JTEKT CORPORATION

ｅ５００Ｈ－ＧＳ

(Gear skiving package)

Gear production by compact type general purpose machine

JTEKT CORPORATION

e500H – GS (gear skiving package)

Improved productivity by high peripheral speed machiningImproved productivity by high peripheral speed machining

Integrated gear machining process into machining centerIntegrated gear machining process into machining center

Automatic programming function NCSFC & simple inputAutomatic programming function NCSFC & simple input

Reduced size and weightReduced size and weight

Pursuing high reliability and ease of usePursuing high reliability and ease of use

Evolution of skiving technologyEvolution of skiving technology

JTEKT CORPORATION

A method implementing gear machining by using the r elative speed generated by inclining the tool relative to the workpiece and rotating them synchronously

Actual cutting

speed V 3

Tool

Workpiece

Feed direction

Cross angle φ

Tool cutting speed: V1 200 m/minWorkpiece cutting speed: V2 170 m/minIndex angle (cross angle): φ 30°Workpiece torsion angle: β 0°

Tool cutting speed V 1

WorkpieceCutting

speed V 2

Actual cutting speed : V3 100 m/minV3=V1×SINφ/COSβ

This principle was proposed in Europe in the 1960 e ra, however the levelof engineering at the time was low, and practical u se was difficult.

What is the skiving method?What is the skiving method?

Machining principle of skiving method

JTEKT CORPORATION

Comparison of each gear cutting method

Hob cutting Shaper cutting Skiving cuttingBroach cutting

Outer gear

Inner gear

Shape

Principle

Accuracy

Cost

CT

Machining method

Meshes the workpieces

through rotation and feeds the tool to create the gear

Creates gear by rotating the pinion

cutter and workpiece at the specified

speed, then reciprocating

Creates gear by inclining the cutter and workpiece axis

and rotating synchronously at

high speed.

Cutting

performance

〇 〇

〇

○ 5 – 12 grades ○5 – 12 grades ○ 5 – 12 grades ○ 5 – 12 grades

〇

〇

×

〇

△ △(Special tool) ○○

△ ○○ ◎

Creates gear by withdrawing a tool with gear-shaped

blades arranged like a saw.

×

JTEKT CORPORATION

Merit of skiving

Inco

mpl

ete

gear

sha

pe

Hobbing Skiving

Inco

mpl

ete

gear

sha

pe

Size reduction of product

• Shortening of incomplete gear shape section

Contributes to size and weight reduction of the product

Size reduction

JTEKT CORPORATION

Merits of skiving

Improved productivity

5 times the cutting speed with high machining ability

Depends on feed axis.

Depends on rotating axis.

V: 100 - 300m/min

V: 40 - 60m/min

Gear shaper

Skiving

Recess section3 – 5 mm

Low product strength

High product strength

Skiving

Gear shaper

Improved product strength

No need for recess section

Contributes to improved product strength

JTEKT CORPORATION

Conventional

New technology

Lathe Hobbing Shaper Cham-fering Drilling

LatheHobbingmachine

Gear shaper Chamfering machine

Machining center

Skiving (gear cutting)Lathe Chamfering Drilling＋

＋ ＋

Machining process

Machining center

One chuck machining from lathing to gear cutting an d drilling

Machining equipment

Machiningprocess

Machiningequipment

Integrated gear machining processes to machining center

Merits of gear machining by machining centerMerits of gear machining by machining center

JTEKT CORPORATION

2005 Began skiving engineering development2006 Began production of gear parts

Established element/control/tool/machining technology

Internal gear

Sun gear

Coupling

30,000 sets/m

25,000 sets/m

25,000 sets/m

JTEKT initiatives in skiving

History of engineering developmentHistory of engineering development

2013 Skiving machining unite500H-GS released

Production resultsProduction results

JTEKT CORPORATION

We independently develop the engineering necessary for skiving and provide all equipment,

controls, tools and machining conditions.

