solutionsgear grinding€¦ · single profile gear grinding forms the exact shape of each gear...
TRANSCRIPT
1
800.835.9999 / weilerabrasives.com
GEAR GRINDING
SOLUTIONSGEAR GRINDING
SOLUTIONSGEAR GRINDING
SOLUTIONSMaximize your machine efficiency with products specifically designed for high performance gear grinding and deburring.
2
DRIVING PRODUCTIVITYPeople who take work seriously partner with Weiler. We work collaboratively to help solve our customers’ biggest challenges.
We understand that every production operation is different, so is every production challenge. One solution does not fit all.
Weiler experts can examine your specific production and product challenges and develop customized solutions that optimize your operation.
Together we will maximize productivity enabling your business to be more efficient and ultimately more profitable.
WORLD-CLASS CAPABILITY
• Best-in-class lead-times
• On-site technical support
• CNC finishing
• Newest abrasive and bond technologies
• Extensive R&D capabilities
• Green manufacturing footprint
• Precision tolerances
• Unrivaled safety inspection
• Global distribution network
• Custom wheel shapes
SINGLE PROFILE CONTINUOUS GRINDING BEVEL
Straight or Spiral Bevel Gears
Plunge or Continuous Grinding
Wheel Shapes for Multiple Applications
Small Grinding Zones
Multiple Tooth Grinding
Efficient Machine Throughput
Large Grinding Zones
Single Tooth Grinding
Larger Stock Removal
3
HONE DEBURRING PRODUCTSDRESSING TOOLSHOB SHARPENING
Hob Cutter Maintenance
Multiple Machine Offset Variations
Improve Surface Finish
Correct Gear Geometry
Remove Grinding Burrs
Improve Surface Finish
Maintain Workpiece Geometry
Maintain Grinding Wheel Form
Extend Grinding Wheel Life
Provide Consistent Surface Finish
Increasing Competitive Capability Through Process Improvements
Weiler Process Solutions (WPS) is a structured application engineering
program designed to provide Weiler Abrasives customers with engineering
support to identify value-added cost savings opportunities in their respective
processes. WPS is a comprehensive process where our expert application
engineers assess a specific process to identify improvement opportunities
resulting in quantifiable cost savings.
For more information and to schedule a consultation with a WPS expert visit: weilerabrasives.com/wps To discuss specific requirements with a specialist call: 800.835.9999.
WPS BENEFITS INCLUDE:• Reduced cycle times
• Elimination of bottlenecks
• Reduced consumable and tooling cost
• Elimination of rejections and rework
• Reduced energy consumption
• Reduced work in process
• Documented cost saving
• Documented best practices
• Elimination of process variability
4
SINGLE PROFILE WHEELSSingle profile gear grinding forms the exact shape of each gear tooth and can be used to grind from solid or used to finish grind after machining. Opposing teeth surfaces are ground simultaneously to maintain continuous geometry of the desired gear tooth shape. Single profile grinding wheels are designed to be used on large contact areas.
H
J
D
TV U
SINGLE PROFILE A - 4N D/J X T/U X H – V
TYPE 27: DEPRESSED CENTER
Grinding Faces
P
P
H
J
D
T
F
V U
G
SINGLE PROFILE B - 5Y17 D X T/U X H – P X F – V
Wheel dimensions are configured based on machine capabilities and the size of the gear tooth being produced. When using a wider faced grinding wheel, single or double recesses can be added to aid in mounting a wider grinding wheel on a shorter arbor shaft.
