Superdry coatings are available in two versions. The Superdry 1 coating is used for hobbing at cutting speeds of up to 200 m/min; when the Superdry 2 coating is used on the Mach 7 substrate, the cutting speed of the same gear can be as high as 250 m/min. The Superdry 2 coating is basically an AlCrN coating, and Mitsubishi has applied for a patent for its additional ingredients.

Tool life and gear machining efficiency can also be improved by optimizing the geometry of the gear cutter. Optimizing tool geometry is a less expensive way to increase tool life and machining efficiency by adding tool coatings or switching to a stronger tool base. The idea of ​​Alexander Klein of the University of Aachen in Germany is not how to make the tool itself tougher, but how to make the chip damage to the strip blade used for bevel gear face milling. After studying the chip formation mechanism, Klein designed a cutting shape that allows the chips to flow evenly out of the tool. He developed an experiment that simulates the bevel gear surface hobbing process, allowing you to study different tool design options and observe the tool's ability to form harmless chips. His research demonstrates that with the new strip blade design, tool life can be increased by 115% compared to older and new K10F carbide tools (TiAlN coated). Klein said that Gleason has patents for the research and may soon develop commercial products for his tool design. “Although better tool wear performance does not depend entirely on better chip flow,” Klein explains, “but the improvement in chip flow can at least reduce the arc of the tool tip (the part between the tool tip and the plane cutting edge). ) thermal load and mechanical load."

Gear cutting machines have also become more versatile, allowing multiple machining operations to be performed in one installation. For example, Liebherr of Germany and LMT-Fette have cooperated to improve the fine rolling process. In one installation, the rough cutting, finishing and chamfering of the gear workpiece can be completed with only one hob.

Since the current hobbing machine does not allow automatic tool change, the same high quality hob is usually used for rough cutting and fine cutting in the finishing process, and the tool is prone to premature wear. In order to extend tool life, in the tool design, the rough cut zone can be distinguished from the fine cut zone, and the wear performance of each zone can be optimized separately. According to Darryl Witte, business manager of LMT-Fette's Gear Cutting Group, the number of workpieces that can be machined has increased several times since the current fine hobs are no longer worn from roughing. Liebherr and LMT-Fette have collaborated to develop this concept of hobbing, with Liebherr providing hobbing technology that enables the use of multi-zone hobs.

The same development team at both companies also invented a patented fine hob tooth profile that eliminates the convex error (called "deformation") of the helical gear with toothed shape modification. Usually, in order to eliminate such deformation, it is necessary to perform additional finishing such as shaving or caries. The use of a twist-free fine roll means that it is possible to cancel these subsequent finishings.

“Twist-free technology enables the hob to overcome the drawbacks of typical finishing, but it does not achieve the required flank modification,” said Liebherr's Oliver Winkel. Adding a chamfering knife to this tooling system provides more value for the same installation and removes burrs before removing the workpiece from the hobbing machine.

“In the past few years, we have made significant progress in improving the machining performance of gear cutters. The durability of the cutters continues to increase. A hob can usually process 8,000 workpieces before regrind, compared to the previous hobs. Milling 200 to 200 workpieces requires regrind.” Star Ware (representing the gear cutting manufacturer Samputensili and Star Cutter, a company of gear cutters) Tom Ware said, “Today's gear hobbing machines can reach 450m/min. However, the current hobbing accuracy can reach the grinding accuracy of 5 to 10 years ago."

According to Ware, Sampotensili now offers a hobbing machine that can perform a variety of machining operations in one installation, for example, in addition to cutting, it also allows for simple turning of the groove deburring. This additional feature can be added to any of the Sontonsley CNC hobbing machines. Star SU also offers a patented composite tool that performs hobbing and chamfering with the same tool.

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