Necessary engineering for skiving method

High speed/high rigidity workpiece axis• N=3,000 min-1 spec.• Compaction by built-in motor• Compatible with automatic hydraulic fixture

• Tool design based on JTEKT original gear creation theory

Optimum machining conditions• Selects the optimum machining conditions according to the customer’s product

TOYOPUC-MC70

Low resistance tool design

• High accuracy skiving control by high speed synchronization

• Simple programming function

Skiving

High speed/high accuracy gear cutting control

Element engineeringElement engineering Control engineeringControl engineering

Tool engineeringTool engineeringMachining engineeringMachining engineering

JTEKT CORPORATION

Largest possible chip drop port is secured directly under the cutting point.Bed structure does not accumulate chips.

Center trough

Pursuing high reliability and ease of use

This JTEKT machining center base has been installed in many parts production lines and is capable of:

High productivity• High speed

Rapid feed: 60 m/minATC : C-C 2.5 sec

Supporting multiple applications• Hydraulic fixture

Automation

High reliability• Chip processing ability• Structure is easy to maintain

[Correspondence to mass production]

JTEKT CORPORATION

Operator door opening up to the ceiling⇒ Well-litNo coolant drip

Machine structure and cover shape designed with consideration to

work easiness

Short distance from machinefront to pallet center.

⇒ Comfortable work posture

• No square and cumbersome protrusion • Easy to make line layout

Pursuing high reliability and ease of use

[Human-friendly cover shape]

JTEKT CORPORATION

B軸

C軸

High speed rotation lathing spindle unit

●e500H-GS Skiving machine

e500H-GS

Developed lathing spindle unit (3,000 min -1) with high speed and high rigidity

A axis

Enables both high load and low rising temperature by adoption of

large dia. ceramic balls.

Large dia. high ability bearing with high accuracy, high rigidity

and low rising temperature

Achieves torque full machining from low speed to high speed

(3,000 min -1) through adoption of constant torque servo motor.

High speed, high torque built-in motor

Achieved size reduction of total length through storage in the

hollow type spindle.

Hydraulic type draw bar compatible with auto chuck

(detachable)Achieved total length compact

distributor with air press. 2-port, hyd. 2-port and application of high

peripheral speed (3.9 m/s) seal.

JTEKT-made distributor with multi port correspondence to

high peripheral speeds

B axis

JTEKT CORPORATION

JTEKT CNC TOYOPUC-MC70

PLCTOYOPUC-PC10EL

Servo I/FＭＥＣＨＡＴＲＯＬＩＮＫⅢ

③ Multibus② Optimum program management

① High performance CPU

0 10000 20000 30000 40000 50000

整数演算

浮動小数点演算

メモリ

MC50

MC70

CPU benchmark (score) Measuring tool: CrystalMark Ver. 0.9.99.173 ALU value

10 times the performance ratio

Servo communication is not influenced by PLC communication and synchronization performance has been significantly increased.Gives priority to the important

processing that influence cycle time.

Achieves effective CNC processing.

Achieves high skiving accuracy with high calculation ability.

Cuts waste time and raises net rate.

ＣＮＣ

TOYOPUC

MC70

PLC

Servo I/F

ＣＮＣ

MC50

PLC

Servo I/F

Single bus Multibus

Communication speed : 4 times

Good

(Score)

CNC

TOYOPUC-MC70

JTEKT CNC achieving skiving principleJTEKT CNC achieving skiving principle Compared with conventional CNC MC50.

