-MC70 High accuracy skiving control by high speed synchronization Simple programming function Machining engineering Optimum machining conditions Selects the optimum machining conditions according to the customer s product Skiving Tool engineering Low resistance tool design Tool design based on JTEKT original gear creation theory We independently develop the engineering necessary for skiving and provide all equipment, controls, tools and machining conditions.

5 sec Supporting multiple applications Hydraulic fixture Automation High reliability Chip processing ability Structure is easy

10 Pursuing high reliability and ease of use [Correspondence to mass production] This JTEKT machining center base has been installed in many parts production lines and is capable of: High productivity High speed Rapid feed: 60 m/min ATC : C-C 2.5 sec Supporting multiple applications Hydraulic fixture Automation High reliability Chip processing ability Structure is easy to maintain Center trough Largest possible chip drop port is secured directly under the cutting point. Bed structure does not accumulate chips.

Pursuing high reliability and ease of use [Human-friendly

make line layout Operator door opening up to the ceiling

11 Pursuing high reliability and ease of use [Human-friendly cover shape] No square and cumbersome protrusion Easy to make line layout Operator door opening up to the ceiling Well-lit No coolant drip Short distance from machine front to pallet center. Comfortable work posture Machine structure and cover shape designed with consideration to work easiness

High speed, high torque built-in motor e500h-gs Achieves torque full machining from low speed to high speed (3,000 min -1 ) through adoption of constant torque servo motor.

12 High speed rotation lathing spindle unit e500h-gs Skiving machine B 軸 B axis Large dia. high ability bearing with high accuracy, high rigidity and low rising temperature Enables both high load and low rising temperature by adoption of large dia. ceramic balls. High speed, high torque built-in motor e500h-gs Achieves torque full machining from low speed to high speed (3,000 min -1 ) through adoption of constant torque servo motor. JTEKT-made distributor with multi port correspondence to high peripheral speeds Achieved total length compact distributor with air press. 2-port, hyd. 2-port and application of high peripheral speed (3.9 m/s) seal. C 軸 A axis Hydraulic type draw bar compatible with auto chuck (detachable) Achieved size reduction of total length through storage in the hollow type spindle. Developed lathing spindle unit (3,000 min -1 ) with high speed and high rigidity

13 JTEKT CNC TOYOPUC-MC70 JTEKT CNC achieving skiving principle Compared with conventional CNC MC50. 1 High performance CPU Achieves high skiving accuracy with high calculation ability. Cuts waste time and raises net rate. Memory メモリ Floating 浮動小数点演算 decimal point calculation CPU benchmark (score) Integer 整数演算 calculation Measuring tool: CrystalMark Ver ALU value 10 times the performance ratio MC50 MC70 Good (Score) CNC TOYOPUC-MC70 2 Optimum program management Gives priority to the important processing that influence cycle time. Achieves effective CNC processing. PLC TOYOPUC-PC10EL Servo I/F MECHATROLINKⅢ 3 Multibus Servo communication is not influenced by PLC communication and synchronization performance has been significantly increased. CNC MC50 Single bus PLC Servo I/F CNC TOYOPUC MC70 Communication speed : 4 times Multibus PLC Servo I/F

JTEKT CNC TOYOPUC-MC70 Simple programming NCSFC Flow display possible to understand the flow of machining Simple programming through input of gear data and

[mm] Outer/inner teeth Outer: 1 Inner: -1 Tool data Tool amount Tool torsion angle [ ] Tool dia.

