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GEAR CUTTING BY MILLING TECHNOLOGY

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Core competences:

Helical gears

Double helical gears

Spur gears

Internal gears

Straight bevel gears

All-in-one solution is what we do

Drawing Software CAM model

Simulation Complete machining Finished components

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Productivity & machine price

Gear cutting of spur gear sample: diameter = 5 640 mm, m = 30 mm, z = 186 mm, b = 500 mm

Type of machining Machine Total time (hrs)

Machine price (%)

Hobbing Old conventional hobbing machine from ´60s 602

CNC milling (including finishing) CNC milling machine 158 100%

CNC hobbing CNC Gear hobber 24 200%

Total time (hrs) Machine price (%)

Wider using possibilities

CNC hobbing machine

CNC milling

machine

Gear cutting

Gear cutting Power industry Railway industry Aerospace industry Construction industry Mining industry Shipbuilding industry Defence industry Other industry areas

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Benefits of using the TOS KURIM CNC gear milling

machine towards the CNC hobbing machine

The same machine can be

used for all types of toothing

– helical, spur, herring-bone,

Bevel and internal teeth

Teeth can be rough with

high strength of up to

400 HB

Standard tools is

possible to buy within

several days, compared

with delivery times of

roughening tools for

hobbing machines,

which are between 12

and 18 weeks

The machine can be used

without any modifications

as a standard horizontal

boring machine or a

machining centre, without

any further adjustment

» » » » » » wider using

possibilities

Cutting tools are much

more cheaper then special

cutting tools for hobbing

machines

Standard tools use

exchangeable inserts

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Benefits of using the TOSKURIM CNC gear milling

machine

The whole gear manufacturing process is managed by a software suite, exclusively developed in partnership with HAVLIK GEAR ,that gives control on all phases

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3D simulation, easy gear modification, machining time calculation and finally selection the most efficient manufacturing strategy are the main features of the TOS KURIM gear milling solution

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TOS KURIM CNC gear milling machine

The solution is recommended for gear diameter 4 – 10 m or more with the below guaranteed accuracy

Accuracy per ISO 1328 3 4 5 6 7 8 9 10 11

Accuracy per DIN 3962 1 2 3 4 5 6 7 8 9 10 11 12

Accuracy per AGMA 16 15 14 13 12 11 10 9 8 7 6 5

Accuracy per JIS 0 1 2 3 4 5 6 7

Max roughness Ra [nm]

0,1 –

0,2 0,4 0,8 1,6 1,6 3,2 6,3 12,5 25

Max gear speed [m/s] 80 60 35 15 8 5 3 3 3

Max gear speed – helical gears [m/s] 100 80 50 30 12 8 5 3 3

TOS KURIM CNC gear milling machine

(Grinding machine)

Milling

Indicative table for choosing the degree of accuracy by identifying the area of determining the degree of accuracy

Area Accuracy ISO Accuracy AGAMA Control gears 2 - 4 13 - 12 Measuring Devices 3 - 6 13 - 10 Turbine gearboxes 3 - 5 13 - 11 Aicraft gearboxes 3 - 6 13 - 10

Machine tools 3 - 7 13 - 9 Aircraft engines 5 - 6 11 - 10 Speed gearboxes 5 - 6 11 - 10 Automobiles 6 - 7 10 - 9 Industrial gearboxes 7 - 8 9 - 8 Light ship engines 7 9 Rolling mills, locomotives 8 - 9 8 - 7 Heavy marine engines, tractors 8 - 9 8 - 7 Construction and agricultural machinery 8 - 10 8 - 6 Textile machinery 7 - 9 9 - 7

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Havlik Machinery, Canada

Machine: FUQ 150 VR/11 Type: Floor type machining centre Commissioning: 8/2006 Basic parameters: X = 11 000 mm, Y = 1 500 mm , Z = 2 500 mm Power: 30 kW End user: Companies all around the world

The Havlik companies have been in the gear manufacturing related business for over 100 years. Main business emphasis is on open gearing, special gearing, replacement gearing, bevel and worm gearing, gear units and gear grinding of all sizes

Z =

2 50

0 m

m

CNC rotary table

Machine is equipped with automatic interchangeable milling heads: two axis head type VK, universal head type VO, straight head type VA1, customized head type VZ1

Rotary table type CES: table size: 2 000 x 2 500 mm, linear axis: v = 2 250 mm, loading capacity: 25 t

Clamping plates: size: 6 400 x 1 885 x 400 mm, size: 2 000 x 2 000 x 400 mm

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Havlik Machinery, Canada

Machine: FUQ 150 WR/9

Type: Floor type machining centre

Commissioning: 1/2008

Basic parameters: X = 9 000 mm, Y = 1 500 mm , Z = 2 500 mm

Power: 30 kW

End user: Companies all around the world

CNC rotary table

Machine is equipped with shift-out quill ø 170 mm, W = 400 mm and additional milling head type IPS

Two rotary tables type CES: table size: 2 000 x 2 500 mm, linear axis: V = 1 250 mm, loading capacity: 25 t

Z =

2 50

0 m

m

CNC rotary table

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Interchangeable milling heads used by Havlik

company

Two axis head type VK Universal head type VO Straight head type VA1

Max. torque: 1 000 Nm

Spindle speed: 4 000 rpm

Motor output: 30 kW

Max. torque: 1 250 Nm

Spindle speed: 4 000 rpm

Motor output: 30 kW

Max. torque: 2 000 Nm

Spindle speed: 4 000 rpm

Motor output: 30 kW

Special interchangeable milling head VZ1

for internal gear cutting

Max. teeth width

Type VZ1 Units Max. torque 630 Nm Spindle speed 4 000 rpm Motor output 30 kW Spindle taper ISO 50

