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Gear Manufacturing


machine other parts. Generally speaking, it can also offer a higher quality finished product in pre-heat treat stage. Essentially, the gearMILL software develops the most ideal toolpath to create the gear with a standard machine and tooling. “A good gear geometry is the key to everything,” Chaphalkar explained.


Any Gear, Any Size


DMG MORI has been developing its gear solutions offer- ing since 2006. In 2010, Sandvik Coromant (Fair Lawn, NJ) invented the process of InvoMilling, a unique approach to making spur and helical gears using indexable insert cutters by slot milling and turn-milling in a path that moves the cutter along an involute path. “It was a very new thing,” Chaphalkar said of the method. “Nobody was doing it this way.” So the two powerhouse companies decided to partner on commercializing the new technology. DMG MORI developed software that develops the toolpath based on the gear shape, and now InvoMilling is added to hobbing and flank milling


with an end-mill as the choices customers now have to make a gear on a multitasking machine with gearMILL. “Now we have a broad portfolio,” Chaphalkar said. “Spur, helical, herringbone, bevel, spiral bevel, hypoid—whatever type of gear you have, it can be programmed and made.”


Watch Manufacturing Engineering’s Favorite Gear Manufacturing Videos at http://tinyurl.com/gearmanufacturingvideos


One of the main challenges in traditional gear production is the lead time for acquiring the right hob to make a part, which can take up to 8–10 weeks if you don’t have the right size in stock already. But using a standard machine and tools eliminates most of that waiting, Chaphalkar said. “You will already have the tools most of the time. There is no waiting in most of the cases.”


For more information on gearMILL, visit http://tinyurl.com/ dmggearbrochure or http://tinyurl.com/sandvikgearbrochure. —Sarah A. Webster, Editor in Chief


A Deeper Look at InvoMilling


Sandvik Coromant developed its InvoMilling gearcutting program and CoroMill 171 and 172 indexable carbide disk cutters to provide maximum flexibility for its customers who wanted to manufacture gears in smaller lot sizes, typically for applications like heavy trucks, agricultural and construction equipment. Sandvik Coromant worked initially and proved the concept with DMG MORI, which integrated the software into its CNC controls. InvoMilling will soon be available through other major machine tool makers as well. “We are seeing a shift in how gears are being made because of the availability of advanced technology, includ- ing multitask machines, even three-axis vertical machining centers with fourth axis rotary tables, and five-axis machining centers,” said Aaron Habeck, marketing project manager, Sandvik Coromant.


“High-volume gear manufacturing for automotive applica- tions like transmissions is still going to be done on traditional hobbing machines using high speed steel. But InvoMilling and full form disk cutters allow our customers who want to produce gears on non-traditional gearcutting machines, the ability to cut splines or gears. With a multitask machine, they can machine the part in one setup using the main spindle and subspindle to do all the turning or the milling of flats and keyways and drill/tap holes,” said Habeck.


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