GEAR MILLINGwith indexable inserts> Gasher, Hobs and Endmill <

2012Klaus Peter WichmannManager Gear MillingEngineered Solutions Europe

© 2008 Kennametal Inc. l All rights reserved. l Proprietary and Confidential l 1

PRODUCT OVERVIEW

Insert „tooth root“- 4-edged- negative

R < 10 R >= 10

GEARMILLING GASHER – GASHER ROUGHING

Application:- Roughing with unequal stock (±0,15)- Module: >10Gasher data:- D1=270 – 500Cutting data:- AP: upto 50 mm (about module 22) one pass- vc = 130 - 180 m/min- fz = 0,45-0,65 (hm,max=0,15)

Insert „tooth flank“- 8-edged- positive

Insert „tooth root“- 2 / 4-edged- positive

R < 10 R >= 10

GEARMILLING GASHER – GASHER FINISHING

Application:- Finishing (about quality Q8-9)- Module: >10 (Zmin. about 60-80)Gasher data:- D1=270 – 500Cutting data:- AP: upto 40 mm (about module 18) one pass- rec. upto 2mm stock for finishing cut- vc= 130-200 m/min, fz= 0,25-0,45 (hm,max=0,12)

Insert „tooth flank“- 4-edged- positive

internal external

GEARMILLING GASHER– DUPLEX / TRIO - GASHER

Insert „tooth root“- 2 / 4-edged- positive

R < 10 R >= 10

Application:- Roughing & Finishing- Module: 8 - 40Gasher data:- D1=270 – 500Cutting data:- AP: upto 40 mm (about module 18) one pass- rec. upto 2mm stock for finishing cut- vc= 130-200 m/min, fz= 0,25-0,45 (hm,max=0,12)

Insert „tooth flank“- 4-edged- positive

internal (external)

Insert „tooth root“- 2 / 4-edged- positive

R < 10 R >= 10

GEARMILLING GASHER– GASHER FINISHING “PINION”

Insert „tooth flank“- 4-edged- positive

external

Application:- Finishing (about quality Q8-9)- Module: >10 (Zmax. upto 60)Gasher data:- D1=270 – 500Cutting data:- AP: upto 40 mm (about module 18) one pass- rec. upto 2mm stock for finishing cut- vc= 130-200 m/min, fz= 0,25-0,45 (hm,max=0,12)

Ins: „root“ & protuberance- 4-edged- positive & negative

GEAR MILLING HOB – HOB “Disc Solution”

Ins: „root“ & „flank“- 4-edged- positive & negative

Application:- External gearing, Roughing & Finishing- Module 14-40Hob Data:- D1=250 – 500Cutting data:AP: upto 40 mm (about module 18) one passrec. upto 2mm stock for finishing cutvc = 100 - 180 m/min; hcu= 0,2-0,3mm

© 2011 Kennametal Inc. l All rights reserved. l Proprietary and Confidential l 7

GEAR MILLING HOB – HOB “Segment Solution”

Application:- External gearing, Roughing & Finishing- Module 4,5-14- no. of starts: 1 & 2Hob data:- D1=220 – 360Cutting data:- AP: upto 34 mm (about module 14) one pass- rec. upto 2mm stock for finishing cut- vc = 130 - 250 m/min; hcu= 0,15-0,3mm

SK: „root“, „flank“ &protuberance- 4-edged- negative

GEAR MILLING HOB – HOB “Monobloc”

Application:External gearing, Roughing & FinishingModule 4-7no. of starts: 1 & 2

Hob data:D1=160 – 250

Cutting data:AP: upto 19 mm (about module 8) one passrec. upto 1mm stock for finishing cutvc = 130 - 250 m/min; hcu= 0,15-0,3mm

SK: „root“, „flank“ &protuberance- 4-edged- negative

Solid Profile Insert- 2-edged- positive- negative

GEAR MILLING SPECIALS – SPECIAL GASHER ”Solid Profile”

Application:- e.g.: Gear & Rotor- Internal- & external gearing- Roughing & Finishing- Module 1-4Gasher data:- D1=160 – 250, Zeff=16-32Cutting data:- vc= 160-250 m/min, fz= 0,25-0,5 (hm,max=0,10)

GEAR MILLING SPECIALS – ENDMILLS

Module 1-4GASHER ”Solid Profile Insert”

Module 4-7HOB “Monobloc”

Module 25-40KSSM - IC10 & 12,7

Endmill: HSK-, DV-, KM-, oder PSC- Backend

EXAMPLES OF GEAR MILLING APPLICATIONS

EXAMPLES OF GEAR MILLING APPLICATIONS1) single gasher module 16

2) duplex gasher module 18

3) monobloc hob module 5,5

4) segment hob module 6

5) segment hob module 7

6) disc hob module 36

© 2008 Kennametal Inc. l All rights reserved. l Proprietary and Confidential l 12

GEAR DATA:module m 16no.of teeth Z -89width B 385PA a 20°HA b 7,6°

TOOL DATA:MP2140108D1 = 520D = 100Zeff= 16/8- root: 32x 2141036R09196353POS0202003- flank: 32x 2141037F143879VEX320POE08

