prevent chip buildup thus providing consistent manufactur- ing quality. The machine design also allows for the compact arrangement of the spindle, slides and automation belt, reducing the unit’s footprint and consequently its fl oorspace requirement. The uniform construction of these modular machines makes them ideal for incorporation into production lines, as the component transfer height between machines is the same.
The VLC 200 H
The VLC 200 H vertical gear hobbing machine features technology that also of- fers economic advantages when used in its stand-alone version. The high-performance drives on the main spindle and hob offer torque rates and speeds to guarantee highly productive gearcutting with a max diameter of 200 mm and module 4, allowing them to be dry-milled in short cycle times. To achieve a consistently optimal component quality, the VLC 200 H can be equipped with an optional slide-mounted measur- ing system. As this is located outside the machining area, it is protected from chips and dirt and can be swung out of the way, if required. It is also possible to equip the measuring station with a probe for the quality control of components and a sensor system for component orientation. This allows machining operations to be adjusted at any time while simultaneously keeping a running record for quality control purposes.
The VLC 100 C
As is the case after every gearcutting operation, hobbing on the VLC 200 H poses the question of how the tooth profi le can be chamfered with the highest contour accuracy. The VLC 100 C chamfering machine can be equipped with the relevant technology to suit every requirement. “Which of the technologies we use depends mainly on the workpiece to be machined. We have a choice of bevel chamfering and the newer Chamfer-Cut,” said Jörg Lohmann, head of sales at EMAG Koepfer.
The classic bevel chamfering process, well established in the automotive industry and among its subsuppliers, is used
whenever the workpiece geometry features contour traps requiring it. This is primarily the case with shaft workpieces that feature a hub or with gears featuring a synchronizer ring. It must be emphasized that the tool used in these cases
The VLC 100 C set up to use Chamfer-Cut.
can be easily and cost-effectively resharpened by the user, reducing both tooling and storage costs for new pieces. For workpieces with a more favorable geometry, the VLC 100 C is equipped for use with the Chamfer-Cut method. This method, developed by FETTE, is ideal at aiming for a cost-effi cient, precision chamfering process. “As this method does not throw up a secondary burr, it is particularly suitable for gears that are being honed after hardening,” said Lohmann. The Chamfer-Cut process is carried out in two steps, with the upper surface of the gear contour being chamfered with high accuracy fi rst. The cutting direction is then reversed and the process repeated on the underside of the gear.
The combination of the VLC 200 H and the VLC 100 C, with either Chamfer-Cut or bevel chamfering technology, provides production planners with a variety of possibilities to design and optimize their gear production.
Edited by Yearbook Editor James D. Sawyer from information provided by EMAG LLC.
53 — Motorized Vehicle Manufacturing 2015
Photos courtesy EMAG LLC
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