WHEEL CONFIGURATIONS
PERFORMANCE TIERS
H
D
T
V
U
P
F
SINGLE PROFILE C - 7Y3 D/G X T/U X H – P X F/G - V
TIER TECHNOLOGY ATTRIBUTES VALUE
Max Performance V59-MAX Dual high performance ceramic paired with superior V59 bond technology
• Maximum cut rate • Longest wheel life • Superior form holding ability • Large depth of cuts
High Performance V59 Engineered aluminum oxide abrasive paired with high performing V59 bond technology
• High performance at lower price point • Cool cutting • High material removal rate • Reduced dressing
Performance V35 Premium aluminum oxide abrasive paired with advanced V35 bond technology
• Excellent cost performance • Suitable for low to medium removal rates • Excellent surface finish
5
Minimum MaximumDiameter (mm) 150 610
Arbor Hole (mm) 20 254Thickness (mm) 20 127V Angle (Deg) Application Specific
Max Operating Speed 80 m/s
SIZES AVAILABLE
CASE STUDY: GAINING EFFICIENCY TO MEET CUSTOMER DEMANDS
Shape Typical Thickness Range (mm)4N <40
5Y17 40-607Y3 >60
Common EquipmentLiebherr
KlingelnbergGleason
KappSamputensili
With this single profile gear grinding application, our Weiler 16 gear grinding
wheel helped increase material removal, reduce dressing, and cut their total
grinding time by almost 50%.
CHALLENGE: This customer was looking to improve the overall efficiency of their grinding operations to overcome issues they were having meeting customer order deadlines. They consistently had a backlog at their grinding machines causing them to miss customer order deadlines and were at risk of losing key customers.
SOLUTION: The Weiler Industrial Grinding Team designed a wheel utilizing a custom blend of high-performance ceramic grain to increase metal removal rate and improve form retention. This grain combination paired with Weiler’s proprietary vitrified bond technology resulted in a grinding wheel that alleviated this customer's grinding backlog.
RESULT: Weiler’s custom gear grinding wheel allowed this customer to increase overall grinding efficiency and meet their customers’ demands. The Weiler team utilized the WPS process to realize the following improvements:
Material Removal Rate
43%Increase
Form Retention
51%Reduction in Dressing
Cycle Time
44%Reduction
6
CONTINUOUS PROFILE WHEELSContinuous generation gear grinding forms the desired gear profile into the workpiece while the gear is rotating. Continuous profile grinding allows for faster cycle times and can be used for both small and large contact areas depending on gear size. Hybrid generative wheels can also be produced to eliminate wheel changes or machine-to-machine workpiece changes to conduct the task of roughing and finishing simultaneously.
H
D
T
CONTINUOUS PROFILE A - A – 1Z D X T X H
HD
T
V
M=MODUL
CONTINUOUS PROFILE B - 1ZB D X T X H – M/V
Continuous generative wheels can be supplied with or without a profile. Unprofiled wheels allow flexibility to the consumer when multiple gear profiles are being produced. Profiled wheels are available with up to 7 starts and can have modules of 0.5-12 profiled with tight tolerances in a ready-to-use state for consumers with high production volumes.
WHEEL CONFIGURATIONS
PERFORMANCE TIERS
TIER TECHNOLOGY ATTRIBUTES VALUE
Max Performance V59-MAX Dual high performance ceramic paired with superior V59 bond technology
• Maximum cut rate • Longest wheel life • Superior form holding ability • Large depth of cuts
High Performance V59 Engineered aluminum oxide abrasive paired with high performing V59 bond technology
• High performance at lower price point• Cool cutting • High material removal rate • Reduced dressing
Performance V35 Premium aluminum oxide abrasive paired with advanced V35 bond technology
• Excellent cost performance • Suitable for low to medium removal rates • Excellent surface finish
*B = # of Starts
7
Cycle Time Decreased
27%Decrease
Form Retention
51%Reduction in Dressing
Reduction in Passes per Part
44%Decrease
SIZES AVAILABLE
Minimum MaximumDiameter (mm) 150 450
Arbor Hole (mm) 50 150Thickness (mm) 100 250
Pressure V Angle (Deg) Application SpecificStarts 1 7
Module 0.5 12Max Operating Speed 80 m/s
Common EquipmentLiebherr
KlingelnbergGleason
ReishauerKapp
CASE STUDY: DECREASE CYCLE TIME TO MEET PRODUCTION DEMANDS
This gear grinding application increased the output by 28%
eliminating the bottleneck to meet production demands.
