~) / 7&0. Gleason No. 610 Universal Hypoid Gear Machine

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1 ~) / 7&0 Gleason No. 610 Universal Hypoid Gear Machine

2 Gleason No. 610 The No. 610 Universal Hypoid Gear Machine sets new standards in precision high speed roughing and finishing of medium and large non-generated hypoid and spiral bevel gears. The No. 610 Machine offers many production advantages where quantities are insufficient to justify separate roughing and finishing machines. Designed primarily for use in the truck tractor and off-the-road equipment field, the No. 610 accommodates gear members up to 20" in diameter and a minimum ratio of 2% to 1. Maximum whole depth is 1.000". Gleason No. 610 advantages range of cutting methods The No. 610 Machine can produce non-generated gears using a wide range of cutting methods: the Equicurv* Method employs a double index arrangement, the Helixform method utilizes an axial advance of the cutter as each blade traverses the tooth slot. Non-generated gears can also be cut by the Formate, Single Cycle and Cyclex Methods. the Equicurv* method The Equicurv* method is a recent development for high production of non-generated Equidep* spiral bevel and hypoid gears. Equidep is the generic name applied to Gleason spiral bevel and hypoid gears with constant depth teeth cut with relatively small diameter cutters. Initial trials indicate the following advantages for these gears: simplified calculations, true conjugacy and m1mmum development, stability of tooth contact under load, quiet operations, high strength, range of axial adjustment in assembly, minimum effect of heat treatment on tooth contact. The Equicurv cutting method affords a procedure whereby equalization of tooth thickness taper is obtained between the gear and pinion member. *trademark 2 GEAR BOTTOM I GEAR TOP (Pinion Bottom ~ ~ ~ \-xi ffiv:~ 7\atmR EQUALIZED SLOTS ON PINION AND GEAR WHEN EQUID P GEAR IS PRODUCED BY THE EQUICURV METHOD A Figure A shows the equalized slots produced by the Equicurv method. The taper is not removed but divided between the pinion and gear. The gear slot is tapered because the cutter center is at position 1 for cutting the convex I GEAR TOP (Pinion """"--\lll.ll\\\11\11lln>l t \ '\, I \ / \, / )(: small PINION SLOT WIDTH AT THE TOE WHEN THE EQUIDEP GEAR IS CUT SPREAD BLADE B side and at position 2 for the concave side. Where an Equidep gear is cut Spread-Blade, as shown in Figure B, the same cutter position is used for both sides and the resulting tooth slot taper is all on the pinion member.

3 minimum development Equicurv gears can be easily produced with any desired tooth bearing. Because they are conjugate with their mating pinion, quiet operating Equicurv gear sets are obtained directly from calculated settings. Refinements for particular applications are made with only minor subsequent changes. long gear life The Equicurv method produces, in the initial cut, a rectangular tooth bearing which, under a constant load, is longer when positioned at the toe than when positioned at the heel. But, as the load on the pair of gears increases, the bearing tends to lengthen and move slightly from the toe to the heel. Thus, as the load on an Equicurv gear set is increased, the length of the bearing remains relatively constant and its position moves slightly towards the heel. These are the basic characteristics for long gear life and quiet operation. complete tooth bearing control Depending on the selected cutting method, the No. 610 Machine provides complete controls which permit the introduction of the necessary tooth bearing modifications which may be necessary to compensate for heat treat distortions and mounting deflections. The machine settings are quickly made with precision setting bars and an indicator assembly. high quality The Gleason No. 610 Machine produces large spiral bevel and hypoid gears with the ultimate in quality of tooth shape, spacing and finish. Rigidity is improved by design features including an overhead tie which clamps the cutter head and work head together, and a work spindle clamp which provides solid unity of the work spindle and work head. In addition, the machine is designed so that cutting always takes place in the lower quadrant of the gear. The roughing cycle yields excellent quality roughed gears with minimum stock left for finishing, further contributing to production of the highest quality finished gears. increased production Production rates are increased over 100% by a new high speed hydraulic index mechanism, increased machine rigidity, and an improved loading arrangement. Ease of setup and workhandling also contribute to production speed. Simplified, inexpensive setup bars reduce setup time to a minimum and a level load work head provides convenient loading of the gear blanks. An optional crane for cutter and workholding is available for increased handling ease of both cutter and gear blank, further reducing machine downtime. longer cutter life A superior coolant system provides an increased flow of coolant, controlled and directed for the most effective heat removal. This, together with the rigid machine design, increases cutter life on the No. 610 Machine. ease of set-up Four simple adjustments accurately relate the cutter and work. The summary settings are quickly obtained through precision setting bars and indicator assembly. They can be used to set any number of machines to produce identical gears. Scales, verniers and setup fixtures are eliminated. 3

