Auto Gear
The integration of INTEGREX multi-tasking with gear cutting and measurement
| 5-axis machining | Gear machining | Gear measurement | ||
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- 3 types of gear machining methods (gear skiving, hobbing and endmilling) can be performed for high-mix, small volume production to large volume production to meet your production requirements
- High speed and high accuracy gear skiving thanks to unique AG control technology
- Process integration for high-accuracy machining, reduction of in-process time and initial cost.
Gear Cutting
The integration of INTEGREX multi-tasking with gear cutting and measurement
| 5-axis machining | Gear machining | Gear measurement | ||
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Perform a variety of gear cutting processes
Improved productivity thanks to high-speed gear skiving
- High accuracy gear skiving is realized thanks to unique INTEGREX AG control technology
- Rotation of both the main spindle and the milling spindle is synchronized up to the top speed of both spindles to ensure high accuracy gear skiving.
Internal spline cutting applications - INTEGREX i-200ST AG
Thanks to INTEGREX i-200ST AG synchronized control technology, productivity is 6 times higher when compared to conventional internal spline processing. Additionally, with higher speed operation cutting resistance is reduced for higher accuracy
The hob arbor is held on one end by the heavy-duty milling spindle providing sufficient rigidity for high accuracy gear hobbing. With Smooth Gear Hobbing, gear specification data are input to automatically generate the tool path.
| Hob Shift | Modified gear lead and gear crowning | |
| This function shifts the contact point of the hob and workpiece to extend tool life. | By inputting data for a modified gear lead or gear crowning, the tool path for gear hobbing is automatically generated. | |
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Using Smooth Gear Milling software, gear teeth can be cut one by one by a standard endmill. Gear specification data, including data for modified gears as well as modified gear lead and modified gear profile, are input to automatically generate the tool path.
Once a gear has been machined, deburring of front and end edges can be performed with a standard ball-nosed endmill. In cases where the phase of the gear is unknown (such as after gear hobbing), Smooth gear measuring can be used to discover where the tooth gap is before the deburring process takes place.
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Software
Conversational programming of high accuracy gear cutting and gear measurement
Operation Flow
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| Enter data specifications, cutting conditions and measurement data | G code programme for cutting and measurement is generated | Gear cutting and measurement are performed. |
Gear Measurement
Gear tooth radial in-phase location
After using a new or reground tool, a gear tooth can be probed by a touch sensor to determine the required amount of compensation.
This same process can also be used to determine the in-phase positioning of other machined features, such as deburring using a ball endmill or locating a bore on a workpiece face. Accuracy of the in-phase positioning is ± 0.005 degrees (16 μm (0.00063"on a 360 mm (14.17") diameter).
Gear profile and gear lead measurement (Option)
| Gear face measurement by scanning probe |
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- The gear profile and gear face are inspected by a scanning probe after machining in the same workpiece setup.
- Conventionally, gears are machined on special-purpose gear cutting machinery and then are transferred to measurement equipment in another location. This is eliminated by the optional gear profile and gear lead measurement software.
Measurement results are displayed on the MAZATROL SmoothX display
Measurement results shown on the CNC display can be output as a .PNG file by pressing a single key.
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INTEGREX AG Machines
Click here for the INTEGREX AG range