HIGH-SPEED AXIS SYNCHRONIZATION

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Anastasia Ford
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1 HIGH-SPEED AXIS SYNCHRONIZATION Redefining Gear Manufacturing Presenter: Mr. Will Terry Proposal Engineer, Automotive

2 HISTORY OF SKIVING The first power skiving patent was filed in 1910, however, skiving s fullest potential would not be seen for about 100 years. Only after a decade s worth of innovations were machines able to overcome the challenges attributed to the mechanical implementation of skiving - making actual production practical. Prior to 1986, when Pfauter first successfully implemented this process, machines simply weren t capable of minimizing the vibrations caused by high spindle rpms and counteracting the cutting forces generated by skiving.

TOYODA + AXIS SYNCHRONIZATION 1986 GCH32 (Sync Speed: 250 rpms) Cam Lobe Grinder. Synchronized The Rotation Of The Cam Shaft (C Axis) With The Grinding (X Axis) Motion To Make A Cam.

3 TOYODA + AXIS SYNCHRONIZATION 1986 GCH32 (Sync Speed: 250 rpms) Cam Lobe Grinder. Synchronized The Rotation Of The Cam Shaft (C Axis) With The Grinding (X Axis) Motion To Make A Cam. Upgraded from mechanical system and a master part that was slow and prone to failure The GF70M (Sync Speed: 250 rpms) Pin Chasing Machine. Never before seen axis synchronization precision. Pin journal roundness capabilities of microns. The latest model, GF50 (sync speed 500 rpms), is capable of 0.6 microns roundness in high volume production environments Gear Skiving (Sync Speed: 3000/6000 rpms) HMCs. Award-Winning Multipurpose Horizontal Machining Centers released to open market.

5 SYNCHRONIZATION ACCURACY

6 AXIS SYNCHRONIZATION SPEED At 500 RPMs: 3,600 Offsets / Revolution 2 Wheel heads Equals 18,000,000 Offsets / Minute Equals 300,000 Offsets / Second

cutting action generated by the relative speed between the tool and

7 Tool WHAT IS SKIVING? Workpiece Feed Direction Occurs when gear teeth are machined with a cutting action generated by the relative speed between the tool and the workpiece while the two are tilted relative to one another and rotated synchronously. Tool Cutting Speed: V1 200m/min Workpiece Cutting Speed: V2 170m/min Intersecting Angle: φ 30 Workpiece Twist Angle: β 0 Actual Cutting Speed:V3 100m/min V3=V1 SINφ/COSβ

8 COMMON GEAR CUTS HOBBING SHAPING BROACHING

9 SKIVING

10 CYCLE TIME REDUCTION Cutting Speed: 2 to 5 Times Faster SHAPING SKIVING V: 40 to 60 m/min V: 100 to 300 m/min

Compact components must be assembled adding expense and time consuming secondary operations.

11 Incomplete Gear Shape SIMPLIFIED COMPONENT MANUFACTURING HOBBING SHAPING Low Product Rigidity The size and shape of the hobbing tool dictates part geometry. Compact components must be assembled adding expense and time consuming secondary operations. Recess Section: 3 5 Mm Shaping works very close to the shoulder. An undercut in the part is necessary for chip evacuation which can compromise strength of the part.

12 SIMPLIFIED COMPONENT MANUFACTURING Components can be made in fewer pieces eliminating the need for assembly Undercuts are not necessary for the skiving process.

Cam and crank driven shapers have additional efficiency issues derived solely from their

13 SHAPER INEFFICIENCY In shaping, due to necessary cutter geometry, the return stroke is a non machining move. 50% of the machine s motion is unproductive motion. Cam and crank driven shapers have additional efficiency issues derived solely from their construction. The speed at the cutter tip is constantly variable limiting the efficacy of process optimization.

14 PROCESS INTEGRATION 1) 2) 3) 4) 5) 6) 7) 8) 9) Ramp Up Production Affordably Increase Uptime Eliminate Runout Errors Eliminate Concentricity Errors Ease Of Process Improvement Reduce Spare Parts Inventory Reduce Operator Training Costs Reduce Maintenance Training Costs Reduce Load / Unload Time

15 NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: REQUIRED EQUIPMENT TURNING HOBBING SHAPING CHAMFERING MILLING Lathe Hobbing Machine Gear Shaper Chamfering Machine Machining Center Turning+ Hobbing+Shaping+Chamfering + Milling = All In One Machine A One-Chucking Process from Start to Finish

Inside teeth are Shaped 60 SECONDS Other features are Milled 30 SECONDS All 4

16 NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: SAVING TIME 60 second Cycle time per piece The part is Turned 30 SECONDS Outside teeth are Hobbed 30 SECONDS Inside teeth are Shaped 60 SECONDS Other features are Milled 30 SECONDS All 4 operations are completed in one chucking, on one machine, With the same 60 second takt time

NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: MINIMIZING RISK MACHINE RUNNING MACHINE RUNNING MACHINE DOWN MACHINE RUNNING Whole Line is Down = 100% Loss of Production

17 NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: MINIMIZING RISK MACHINE RUNNING MACHINE RUNNING MACHINE DOWN MACHINE RUNNING Whole Line is Down = 100% Loss of Production MACHINE RUNNING MACHINE DOWN MACHINE RUNNING ONLY 33% LOSS OF PRODUCTION Common Down Time Causes: Tool Change Cleaning Breakdown Training Preventative Maintenance Process Improvement

18 NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: SPARE PARTS INVENTORY Tooling Spare Parts Tooling Spare Parts Tooling Spare Parts Tooling Spare Parts Each machine in this line needs dedicated tooling and spare parts specific to each machine No matter how many machines you have in this line, all of the spare parts are the same and the tooling is the same. Spare parts inventory can be dramatically reduced without exposure to catastrophic line failure.

19 NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: TRAINING COSTS Maintenance Training: 320 Hrs Operator Training: 320 Hrs Maintenance 80 hrs Operator 80 hrs Maintenance 80 hrs Operator 80 hrs Maintenance 80 hrs Operator 80 hrs Maintenance 80 hrs Operator 80 hrs Total Training: 640 hrs Consider one team of 2 operators and one team of 2 maintenance members training for one 40 hour week Maintenance Training Total: 80 Hrs Operator Training Total: 80 Hrs Total Training: 160 hrs

NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: INCREASING PRODUCTION If you need to increase capacity by as little as 20% you must add a new

20 NEW TECHNOLOGY CURRENT PROCESS PROCESS INTEGRATION: INCREASING PRODUCTION If you need to increase capacity by as little as 20% you must add a new line. Investment is high. If you need to increase capacity in a parallel line simply add a new machine. Ramp up is quick, simple and cost effective.

21 MACHINE FEATURES WIDE PART RANGE 220mm 30mm 700mm GS300H External 30mm 220mm * Internal 50mm 200mm GS700 External 250mm 700mm Internal 250mm 700mm *Max 300mm. Adequate clearance must be confirmed

22 MACHINE FEATURES HIGH SPEED AXIS SYNCHRONIZATION GS200 6,000 rpm Tool 3,000 rpm Work GS300 6,000 rpm Tool 3,000 rpm Work GS700 6,000 rpm Tool 1,000 rpm Work

23 CONTACT INFORMATION Will Terry Proposal Engineer, Automotive

BPG Blade Profile Grinder reduces sharpening costs for bevel gear cutter blades

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