Research Group Gear Manufacturing Technology
Machines of the Research Group Gear Manufacturing Technology
Liebherr LC 120
The machine tool Liebherr LC 120 is used for gear hobbing of gears and shafts. Parts with a modules up to mn = 3 mm and outer diameters up to da = 125 mm can be machined. Tools of diameters up to da,0 = 90 mm are used. The machine has been modified for the use in research. The tool spindle allows gear hobbing at rotational speeds up to n = 10.000 rpm.
At WZL the machine is predominantly used for public research projects and bilateral contract research on the topic process optimization of gear hobbing. Besides other means of data acquisition measurements of forces and powers are possible.
Gleason Pfauter GP P 600/800
The gear hobbing machine P 600/800 was produced by Gleason-Pfauter. With this machine tool parts of up to diameters of da = 600 mm can be green machined and finished with defined cutting edges. The processes gear hobbing, tooth form milling and skive hobbing can be performed. The processes can be either carried out under wet or dry cutting conditions. Besides manufacturing parts for the use in gear boxes and test rigs analogy trials for research on the manufacturing processes are carried out. Primarily, the fly cutter hobbing process is used. With this machine tool machining of larger modules then usual in the previous research is possible.
Klingelnberg C29 milling machine is a CNC special machine for milling of bevel gears up to a diameter of 290 mm.
In the field of bevel gear cutting tests of tool wear in cutter head systems are performed on the machine.
Due to the increased machine rigidity and the additional possibility of coolant supply gears can also be manufactured by skiving. Therefore tool life investigations of different tool systems are possible.
KAPP VAS 55 P
The KAPP profile gear grinding machine VAS 55 P is used for profile gear grinding of external gears and shafts with a module up to mn = 8 mm or an tip diameter up to da = 300 mm. By the possibility to use two tool spindles and a NC-dressing unit CBN tools (dressable and electroplated) as well as conventional tools made from corundum can be used. The outer diameter of those tools is limited with ds = 200 mm.
At the WZL this machine is used for hard and soft finishing of prototype gears for the test rigs and industrial manufacturing (job shop). Furthermore, the machine is used for trials in public and bilateral founded research projects with the aim to optimize processes and tools.
LIEBHERR LCS 380
The LIEBHERR gear grinding machine LCS 380 is used for hard and soft finishing of gears and shafts with a module up to mn = 8 mm and an tip diameter up to da = 400 mm with generating gear grinding process as well as profile gear grinding process.
Due to the different possibilities for tool clamping systems for grinding CBN tools (dressable and electroplated) as well as conventional, corundum tools can be used. The tool dimensions are limited by an maximum external diameter of d0a = 320 mm and a tool width of b0 = 230 mm. The number of starts is limited by the maximum number of machine table revolutions (1,200 rpm).
At the WZL the machine is used for public and bilateral founded research projects. Current topics focus on process optimization and analysis. Therefore, it is possible to measure cutting forces, temperatures and spindle power in dressing and machining.
The machine Profiroll PR15HP is a thread and profile rolling machine. The external cross-rolling method is applied, which is used to roll gears from cylindrical blanks or for surface densification rolling of porous, powder metal gears. With a rollable workpiece diameter of 3 mm to 70 mm and tool diameters between 120 mm and 195 mm, the machine is used to roll small gears. Basic investigations in a analogy process with cylinder-rolling are also possible. The machine is used for public funded projects at WZL in the field of research of densification rolling of powder metallurgy gears. Additionally it is used for bilateral research on the topic of optimization of the gear rolling processes.
Gildemeister NEF 480
The turning machine NEF 480 is a Gildemeister machine tool in horizontal orientation. The machine is mainly used for analogy trials. Thereby constant chip geometries are reproduced and characteristics of materials and tools like influence of cutting edge radius, coatings, etc are investigated. Furthermore cutting force coefficients for the used force models in gear hobbing are determined. The advantage of this type of trials is the fast workpiece and tool purchase and the easy trial design.
Grinding Burn Test
For testing and analysis of process related microstructure damages at the WZL different non-destructive and destructive test methods are available. By nital etching process related microstructure damages according to ISO 14104 can be visualized and determined. The available STRESSTECH Rollscan 300 can be used for Barkhausen noise measurements at gear flanks and plain material samples. Further analysis can be carried out by measurements of residual stresses and metallographic microstructure analysis.
The gear measuring center Klingelnberg P40 is a CNC-controlled measuring machine for workpieces with a diameter range up to 400 mm. The machine is suitable to measure spur and helical gears as well as bevel gears and wormgears. Measuring units are the dimensions, form and location of rotationssymetrical workpieces. The measuring center is using a 4-axis path control in conjunction with a 3D-measuring system. In addition to measure workpieces the Klingelnberg P40 is able to measure worktools for example hobs, shaper- and shavingcutters. Several software modules offer the possibility to save exact measuring procedures and to automating the measuring jobs.
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