CUTTING DATA:vc = 160m/minvf = 900mm/min(up to 1100mm/min)fz = 0,574hm = 0,147mmDOC = 33mm

RESULT:target: 2 rings / cutting edge⇒ tool life: 5x gear rings⇒ +150% increase of tool life- very good performance/ smooth cutting- 20% less machine power

SAMPLEMODULE 16 - Single Gasher internal gearing, finishing

© 2008 Kennametal Inc. l All rights reserved. l Proprietary and Confidential l 13

GEAR DATA:moduleno.of teethwidth BPA a°DiDf

TOOL DATA:D1DZeffroot:flank:

CUTTING DATA:1st pass: AP [mm] 25vc [m/min] 180vf [mm/min] 4002nd pass: AP [mm] 35vc [m/min] 180vf [mm/min] 5603rd pass: AP [mm] 42 (incl. topping)vc [m/min] 180vf [mm/min] 560

RESULT:target: 3 rings / cutting edge

⇒ tool life: 3x gear rings⇒ SAVING: more than 50%

machining time (justmilling)

⇒ no turning process needed(incl. topping)

SAMPLEMODULE 18 - Duplex Gasher internal gearing, roughing

m 18Z -9535720°17221800

= 420= 80= 10/540x R12196357NES73x FR151566R

© 2008 Kennametal Inc. l All rights reserved. l Proprietary and Confidential l 14

GEAR DATA:module m 5,5no.of teeth Z 39OD 243,3width B: 82PA a: 20°HA b: 19°HH leftMAT.: 18CrNiMo7-6

TOOL DATA:MP2146962D1 = 150Backend: PSC80Zeff= 8/8- 100x 2146962U09244711NEE06

MACHINE DATA:MORI SEIKI NT 5400multiple axxis mill/turn

center

CUTTING DATA:Cut 1-3 (roughing)vc = 160m/minvf = 2 mm/WRhcu = 0,2 mmCD1 = 8,0 mmCD2 = 5,0 mmCD3 = 3,6 mmCut 4 (finishing)vc = 200m/minvf = 4 mm/WRhcu = 0,12 mmCD4 = 0,5 mm

RESULT:Target: gear milling on mill/turn centerwithout counter bearing on the hob toolResult: First time ever that such a bigmodule gear was manufactured on a mill/turnQuality: between DIN 4 and 6 (req. Q10)

SAMPLEMODULE 5,5 – Monobloc - Hob

© 2008 Kennametal Inc. l All rights reserved. l Proprietary and Confidential l 15

GEAR DATA:module m 6,0no.of teeth Z 85OD 548,49 mmwidth B 65PA a 20°HA b 18°HH rightCD 15,6 mmMAT.: 18CrNiMo7-6

TOOL DATA:2001128 hob cutterD1 = 260D = 60 H6Zeff = 12No of starts = 1 rh

Insert 2001129/2001130

CUTTING DATA:Cut 1conventionalvc = 250 m/minrpm = 306 rev/minvf = -4,5 mm/WRhcu = 0,17 mmCD1 = 15,6 mm

t = 9,2 min

lifetime = 100 pc(per cutting edge)

MACHINE DATA:

LIEBHERR LC 600

RESULT:

Target: increasing of lifetime,reduction of cycletime.

Result: cycletime 50% faster thanwith HSS

Gear quality DIN 8 in one cut(expected was Q10)

Lifetime 100 pieces per cuttingedge, 400 per insert set

Cost safement 40% against HSS

SAMPLEMODULE 6 – Segment - Hob

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GEAR DATA:Module 7# Teeth 71pa 20°helix 10°D 517mmWidth 145Material: 18CrNiMoQuality 8

CUTTING DATA:vc = 140 m/minfa = 4 mm/ WRCoolant: Oil

MACHINE DATA:ZFWZ08 Modul

TOOL DATA:D 270 mmLenght 310 mmZ eff. 22,5 / 7,5Z tot. 310Segm. 33# Starts 1 (LH)Class A

RESULTS:machining time => 23,4 min (Saving 15 %)toollife => 75 Gears (+ 50% as expected)Quality:ISO 8-9

SAMPLEMODULE 7 – Segment - Hob

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GEAR DATA:module m 36no.of teeth Z 296Dia 10,8mthickness 960mmcast steel (30 HRC)

SAMPLEMODULE 36 – Disc - Hob

CUTTING DATA / RESULT:1st pass: stock 1,2mm- vc=80m/min; axial feed 6mm; insert change2nd pass: stock 0,6mm- vc=95m/min; axial feed 5mm; insert changefinish pass: stock 0,85mm- vc=95m/min: axial feed 5mm

Result:bright surface with some matt elements to end of cut;Ra=0,5-1,0; no wear visible

TOOL DATA:D1 = 550; L = 570- 10 effective teeth- 80 root and 80 flank inserts- pockets seat with shims

(±0,005mm)- quality AA acc. DIN 3968

Thank you very much for your attention