Smart. in Sight with Digital Services Employing AR Technology
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2018/2019 solutionsgear manufacturing technology magazine Bright Future Smart. In sight with digital services employing AR technology. The Evolution of At the Speed of Light Chamfer Cutting Innovations in Hard Power Skiving, non-contact laser inspection, and Closed Loop manufacturing. Customer Success Metalcastello meets surging demand with Power Skiving. Welcome to Gleason Dear Valued Customers: You’ve heard it called Industry 4.0 or perhaps the Smart Factory – the convergence of new digital technologies that are fast re-shaping the way we make things. Like those that came before it, this latest industrial revolution is creating considerable upheaval, as well as enormous opportunity for new products that work intelligently together to reduce John J. Perrotti downtime, improve quality and deliver a host of other benefits. President and Chief Executive Officer We call that Smart. It’s an exciting time at Gleason. With the industry’s approach that optimizes the production process by most comprehensive array of solutions we’re helping networking Gleason Power Skiving machines directly with our customers benefit from smart new technologies in Gleason GMS® metrology equipment. Measurements every gear manufacturing category. We’re leveraging and the resulting corrective actions are fast, accurate and breakthroughs in digital, Augmented Reality, laser, automated. software, designs and innovative processes to meet long- Our Gleason 4.0 solutions have four families: gUptime, standing – or brand new – gear design, production and gProcess, gProduction and gTools. We are developing inspection challenges. the digital world for gearing around these families. The As our Cover Story suggests, we’re leaving no stone goal: zero planned downtime, connectivity from design to unturned. With the addition of a new Chamfer Hobbing production and inspection – and most of all, extraordinary process, we now have expanded our array of integrated, value for our customers. automated and productive chamfering solutions to reduce Exciting developments are taking shape in gear, gearbox cost and improve quality. and drivetrain design as well. A new interface connecting We have truly revolutionary advancements with our GMSL our KISSsoft and GEMS software empowers designers multi-sensor Inspection System, which uses non-contact with new product optimization tools. We also continue with laser scanning to acquire massive amounts of data at solutions to better link design and production. rapid speed compared to tactile probing, opening new …And much more. We’re excited about what the future frontiers in gear analysis. With the new GRSL, we’ve holds. We hope you partner with Gleason when taking the employed the same non-contact laser scanning technology next step down this smart new technology path. for in-line inspection. Hard Power Skiving has become an economical option for fine finishing, and includes a Closed Loop systems 2 Welcome to Gleason Features 2018/2019 04 Cover Story: The Evolution of Chamfer Cutting 08 Bright Future In Sight With Digital Services 04 10 Power Skiving as a Hard Finishing Alternative 12 In-Process Gear Inspection at Light Speeds 08 14 New Technology Center in Switzerland 16 Precision Segmented Collets Improve Workholding Life 10 18 Pentac®Mono for Bevel and Hypoid Gear Sets 21 Dressing Tools for Grinding and Honing Applications 12 22 Powerful Gear Design 24 Spheric® Power Honing With the New 150SPH 14 26 Metalcastello/Italy: Adding Power Skiving to Meet Surging Demand 29 IT S.A./Switzerland Improves Machine Performance with 22 Gleason Global Services 30 KHK/Japan Sets the Standard in Stock Gears 24 26 © 2018 Gleason Corporation. All Rights Reserved. SOLUTIONS is published regularly throughout the year, and distributed worldwide. Please address correspondence to: Christian Albrecht, Editor, SOLUTIONS. Gleason Corporation. 1000 University Ave., P.O. Box 22970, Rochester, NY 14692-2970 U.S.A., 585-473-1000 • Fax 585-461-4348 • www.gleason.com • e-mail: [email protected] 3 Cover Story The Evolution of Chamfer Cutting New Genesis® 160HCD Hobbing and Chamfering Machine adds Chamfer Hobbing to integrated chamfering and deburring solutions. utomotive gear manufacturers potential for sharp, brittle edges after Chamfer Solutions for Every A in particular recognize that heat treat, as well as to avoid material Application premature transmission failure, plus conditions in the tooth flank prior to At Gleason, we’re working to offer less-than-optimal fuel efficiency, or the hard finishing operations. these manufacturers chamfering and unacceptable noise can result from Chamfering and deburring are deburring solutions that are just as easy application of transmission gears particularly critical in advance of the to apply as the primary soft and hard operating with anything less than honing process, where excessive processes. With our latest Genesis® a flawless tooth flank. For these stock and hardened burrs can greatly series of hobbing and chamfering manufacturers, generating a chamfer diminish honing tool life and, as a machines, we give users the ability to to precise customer specification for result, significantly increase cost per apply the optimum chamfering process size, shape and angle is of critical piece. for their particular application – up to importance in order to minimize the and including truck-size gears. 