CHALLENGE: A spike in demand for helical gears resulted in a significant bottleneck in the customer's continuous gear grinding operation.
SOLUTION: The Weiler Industrial Grinding Team designed a wheel utilizing our new high porosity vitrified bond system that increased cutting efficiency and form retention. The higher metal removal rates and reduced need for dressing increased the output of this customer’s machine by 28%, eliminating the bottleneck and allowing them to meet production demands.
RESULT: eiler’s gear grinding wheel allowed this customer to decrease cycle time by reducing the number of passes per part and increasing the number of parts run between dressing the wheel. The Weiler team utilized the WPS process and realized the following improvements:
8
BEVEL GEAR GRINDINGBevel gears can be ground in both static and continuous operations. Static operations are primarily used for straight bevel grinding where the profile is plunge ground into a stationary workpiece. Spiral bevel grinding uses a continuous operation in which the grinding wheel and the workpiece rotate in unison to generate the desired profile along the angled plane of the gear.
PERFORMANCE TIERS
TIER TECHNOLOGY ATTRIBUTES VALUE
Max Performance V59 High performance ceramic paired with superior V59 bond technology
• Maximum cut rate • Longest wheel life • Superior form holding ability • Large depth of cuts
High Performance V35 Engineered aluminum oxide abrasive paired with V35 bond technology
• Higher performance at lower price point• Cool cutting • Medium material removal rate • Reduced dressing over V57
Performance V57 Premium aluminum oxide abrasive paired with advanced V57 bond technology
• Excellent cost performance • Suitable for low material removal rates • Excellent surface finish
T
V
D
UV1
W
H
T
V
P
D
U
E
T1
W
F
BEVEL PROFILE A - 6PZ D X T/T1 X H – W E V
T
D
W
BEVEL PROFILE B - 2Z D X T – W
Bevel grinding wheel shapes are machine setup specific. Factory profiles for ready to use products can be applied using tight tolerance CNC finishing processes. Unprofiled wheels are also available for the consumer to profile in-machine. Wheel mounting variations include standard arbor hole, nut inserted back, and glued to steel plate.
WHEEL CONFIGURATIONS
BEVEL PROFILE C - 2ZB1L – D X T/U – W V/V1
* Mounted to Custom Backing Plate
9
SIZES AVAILABLE
HJ
TK
EF
P
D
W
CUP PROFILE A - 11 D/J X T X H – W E K
Minimum MaximumDiameter (mm) 75 400
Arbor Hole (mm) 25 150Thickness (mm) 25 150
Max Operating Speed 80 m/s
Common EquipmentKlingelnberg
Gleason
H
T
EF
P
D
W
CUP PROFILE B - 6 D X T X H – W E
10
H
J
D
T
V
U
PF
HOB PROFILE A - 3K4 D/J X T/U X H – P X F – V
H
J
D
T
V
U
P
F
HOB PROFILE B - 3K5 D/J X T/U X H – P X F – V
HJ
D
TV
U
HOB PROFILE C - 3 D/J X T/U X H – V
HJ
D
T
V
U
J1
N
HOB PROFILE D - 3K7 D/J/J1 X T/U/N X H – V
Hobbing is a milling process that is used to machine gears instead of grinding from solid. Hob cutters need proper maintenance to maintain life, cut quality, and cutting effectiveness.
HOB SHARPENING WHEELS
PERFORMANCE TIERSTIER TECHNOLOGY ATTRIBUTES VALUE
Max Performance V59 Single high performance ceramic paired with superior V59 bond technology
• Maximum cut rate • Longest wheel life• Superior form holding ability • Large depth of cuts
High Performance V35 Engineered aluminum oxide abrasive paired with V35 bond technology
• High performance at lower price point• Cool cutting • Medium to high material removal rate • Reduced dressing over V57 technology
Performance V57 Premium aluminum oxide abrasive paired with advanced V57 bond technology
• Cost performance • Low to medium removal rates• Excellent surface finish
Hob sharpening grinding wheels are offered in several sizes and shapes to fit the machine offset requirements of both CNC and Manual Hob sharpeners.