4 Gleason No. 610 features Equicurv double index level load work head STOCK REMOVED WITH OUTSIDE SEMI FINISHING AND FINISHING BlADES THE EQUICURV CUTTER SCHEMATIC OF STOCK REMOVAL ON GEAR BY THE EQUICURV METHOD level load position The recently developed Equicurv method divides tooth thickness taper of Equidep gears between the gear and the pinion. In order to introduce taper into the gear slot, the Equicurv method separates the cutting of the concave side (outside blades) from the cutting of the convex side (inside blades). This is done by arranging the outside blades on one section of the cutter periphery and the inside blades on another, with a gap between (as shown). In this gap, a second index introduces taper into the gear. This is obtained by using an index plate with twice the number of teeth as the gear being cut and a special timing arrangement. work advance 4 cutting position

5 When the work head is in the horizontal "level-load" position, the work can be rapidly and conveniently loaded. This feature provides the added benefit of safety since the work spindle is widely separated from the cutter when the work is mounted or removed. Once the work is chucked, the work head is raised to cutting position, the overhead tie is clamped, and cutting begins. When the last tooth is finished, the clamp is released and the work head is returned to the "level-load" position. index mechanism INDEX AND GENEVA PLATE GENEVA INDEX DRIVE INDEX DRIVE HOUSING POWER } The new unique index mechanism, located in the work head, is hydraulically operated by means of an index rotor piston which operates in a timed relation with the continuously rotating cutter. When the last cutter blade clears a tooth slot, hydraulic pressure advances the index drive clutch so that it engages a clutch connected to the index rotor piston. This motion forces oil into the shuttle valve moving it to the forward position, disengaging the lockup pawl from the index plate. The work spindle clamp is unlocked through a shuttle valve exhaust as pressure is placed on the index rotor piston. As the rotor piston is rotated through 1800, one Gerieva pin engages a Geneva slot and rotates the work spindle through one tooth index. 5

6 No. 610 features chamfering attachment and deburring unit precision stock division overhead tie i During roughing optional chamfering attachments, one for inside chamfering and the other for outside chamfering, are available for the No. 610 Machine. The new simplified tooth chamfering units consistently produce a well proportioned chamfer. While finishing, an optional deburring unit is mounted on the workhead and provides a quick and efficient means of removing the burr from the root of the finished tooth slot, thereby eliminating a separate deburring operation. automatic chip removal Coolant oil and chips are flushed into a well in the machine frame. Here a rotating screw-type chip conveyor removes the chips and deposits them in a location for convenient removal. A constant flow of coolant oil is assured, coolant loss is reduced to a minimum, and cleaning of the machine bed is eliminated. A stock dividing gage provides convenient stock division of the roughed gear while the work head is in the horizontal load position. The gage probe is manually pressed into a tooth slot. An indicator light signals when the gear is precisely stockdivided. The gear is then chucked and the work head raised to cutting position. This machine is equipped with an electrical interlock system which insures that the cutting cycle cannot begin until the gear has been properly stock-divided. Therefore, no damage can occur to the cutter or work resulting from improper positioning of the rough cut gear on the work spindle. An overhead tie provides a fixed relationship between cutter and work. When the work head is raised into cutting position, the tie is hydraulically clamped; hydraulic pressure on the clamp is maintained throughout the cutting cycle. work spindle clamp A new hydraulic mechanism rigidly clamps the work spindle to the housing, providing increased rigidity during cutting and leading to improved surface finish and tooth spacing. The clamp is automatically released when the work is indexed and automatically locks again after indexing. 6