14 JTEKT CNC TOYOPUC-MC70 Simple programming NCSFC Flow display possible to understand the flow of machining Simple programming through input of gear data and tool data cutting condition to the screen Gear data Workpiece teeth amount Teeth torsion angle [ ] Module [mm] Material dia. [mm] Outer/inner teeth Outer: 1 Inner: -1 Tool data Tool amount Tool torsion angle [ ] Tool dia. [mm] Cutting condition Cutting width [mm] Margin [mm] Cross angle [ ] Cutting speed [m/min] Tool feed amount [mm] Y axis travel speed [mm/min] XZ axes return travel speed [mm/min] Part axis rotation dir. CW: 1 CCW: -1 Offset angle offset dir. add: 1 subtract: -1

15 Lathing function by machining center Second spindle function (lathing spindle) High speed rotation lathing spindle compatible with automatic hydraulic fixture Can lathe using machining center by equipping the high-speed lathing spindle

Tool to be fabricated Calculates cutting resistance Tool

16 Skiving tool Tool designing Workpiece Machining accuracy Workpiece Tool path Cutter Machining simulation Optimization Tool to be fabricated Calculates cutting resistance Tool blade shape Skiving tool JTEKT developed the skiving tool in-house

17 Evolution of skiving engineering Evolution of simulation engineering and control engineering High accuracy Tool position compensation reducing machining errors Highly functional skiving tool design engineering reducing cutting resistance Arbitrary tooth shape of inner and outer teeth and tooth trace shape control

Target workpieces Range of target workpieces Gear type Outer 外歯 teeth Inner 内歯 teeth 歯車種類 Gear type 平歯車内歯歯車ハスハ歯車スフライン Spur gear / internal gear / helical gear / spline 対象ワークサイズ Target workpiece

18 Target workpieces Range of target workpieces Gear type Outer 外歯 teeth Inner 内歯 teeth 歯車種類 Gear type 平歯車内歯歯車ハスハ歯車スフライン Spur gear / internal gear / helical gear / spline 対象ワークサイズ Target workpiece size φ30~φ220mm φ50~φ200mm Total 全長 length 100mm 以下 or less 最大モジュール Largest module ワーク材質 Workpiece material 加工精度 Machining accuracy ( 参考 (reference) ) 2.5 Ferrous 鉄系材料 materials ((before 焼入前 hardening) ) Equivalent JIS N7 to 級相当 JIS grade N7

Machining example 1 Example of high productivity Conventional Lathe Hobbine machine Shaper Deburring machine Machining center Now Workpiece Machining center Module 1 Inner teeth Machining results

19 Machining example 1 Example of high productivity Conventional Lathe Hobbine machine Shaper Deburring machine Machining center Now Workpiece Machining center Module 1 Inner teeth Machining results Machining time m 2.4: 30 sec. m 1.0: 10 sec. Machining accuracy (m 2.4) Tooth shape: 12.8 µm JIS grade N7 Tooth trace: 3.8 µm JIS grade N4 Module 2.4 Outer teeth Effect 70% reduction Production volume: 4,500/month 70% reduction Side gear Material: SCM415 Size: Φ81 41 mm Equipment cost Conventional Now Equipment expense Machining cost Conventional Now Machining expense

20 Machining example 2 Example of large module (M 3.5) Workpiece Internal gear component Machining conditions Cutting speed: 150 m/min Feed: 0.15 mm/rev Machining time: 80 sec. Effect % reduction 85% 削減 Workpiece O.D.: Φ98.5 mm Module: 3.5 Material: SCM415 Conventional (Shaper) 60 Now (Skiving)

Machining example 3 Example of high accuracy machining Test piece Material: SCM440 Size: Φ190 20 mm

15) Enlarged image of internal teeth Machining specifications Module (mm) No. of teeth Pitch circle dia.

21 Machining example 3 Example of high accuracy machining Test piece Material: SCM440 Size: Φ mm Machined part: Internal teeth (Module 1.15) Enlarged image of internal teeth Machining specifications Module (mm) No. of teeth Pitch circle dia. Helix angle ( ) Helix direction Right Tooth shape accuracy Machining results Machining time (sec.) Tooth shape accuracy (µm) Tooth trace accuracy (µm) Tooth trace accuracy

HIGH-SPEED AXIS SYNCHRONIZATION

HIGH-SPEED AXIS SYNCHRONIZATION Redefining Gear Manufacturing Presenter: Mr. Will Terry Proposal Engineer, Automotive HISTORY OF SKIVING The first power skiving patent was filed in 1910, however, skiving