WHEEL CONFIGURATIONS
SIZES AVAILABLEMinimum Maximum
Diameter (mm) 100 400Arbor Hole (mm) 25 125Thickness (mm) 10 75
Max Operating Speed 80 m/s
Common EquipmentKlingelnberg
Kapp
11
STRAIGHT DRESSING PROFILE DRESSING STEP DRESSING HAND-HELD STICK
Wheel dressing usually performed with a single point or cluster tool where movement is required along the
face profile of the grinding wheel
Wheel face dressing that achieves a desired special form. Dressing rolls are the tool of choice.
Form dressing usually conducted on face angled wheels with a single profile super abrasive
dressing wheel.
Commonly used on manual grinding machines to cleanup the face of a grinding wheel.
Abrasive Hone Wheels are used to improve surface finish and to modify or correct the gear tooth geometry. Typically finer grit abrasive wheels are used in the honing process.
HONE WHEELS
H
D
T
HONE PROFILE - 1 D X T X H
WHEEL CONFIGURATIONS
PERFORMANCE TIERSTIER TECHNOLOGY ATTRIBUTES VALUE
Max Performance V59-MAX Dual high performance ceramic paired with superior V59 bond technology
• Maximum cut rate • Longest wheel life • Superior form holding ability • Large depth of cuts
High Performance V59Single high performance ceramic paired
with engineered aluminum oxide abrasive bonded with high performing V59 bond technology
• High performance at lower price point• Cool cutting • High material removal rate • Reduced dressing
Performance V35/V57 Premium aluminum oxide abrasive paired with either V35 or V57 bond technology
• Excellent cost performance • Suitable for low to medium removal rates • Excellent surface finish
SIZES AVAILABLE
DRESSING TOOLSDressing tools are a critical aspect of the grinding process to maintain the form of the abrasive wheel while also ensuring a consistent RA finish is being applied to the workpiece. Dressing or truing a grinding wheel periodically throughout the life of an abrasive wheel helps remove any material loading that could hinder performance.
Minimum MaximumDiameter (mm) 300 762
Arbor Hole (mm) 50 508Thickness (mm) 10 120
Max Operating Speed 80 m/s
12
All grinding and shaping operations produce some type of burr or leave a sharp edge. On power components such as gears, these undesirable by-products are especially troublesome. Removing burrs and sharp edges improves the quality, performance, and reliability of the finished part.
DEBURRING PRODUCTS
800.835.9999 / weilerabrasives.comWC2038 / 10195BP / ©2019 Weiler Abrasives Group. All Rights Reserved.
WEILER ABRASIVES GROUPWeiler Global HQOne Weiler Drive Cresco, PA 18326 USA Weiler de MéxicoQuerétaro, México
Weiler do Brasil São Paulo, Brazil
Weiler EMEA HQMaribor, Slovenia Zrece, Slovenia Loce, Slovenia Oplotnica, Slovenia
Bindlach, Germany
For the full offering of Weiler gear deburring products, please refer to our Gear Deburring with Brushes Brochure. For more information and to schedule a consultation with a WPS expert visit: weilerabrasives.com/wps To discuss specific requirements with a specialist call: 800.835.9999.
WHY ARE BRUSHES IDEAL TOOLS FOR DEBURRING GEARS?
• Brushes do not alter part geometry• Brushes remove burrs, round sharp edges, and improve surface finish• Brushes are ideal for automation
CASE STUDY: DEBURR PUMP GEARPROBLEM: Pumps are extremely susceptible to failure due to burrs. Due to the tight fit between components, all edges must be deburred and radiused to ensure proper function. Proper deburring of rotating pump gears is especially important. SOLUTION: A dedicated machine running 14" Nylox® wheel brushes at 900 RPM was a low-cost solution for deburring these gears. By using dedicated equipment, cycle time was minimized and an acceptable edge condition was achieved.
Before
After