According to the German Automobile Manufacturers Association (VDA), German automakers invest a total of 23.5 billion euros a year in research and development, about half of which is used to develop new drive systems including clean diesel engines and electric motors. How does this dynamic study affect production at the sub-supplier or contract manufacturer level? In terms of gear manufacturing, the KOEPFER K300 gear hobbing machine (which uses different techniques to machine gears made of different materials) offers us a highly flexible production method - the cutting process, which is the production of gears with a maximum modulus of 4 Universal solution.
Gears are an indispensable component in the car's production process. Without gears, cars will be difficult to move. Of course, gears are not only used in powertrains, but also in power steering systems, control components, auxiliary drives (such as seat adjustment), and differential gears - we can't imagine the absence of gears in these devices. As the importance of hybrid drives increases, so does the number of gears required. Gear materials for automotive production range from high-strength steels to relatively soft, lightweight plastics. The choice of multiple materials for gears brings convenience to automotive production and processing, but it is a daunting task for production planners in the subcontracting industry because they need to consider which manufacturing solutions in the market can meet Future development needs? After all, the batch size, geometry, and even material content of many components are constantly changing.
“This problem is the original intention of our K30 gantry machine,†explains Jörg Lohmann of KOEPFER, an EMAG subsidiary. “After final analysis and verification, the machine we designed is a fully-fledged universal solution. Its capacity and performance. Levels can benefit multiple production stages associated with gear production.†First look at its range of workpieces. For example, the K 300 is the same as a large helical gear with a modulus of 4 when machining a pinion shaft with a modulus of one. effortlessly. It can also handle a wide range of materials, from alloy steel and aluminum to copper, bronze and even plastics. One of the great advantages of the K300 is that it can be produced in a very short setup time. Thanks to the quick-change clamping system for the spindle, tailstock and hobbing head, the new workpiece can be set up in just 20 minutes, including automatic control. This is achieved through the clever use of NC technology, the teaching function of the NC technology allows the user to prepare for the production of the next component through the automatic control component, even the clamping force value of the tailstock can be saved in the settings. This makes machine tool production simple and easy. The K300's ergonomic mechanical design keeps the operator's operating distance to a minimum, so the hobbing machine K 300 can quickly prepare for the next machining task. This new design operation is also suitable for wet and dry machining, ensuring that all setup work is easy to operate. The tilting angle of the hob is designed to achieve optimum chip flow during dry and wet machining.
KOEPFER K300 hobbing machine: almost any gear can be machined on this automated universal machine. The body of the advanced anti-vibration mineral material is combined with a closed frame structure and a thermally stable design to ensure efficient machining.
Higher component quality and lower processing costs
The K300 uses many high-tech solutions during the machining process. For example, engineers rely on a “closed box†design of a vibration-resistant polymer granite machine base, a closed frame structure with a main shaft and tailstock connected by a yoke that ensures that the tailstock and spindle are even hobbing. The maximum rigidity can be maintained even when the maximum clamping force or machining force is generated during machining. High stiffness can improve the quality of the gear unit of the machined workpiece. The above also applies to the thermal symmetry of the machine tool. The load ratios on the main shaft and the tailstock are similar, and the heat source, such as the electrical cabinet, is placed in an optimal position and then attached to the back of the machine. This design ensures excellent thermal stability and a uniform and stable process.
Usually a variety of different gear cutting techniques are allowed in the machine tool production process, such as high performance hobbing, scraping and hard milling of cylindrical gears. It is also possible to use a plunge and tangential hobbing process to machine the worm gear. Straight bevel gears can be machined by continuous indexing or Conikron, and water-cooled servo motors power each machining axis. This means that there are no mechanical transmission components during the machining process, so that the power transmission system does not have strong vibration, thus achieving high-value rolling head function. The latter's service life is significantly extended, the processing cost is reduced, and the quality of the gears obtained is also extremely high. Another feature of the hobbing machine K300 is the NC tool for auxiliary tools such as assembly, deburring and sensors (accurate positioning of the hobbing process through marking holes, straight grooves and other geometric features).
The hobbing machine K300 can be equipped with up to 15 active NC axes, including 7 tool axes, 1 auxiliary NC axis and all other available automatic axes. A large number of axes ensure high output levels. The KOEPFER quick-loading device with V-calipers is the basic component of the automatic workpiece transport system and is suitable for workpieces weighing less than 10 kg. For the diversity of workpieces, the supplied blank and finished workpiece libraries such as chain workpiece libraries, gravity track workpiece libraries, recirculating storage conveyors and workpiece unloading systems (eg with slotted conveyor belts) are also available in a wide range of models.
The figure clearly shows that the hobbing head is inclined at a 45 degree angle. This design allows the swarf to achieve optimum results in both dry and wet processing.
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