4 Cover Story Cover Story The new Chamfer Hobbing process offers an extremely effi cient solution to create the desired chamfer without secondary burrs. Chamfer rolling, available on the Chamfering is performed using a those commonly produced in the Genesis 210HiC Hobbing Machine Gleason Chamfer Hob, with diameters chamfer rolling process are also easily and horizontal P90CD, is ideal for similar to a gear hob, made with the achievable. planetary pinion applications requiring latest high-speed steel materials like In the Chamfer Hob design process, particularly fast cycle times (10 seconds G50 and featuring AlCroNite®Pro Gleason software is used to identify or less chip-to-chip) or for shafts with coating for exceptional tool life in dry and avoid all potential collisions of the little or no clearance below the root cutting conditions. Gleason Chamfer tools with the counter flank and with diameter. The formation of a secondary Hobbing employs one Chamfer Hob interfering contours above and below burr requires removal by an additional for each tooth flank, with a tooth profile the actual gearing. operation downstream in advance of a which is specifically designed for the subsequent honing operation. particular chamfer form to be realized. Finally, the Gleason Chamfer Hobbing process offers tool shifting which, as As an alternative, Gleason now offers a This design delivers greater flexibility – compared to competitive processes, new process called Chamfer Hobbing. It comma or parallel-chamfer forms are delivers increased tool life and minimal delivers, in parallel to hobbing, long tool possible as well as chamfers along change times resulting in lower cost- life cutting dry, and does not generate the tooth edge only, or including per-piece. a secondary burr requiring removal the root area. Chamfer angles like downstream. Chamfer Hobbing for Lower Cost Per Workpiece The new-design Genesis 160HCD combines the proven Genesis vertical hobbing platform with an integrated chamfering/deburring station to perform the Chamfer Hobbing process in parallel to hobbing, and thus achieving cycle times that satisfy the requirements for automotive MT, DCT, and electrical spur gear transmissions. A high speed 2-position gantry loads the workpiece for hobbing, transfers the workpiece to the chamfering station and then delivers the finished workpiece to the parts conveyor. 5 Cover Story Contour Milling: Mastering Chamfers on Larger Gears Chamfer Contour Milling offers producers of larger, ‘truck-size’ gears a fl exible, easy and economical process for their increasingly important chamfer/deburr operations. hile chamfering gets increased generally a star-shaped body with 2-4 the chamfer size and angle depends W focus with automotive-size standard, replaceable indexable carbide on machine movements and not on gears, effective solutions for larger, inserts – contour mills the chamfer with the tool design, the process is quite ‘truck-size’ gears are becoming nearly the desired characteristics. universal. It can, with only a few set as important – and more readily of indexable carbide inserts, cover The Chamfer Contour Milling process available. parts ranging from module 2.5 mm is similar to hobbing in that it is to the maximum machine capacity of The new continuous ‘fly cutting’ continuously indexing and creates a module 8 mm. The process enables process offers significant advantages cutter path that envelopes the tooth just a relatively few different standard for improving chamfering flexibility as geometry from the outside of the part insert blade sets to accommodate a well as reducing machine and tooling in. All six axes in the chamfer unit are wide range of gear sizes, geometries costs as compared to chamfering on a used during generation of the tool path, and chamfer requirements. Due to the dedicated, stand-alone machine. The and the tool seeks to use the straight size of the cutter some clearance below continuous fly cutting process, called side of the indexable blades to optimize the root diameter is necessary to avoid Chamfer Contour Milling, generates a the process. The result is a faceted collision. This requested clearance chamfer along