Page 44
www.us-
tech.com
September, 2020 Production
Power Skiving Provides High Quality, Productivity and Cost Efficiency in Gear Cutting
By Dr. Manfred Berger, Stephen Doerr and Mario Gruenberg, FFG T
he technology of power skiving has been known for more than a centu- ry. With the growing availability of five-axis machine centers, it has found its way into individual and series production, due to its inherent
process flexibility. With e-mobility on the rise, the market is demanding high precision (low
running noise), high power transmission (torque and speed) and high product flexibility in volume manufacturing. The use of planetary gears for reduction or as a differential in the drive system also increases the demand for internal gears.
As with all manufacturing technologies, quality, cost optimization, flex-
ibility, and productivity are top concerns. In addition to conventional gear ma- chining processes, such as hobbing, gear shaping and broaching, skiving is a continuous machining process for soft and hard machining of internal and ex- ternal gears. The skiving process is characterized by the way that the tool and work-
piece axes are arranged in relation to each other — internal and external gears are placed at an angle. Coupling the rotation of the workpiece and tool allows relative movement of the cutting edge in the tooth space. By superimposing a feed motion, both parts add to the movements of the
feed speed and guide the cutting edge along the workpiece axis. This way, the tooth space is “peeled out” of the workpiece in several cuts. The cutting speed results from the rotational speeds of the tool and
workpiece in relation to the axis cross angle. The skiving process offers short machining times, approximately 30 to 50 percent of conventional flexible gear shaping, as well as the ability to apply the gearing close to an interfering con- tour. The smaller the axis cross angle, the closer to the interference contour.
Power Skiving Equipment FFG offers power skiving in several different machine designs, including
the MODUL gear cutting system, HESSAPP vertical turning machine for disc-type components, and the BOEHRINGER shaft turning centers. In an isolated comparison of the machining scope for gear cutting, power
skiving can keep up with broaching and gear shaping, but loses to classical gear hobbing in terms of economy. Power skiving offers a range of advantages, such as eliminating multiple
clampings, saved floor space, lower total investment, short machining times, process flexibility, the possibility of dry machining, and broad competence of machine and tool suppliers. Another clear advantage of power skiving is in process integration.
FFG’s multiple path approach to machine development allows the company to provide additional machining technologies in the same platform. With the power skiving option on the HESSAPP DVH 500, the company is aiming at customers who apply a gear to the turned part. With the MODUL VS 250, the focus is on classic manufacturing of gears and transmissions.
Software Control FFG’s skiving software is compatible with IWU Chemnitz’ “SkiveAll,”
which contains algorithms for the component quality optimization. A kine- matic process model is created from the workpiece analysis and the required tool geometry is calculated. When coupled with a measuring machine, the data is transferred in GDE
format or customer-specific formats. This allows a closed process chain to be maintained from the workpiece drawing to the finished product. Another component is the MODUL TOOL MANAGER, a sophisticated
tool management system that has already been supplied with gear hobbing machines. FFG also offers support through the digital maintenance manual installed on the machine, which provides maintenance and repair instructions in words and images directly on the system. The MODUL VS 250 complements a successful product range of gear
hobbing machines with power skiving. These systems are targeted at automo- tive producers and suppliers, regardless of the drive system. The DVH 500 L WS is a vertical pick-up turning machining center,
which can pick up and machine workpieces with a swing diameter of 19.7 in. (500 mm). The x-axis can be equipped with linear drives if required and the system provides turning, drilling, milling, and grinding, along with an option- al swiveling tool spindle as part of the power skiving package. Both machines can be integrated into existing production lines for
wheels and shafts as a replacement or can be used in FFG’s turnkey systems. Process-specific machine groups are designed into the systems from the out- set, which then allows them to be configured specifically for each customer’s
requirements. Contact: FFG Europe & Americas, 6015 Center Drive, Sterling Heights,
MI 48312 % 586-446-7300 E-mail:
paul.chen@
mag-ias.com Web:
www.ffg-ea.com r
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84 |
Page 85 |
Page 86 |
Page 87 |
Page 88 |
Page 89 |
Page 90 |
Page 91 |
Page 92