Clamping automatic Cooling Low + high pressure

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Vítkovice Gearworks, Czech Republic

Machine: FUQ 150 – VR/14

Type: Floor type machining centre

Commissioning: 11/2007

Basic parameters: X = 14 000 mm, Y = 1 500 mm , Z = 2 200 mm

Power: 30 kW

End user: Companies all around the world

Machine is equipped with automatic interchangeable milling head:

universal milling head type VO

Clamping area:

two clamping plates: 6 400 x 1 885 x 400 mm, rotary table type ISN 1 000

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External gear cutting – double helical gears

Double helical gears, overcome the problem of axial thrust presented by "single" helical gears, by having two sets of teeth that are set in a V shape. A double helical gear can be thought of as left hand and right helical gears joined together. This arrangement cancels out the net axial thrust, since each half of the gear thrusts in the opposite direction. Big advantage of milling machines is the possibility of machining both sides (left and right hand) at once.

Double helical gears are more difficult to manufacture due to their more complicated shape. The teeth can be aligned at an apex or they can be staggered. The machine controls the alignment of teeth accurately.

Minimization of idle times

For watching movie use the QR Code

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External gear cutting – single helical gears

Helical gears can be meshed in a parallel or crossed orientations. The former refers to when the shafts are parallel to each other; this is the most common orientation. In the latter, the shafts are non-parallel, and in this configuration are sometimes known as "skew gears".

For watching movie use the QR Code

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External gear cutting – spur gear

The spur gear profile is the most commonly used system for gearing today. In an involute gear, the profiles of the teeth are involutes of a circle. (The involute of a circle is the spiraling curve traced by the end of an imaginary taut string unwinding itself from that stationary circle called the base circle).

For watching movie use the QR Code

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Internal gear cutting – internal gear

These have a similar tooth design to that of a spur and helical gears, except that the teeth are formed on the inner surface of a cylinder or cone, and they are more concave in shaped, whereas the teeth of a spur gear are more convex in shape. In fact, the teeth on a annular gear are basically the same shape as the space between the teeth of a spur gear.

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Floor type machining centres

The floor type machining centres have vertical travel of up to 6,000 mm and maximum motor output of 70 kW and are offered with shift-out boring spindle or with automatic interchangeable milling heads; dual configuration is available on request. The production program also includes technological workplaces tailor-made to the customer’s needs.

Basic feature of the floor type machining centres - FU(Q) is its build-up configuration. Clamping area can executed accordingly to the customer request. This machining centres are designed for swarf-machining of materials with a wide range of technological use in operations such as milling, drilling, roughing out, reaming, and threading including thread cutting by chaser. In the basic execution this machine is delivered with control system HEIDENHAIN iTNC 530, digital drives BOSCH-REXROTH and hand measuring HEIDENHAIN. The machine FUQ is equipped with a chain-type tool magazine with code position. Searching and moving of tool into holding position is executed during working operation of the machine. The machine is equipped with automatic interchangeable milling heads, which can be designed according to customers requests.

Benefits: Various working areas:

movable rotary tables / movable rotary tables with hydrostatics /movable rotary tables with VTL ability / clamping plates

Automatic pick-up tool exchange (PICK-UP) Automatic spindle head exchange Two ball screws with measuring in vertical axis enable elimination of deformation when

headstock is being removed out of work Three-step gearbox enables optimum use of motor output within full range of speed Active inspection Hydraulically balanced weight of machine parts moving in vertical direction

(knee, headstock, spindle head) Thermal stabilization of three-step gearboxes and spindle drive chains at spindle heads Finishing operation possible using 5-axis machining Axial tool cooling in all types of spindle heads Axial tool cooling depending on spindle head up to 100 bars Spindle head exchange for customer’s special technological applications Possibility of two independent machines sharing one working area Vertically adjustable operator´s working platform

Automatic interchangeable milling heads

Shift-out quill W

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Various working areas

Clamping plates Rotary tables

Fixed Clamping plate width / length

[mm] 1 500-8 000 / 4 000-22 000

Table clamping area dimensions

[mm]

1 400-3 000 X 1 400-3 000

Load capacity [t/m2] Load capacity [t] 6-60

Torque (S1) [Nm] 10 000-25 000

Movable Table clamping area dimensions

[mm] 1 500-3 000 X 1 500-3 000

Load capacity [t] 10-60

Torque (S1) [Nm] 10 000-25 000

Linear axis travel [mm] 1 250-4 000

Rotary tables with VTL ability VTL tables

Fixed Table clamping area dimensions

[mm] 1 500-3 000 X 1 500-3 000

Carousel table clamping area diameter

[mm] 4 000-8 000

Load capacity [t] 15-70 Load capacity [t] 60-320

Torque (S1) [Nm] 20 000-60 000 Torque (S1) [Nm] 220 000-670 000

Max. speed [rpm] 120-80 Max. speed rpm] 100-25

Movable

Table clamping area dimensions

[mm] 1 500-3 000 X 1 500-3 000

Load capacity [t] 15-70

Torque (S1) [Nm] 20 000-60 000

Linear axis travel [mm] 1 500-4 000

Max. speed [rpm] 120-80

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TRADITION - RELIABILITY - INNOVATION

Turn-key delivery of technology

Guaranteed performance with adjusted technology

Tailor-made customer‘s solutions

Gantry type machining centres Column to column distance up to

10 000 mm

Execution: fixed table / movable table

Motor output 28 – 113 kW

Multi-purpose machining centres

Gantry type machining centres with

carousel or grinding function

Floor type machining centres

Motor output 28 – 70 kW

Vertical turning lathes

Execution: single / double column

Max. turning diameter 4 000 - 16 000

mm

Max. turning height up to 7 000 mm

Max. workpiece weight up to 450 t

Optional with Y axis