Large-Part Machining
Mazak has demonstrated that with a larger sized fi ve-axis multitasking vertical machining center, shops can cost- effectively and quickly produce those occasionally required, low-volume spiral-bevel gear sets in-house. In this way, shops can avoid the long turnaround times associated with farming the job out to a specialty gear shop, which may or may not have a machine large enough or available at the time for the job. Loading a model with a proper contact pattern into a CAM system allows the gears to be programmed the same as any other fi ve-axis part. And from this point forward, the machine tool simply cuts to the model. “A multitasking, fi ve-axis machine tool can cut both ring and pinion gears so accurately and consistently that a shop could, for instance, separately cut fi ve pinion gears and fi ve ring gears,” said Finn. “It could then pair the gears up with one another in no particular order to create fi ve gear sets. Plus, when not machining the occasional gear sets, a shop can use its multitasking machine to cut all of its other parts, including the gear boxes the sets go into and any other associ-
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In process-development testing, Mazak machined a spiral bevel gear set that included a 29-tooth, 22" (559-mm) diameter pinion gear and a 114-tooth, 6' (1.8-m) diameter ring gear (shown) on a Mazak Integrex e-1550V/10 multi- tasking fi ve-axis machining center.
ated transmission components, to maximize machine spindle utilization. It is this production fl exibility that attracts shops to multitasking machines,” said Finn.
In process-development testing, Mazak machined a spiral-bevel gear set that included a 29-tooth, 22" (559-mm) diameter pinion gear and a 114-tooth, 6' (1.8-m) diameter ring gear on a Mazak Integrex e-1550V/10 multitasking fi ve- axis machining center. The gear set was completed in days as opposed to months and machined complete using only one machine. The Integrex e-1550V/10 is a standard model with a two-pallet changer. The machine performs all required machining processes such as milling, turning, boring, drilling and tapping. Its tilting spindle and turning table allow for machining at any angle or cross cutting position as well as for contouring operations. Also for development testing, Mazak used no special tools to machine the ring and pinion. All tools were standard, off-the-shelf and readily available. Pinion gears for the sets are machined from solid cylindrical
pieces of 8620 steel, while the ring gears are machined from forged 4340 carbon steel rings that have about 0.250" (6.3 mm) of additional stock for machining, but lack any near-net teeth shapes. Both gears are fi rst rough-machined in their nonhardened states, then pinion teeth are carburized to Rc ring gear teeth induction hardened to Rc
machined in hard milling operations on the Mazak machine. For machining this particular gear set, a pinion gear is
fi xtured on one of the multitasking machine’s two pallets and a ring gear on the other. While one gear is being machined, a machinist sets up the other at the pallet load station. After it is rough-machined, the pinion gear moves out of the work envelope and the ring gear moves in for its rough-machining. Both rough-machined gears are then sent out for hardening. With its teeth hardened, the pinion gear is relocated back onto
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ManufacturingEngineeringMedia.com | December 2013
62, 55 and both are fi nish-
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