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Gear Honing: Characteristics & Specific applications . Matchless Machines & Technology . What do we want in a Gear?. Where-ever Gears are used, the characteristics required are: Noise-less transmission at high speeds Optimization of power Wear resistance. Why Gear Honing?.
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Gear Honing:Characteristics & Specific applications Matchless Machines & Technology
What do we want in a Gear? Where-ever Gears are used, the characteristics required are: • Noise-less transmission at high speeds • Optimization of power • Wear resistance
Why Gear Honing? • The process of Gear Honing is ideally suited for obtaining these characteristics. • By improving the surface finish and the quality of the Geometry of the Gear tooth, we can achieve interference free Gear performance with full contact between the two rolling surfaces. • This gives extremely smooth rolling of the Gear and thereby noiseless operation, excellent power transmission and low wear.
What is Gear Honing? • Gear honing is a hard finishing process similar to hard shaving. • The flanks of an external teeth gear and an internal teeth honing ring are in rolling contact with a specified radial pressure at a low cutting speed. • The driven work-piece and tool spindles are crossed at a defined angle. • The superposition of the in-feed movements gives a resulting gliding movement running diagonally from tip to root of the tooth flank. • This produces a micro-cutting process with short cutting point engagement.
Advantages of Gear Honing • Favorable surface texture reduces the noise emission in the transmission • Induced residual stresses in tooth flanks increase the bearing capacity • Low cutting speed prevents structure damages (burning) • New machines and tool systems achieve high stock removal rates and direct honing of hardened gears • Quick process and short floor to floor times are ideal for the quantity production • No limitations of gear size; from a small pinion to the final drive gear, all can be honed to perfection!
Gear manufacturing as it once was Green machining Gear forming (forging, sintering, …) Green shaving Heat treatement / Cleaning Grinding Hard shaving Gear honing Finished gear
Gear manufacturing today Green machining Gear forming (forging, sintering, …) Green shaving Heat treatement / Cleaning Grinding Hard shaving Direct-Honing TM Gear honing Fässler Gear Honing Finished gear
Honing ring Tool-spindle Workpiece Workpiece- spindle Pic: Fässler HMX 400 Kinematics of Gear Honing:
Distinguishing marks of gear honing Axial veloc. Cutting veloc. Pitch dia. PCD Radial veloc. Surface structure Cutting velocities 1 … 10 m/s
Fässler Technologies • Fässler Gear Honing • Hard Broaching • Dressing Technology • Tool design and manufacturing Technologies
Fässler HMX-400: 9-Axis X In feed-Axis Z1 Oscillation-Axis A Cross angle adjusting-Axis B1 Swivel-Axis Z2 Headstock-Axis B2 Headstock rotation-Axis C1 Honing stone direct drive rotation-Axis C2 Work piece 1 direct drive rotation-Axis C3 Work piece 2 direct drive rotation-Axis HMX-400
Comparison of Honed vs Ground Gears • The reason of the noiseless behavior of honed gears is the surface structure. • The ground surface in the transverse plane of the gear looks like a saw. • This causes vibrations and the gear is loud. • A honed surface in the transversal cut of the gear looks smoother than the ground gear. • The vibrations are less.
The Honing Process allows you to achieve: • Excellent surface finish and extreme small roughness values • Noiseless surface structure • Extreme good wear behavior due to the induction of high compressive residual stresses (1000 ... 1600 N/mm2). • No thermal stresses; no changes of the material microstructure; no grinding burn! • No bias from the process • Excellent profile and lead qualities (DIN 6 ... 2). • Quite good correction of pitch errors and run out (DIN 6 ... 2). • High process capability because of direct drive technology • Low tooling costs because long tool life of ceramic bonded honing stones • High stock removal possible • Very economic finishing process - especially in mass production
HONING : TIME; COSTING AND ECONOMICS
Cost comparison between various hard gear finishing processes 400% 350% Labour cost 300% Tooling cost Machine cost 250% cost [%] 200% 150% Workpiece data: m = 2 n 100% z = 35 alpha = 15° beta = 33° 50% b = 15 mm da = 91mm 0% Generation Profile Grinding Combi Grinding Direct Honing Green Honing™ Shaving
Cost comparison between various hard gear finishing processes • The preceding chart compares the manufacturing costs for a specific part for the different manufacturing methods. • This benchmarking was made from a well known gear box manufacturer. • The chart indicates that the cost of the green shaving are lowest. • The manufacturing cost for single direct honing is about 1.5 times higher, the costs for combi honing about 2.2 times higher.
SPECIAL FEATURES & ADVANTAGESOF FASSLER - HMX • REASONABLE PRICE; INSTALLATION & COMMISSIONING SERVICES IN INR PAYMENT LOCALLY. • FREE SERVICE DURING WARRANTY AVAILABLE LOCALLY • POST WARRANTY AFTER SALES SERVICE AVAILABLE LOCALLY IN INR OR WITH INR PAYABLE AMC. • TECHNICALLY MOST ADVANCED DESIGN - TWIN SPINDLE - FASTEST CYCLE TIME2-SPINDLE AND 2-HONING STONE CARRIER. • POSSIBILTY OF HONING 2 DIFFERENT GEARS. • FAST SETUP CHANGE • LOWEST RE-DRESSING FREQUENCY • HIGHEST TOOL LIFE • LOWEST TOOL COSTS
In Conclusion…. • We are confident of our process and our Machine! • We have 3 machines successfully installed at Bajaj for Honing gears of their premium 2 wheelers, and one to be installed shortly. • IF YOU ARE STILL GRINDING YOUR GEARS, YOU CAN GIVE US YOUR GEAR DRAWINGS. • WE WILL CARRY OUT HONING TRIALS AND DO A COMPARATIVE CASE STUDY FOR YOUR REFERENCE.