7 vertical cutting forces cutter drive mechanism In addition to the work spindle clamp and the overhead tie, rigidity in cutting and high quality are assured as the cutting forces are directed vertically downward against the machine bed. When the work head is raised into cutting position, the rotating cutter contacts the work so that the blades pass down through the tooth slot located at the lowest point on the roughed gear. 1. Cam Angle Bracket. 2. Modifying Cam Angle Bracket. 3. c-e rougher change gears. 4. c-d finisher change gears. 5. Modifying Cam. 6. Formate roughing cam (shown) replaced by Equicurv disc for finishing. C E 7. Drive gear and pinion. 8. Cutter spindle. 9. Cutter. 10. Drive motor: 11. Speed Change Pulleys. 7

8 Gleason No. 610 specifications capacity Outside cone distance Maximum Minimum Maximum gear pitch diameter (16" dia. cutter, 300 spiral angle) Cutter diameters* Whole depth Root angle Face width Extreme ratio (minimum) Number of teeth work spindle Diameter of taper hole at large end Taper per foot Depth of taper feeds and speeds Cutter speeds (per minute) for roughing Feeds (seconds per tooth) for roughing Cutter speeds (per minute) for finishing Feeds (seconds per tooth) for finishing electrical equipment Main motor 10 HP (2 speed) 5 HP Hydraulic motor 3 HP Coolant motor 2 HP Magnetic chip separator Ys HP miscellaneous Floor space Height Weight Net Gross English 10" 4" 20" 9" to 18" 1.000" 3" 8' to 200' 30' to 100' 50 cycle 1800 RPM 900 RPM 1200 RPM 3600 RPM 1800 RPM *Machine can also be arranged for 5", 6" and 7%" cutters. standard equipment Work spindle bore 32% 4 " x 1;2" taper x %" long. Index arrangement for one part (less index and Geneva plate). Stock divider. Complete electrical equipment for 3 phase, 50 or 60 cycle, alternating current. SO 2172A-SEPT. '65-.oiM 60 to 80 2% to Metric 254mm 102mm 508mm 229 to 456mm 25.4mm 76mm 24m- 61m 9m- 30m 60 cycle 1500 RPM 750_RPM 1000 RPM 3000 RPM 1500 RPM 118" X 86%" 3000 x 2200mm 70" 1780mm 16,500 lbs. 7,483 Kg. 17,500 lbs. 7,937 Kg. extra equipment Index and Geneva plate. Geneva pin plates. Modifying cam. *Chip conveyor. Cutter length and reset fixture. Machine setting indicator assembly. Machine setting bars for roughing and finishing. One pair of change gears to arrange machine for one additional feed. Additional pulleys and change gears. Chamfering attachment less tool. Deburring attachment. Cutter and work handle crane. Cutter handling device. *No provision for manual removal of chips. operation roughing cycle The gear blank is mounted on the work head, which is in the horizontal loading position. The operator chucks the blank and raises the work head to cutting position. (Both functions are completed hydraulically by a simple hand valve). The overhead tie is then locked automatically and the start button pressed. Each gear tooth space is rough cut, as the cutter feeds into the work. When full tooth depth has been attained and the tooth slot completed, the cutter is then withdrawn to permit indexing. After the last tooth is cut, the machine stops automatically, the overarm tie is unlocked, and the workhead is returned to the horizontal position for unloading. finishing cycle After a complete lot of gears has been rough cut, the machine is easily converted to the finish cutting method desired. The system is fully protected by safety circuits so the machine cannot be started before the conversion is completed. A roughed gear is then mounted, stock-divided, chucked on the level-load workhead, the head is raised to cutting position and the overhead tie is hydraulically clamped. One tooth slot is finished with each revolution of the continuously rotating cutter. When the last tooth slot has been finished, a single lever is employed to simultaneously release the overhead tie, return the workhead to horizontal position and dechuck the work. Printed in U. 5. A.

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