Memory

Integer calculation

Floating decimal point calculation

JTEKT CORPORATION

Simple programmingSimple programming

JTEKT CNC TOYOPUC-MC70

ＮＣＳＦＣ

Flow display possible to understand the flow of machining

Gear data

Workpiece teeth amount

Teeth torsion angle [ ° ]

Module [mm]

Material dia. [mm]

Outer/inner teeth Outer: 1 Inner: -1

Tool data

Tool amount

Tool torsion angle [ ° ]Tool dia. [mm]

Cutting condition

Cutting width [mm]

Margin [mm]

Cross angle [ ° ]

Cutting speed [m/min]

Tool feed amount [mm]

Y axis travel speed [mm/min]

XZ axes return travel speed [mm/min]

Part axis rotation dir. CW: 1 CCW: -1

Offset angle offset dir. add: 1 subtract: -1

Simple programming through input of gear data and tool data cutting

condition to the screen

JTEKT CORPORATION

High speed rotation lathing spindle compatible with automatic hydraulic fixture

Lathing function by machining center

Second spindle function (lathing spindle)Second spindle function (lathing spindle)

Can lathe using machining center by equipping the high-speed lathing spindle

JTEKT CORPORATION

JTEKT developed the skiving tool in-house

Cutter

Workpiece

Workpiece

Tool designing

Machining simulation

Optimization

Tool path

Tool blade shape

Tool to be fabricated

Skiving tool

Machining accuracy

Calculates cutting resistance

Skiving tool

JTEKT CORPORATION

Evolution of skiving engineering

High accuracy• Tool position compensation reducing machining errors

・ Highly functional skiving tool design engineering reducing cutting resistance

・ Arbitrary tooth shape of inner and outer teeth and tooth trace shape control

Evolution of simulation engineering and control engineeringEvolution of simulation engineering and control engineering

JTEKT CORPORATION

外歯 内歯

・歯車種類

・対象ワークサイズ φ30～φ220mm φ50～φ200mm

・最大モジュール

・ワーク材質

・加工精度（参考）

平歯車・内歯歯車・ﾊｽﾊﾞ歯車・ｽﾌﾟﾗｲﾝ

全長100mm以下

鉄系材料（焼入前）

JIS N7級相当

2.5

Target workpieces

Range of target workpiecesRange of target workpieces

Outer teeth Inner teeth

Gear type

Target workpiece size

Largest module

Workpiece material

Machining accuracy (reference)

Gear type

Spur gear / internal gear / helical gear / spline

Total length 100 mm or less

Ferrous materials (before hardening)

Equivalent to JIS grade N7

JTEKT CORPORATION

Example of high productivityExample of high productivity

Conventional

Now

Lathe Hobbinemachine

Shaper Machining center

Machining center

Deburring machine

・Machining accuracy (m 2.4)・Machining time

m 2.4: 30 sec.Tooth trace: 3.8 µm JIS grade N4

Tooth shape: 12.8 µm JIS grade N7

Equipment expense

Equ

ipm

ent c

ost

Production volume: 4,500/month

m 1.0: 10 sec.

【Machining results】

【Effect】

Side gear

Module 2.4Outer teeth

Module 1Inner teeth

Material: SCM415Size: Φ81 × 41 mm

Machining example ①

Machining expense

Mac

hini

ng c

ost

70% reduction

【Workpiece】【Workpiece】

70% reduction

Conventional ConventionalNow Now

JTEKT CORPORATION

Example of large module (M 3.5)Example of large module (M 3.5)

Workpiece O.D.: Φ98.5 mmModule: 3.5Material: SCM415

Internal gear component

60

420

(Shaper) (Skiving)

Cutting speed: 150 m/minFeed: 0.15 mm/rev

Machining time: 80 sec.

【Workpiece】

【Effect】

【Machining conditions】

Machining example ②

85%削減

Conventional Now

85% reduction

JTEKT CORPORATION

Example of high accuracy machiningExample of high accuracy machining

Machining example ③

Test piece

Material: SCM440Size: Φ190 × 20 mmMachined part: Internal teeth

(Module 1.15)Enlarged image of internal teeth

Tooth shape accuracy

Tooth trace accuracy

Machining specifications

Module (mm)

No. of teeth

Pitch circle dia.

Helix angle ( ° )

Helix direction

Machining time (sec.)

Tooth shape accuracy (µm)

Tooth trace accuracy (µm)

Machining results

Right

JTEKT CORPORATION