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Faced with increasing tool quality requirements and rising tool cost pressures, the balance between quality, efficiency and cost is increasingly becoming the focus of production companies. In view of the continuous development of high-speed machine tools, high-speed milling, composite machining, and micro-shape cutting have become the main directions for the development of cutting technology. This paper introduces a number of the latest cutting tool technologies in combination with practical applications. They not only have their advanced nature, but also have strong practicality, reflecting the development direction of new manufacturing industries in the future.
The new concept of gear processing "deformation hob"
In close cooperation with customers and machine tool builders, LMT-FETTE and Liebherr Group jointly developed a three-in-one combination gear machining tool. It replaces the previous three-step machining process of roughing-deburring-shaving on different machine tools, a roughing hob, a deburring chamfering cutter and a finishing hob "deformation hob" (Twist-Free-Hob) is mounted on the same shank so that the three steps of roughing hobbing, flank chamfering and gear finishing can be done on the same machine.
Gear cutting and deburring are done on the same machine. All the tools are mounted on one shank without any additional manual or machine grinding, and no need to add deburring machines and tools. This is the most economical gear finishing, especially for mass production of gears of the same or similar specifications. Moreover, roughing and finishing hobs can also be designed independently, with optimized number of teeth, number of slots, and special tooth profiles. In this way, the roughing hob can use the fastest machining speed without having to take into account the final tooth profile quality of the workpiece. The finishing hob "de-forming hob" (Fig. 1), because it does not require a large number of single-re-grinding, the production lot is significantly larger than those of the hobs that are both rough and finished. By correcting the tooth profile error with a finishing hob, a spur gear and a helical gear with no tooth error can be machined. The hob uses a diagonal hobbing method to eliminate the tooth profile error while hobbing the allowance, providing higher gear load carrying capacity and smooth running.
Blue Flag has also developed gear chamfering tools to save the cost of removing gear burrs. The first chamfering cutter removes the burrs on the top of the gear and chamfers. The second chamfering knife removes the root burr and chamfers.
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