Gear cutting machines in modern design are equipped with a rigid structure and a powerful electric motor. The units of the vertical layout are also equipped with hydrostatic bearings, a cooling system and a grooving spindle. A high performance indicator is due to the possibility of increasing the speed of the working part to two thousand revolutions per minute. The functionality and technical parameters of the models are expanded thanks to the CNC, as well as a movable spindle carriage, which allows you to change the position of the hammering element in relation to the machined gear part.
Varieties
Gear shaping machines are divided into three main types:
- Modifications with a movable table in the horizontal plane, which allows for infeed. Also, its design includes a fixed rack.
- Options with a fixed table and a stand, movable horizontally and used to transport the tool at the time of cutting.
- Models with a static table, horizontally moving rack and carriage, able to extend vertically mortising tip, changing the position of its stroke.
An automated unit with a fixed table has more advantages than its counterparts. To make conical teeth possible, one of the tool axes is mounted at a certain angle. On machines used in mass production, an intermediate plate is provided, placed under a vertical rack. Universal modifications are equipped with the ability to tilt the table or counter in the range of 10 degrees.
Gear Shapers: CNC Models
In the program-controlled modification , complex kinematic schemes are replaced by separate engines for the main movement of the chiselling tool and the adjustment of the unit along the axes. In the horizontal plane, the rack moves to change the diameter of the machining of parts with internal and external engagement, as well as radial feed.
The rack moves along the axes in the case of radial removal of the hollowing part at an angle and the finishing of special gear profiles. Moving the carriage in a vertical plane causes a change in the processing area in height. An independent type spindle drive provides the desired rotation of the workpiece, and programmable interaction makes it possible to achieve maximum accuracy by running.
Technical capabilities
CNC gear shaping machines have the ability to change shtosell mobility. The chisel is retracted on the reverse stroke by shifting backward, which simplifies the design of the equipment, increasing its rigidity. You can correct the direction of the tooth with a slight tilt of the working part.
Due to the design features of CNC models, it is possible to expand the functionality, as well as compliance with manufacturing accuracy in accordance with GOST 1643-81. Crown type gears have an identical module and are machined with one mortising tool. The sequence of manipulations in one pass increases the productivity and accuracy of the placement of crowns.
Principle of operation
Technical characteristics of gear shaping machines allow the cutting process to be carried out by reciprocating movement of the working part. Semi-automatic units have a vertical layout. Installation at the center-to-center distance and cutting the tooth to the required depth is adjusted using a table moved by a hydraulic cylinder. The equipment is able to function in commissioning and semi-automatic mode with the possibility of reusable finishing of products.
Changing the circular feed allows an electric DC motor. It receives power from a special amplifier with an automatic machine that switches the cyclic processing of the workpiece. With the help of a three-speed main drive motor, double tool movements per minute can be transformed. Radial insertion is carried out by the work of a wedge slider moved by a hydraulic cylinder. The total tapping range is through the stops, and the idle retraction is through the spindle. The removal of the part at an angle is realized by displacing the rack relative to the axial part of the table. Turnover of the workpiece is taken into account by the electronic pulse controller, which makes it possible to adjust the rolling arc. The machining of gears with internal gearing provides an automatic output tool up.
Setting up a gear shaping machine
The main cut is made from an electric motor with three speed ranges. It aggregates with a pair of cylindrical and interchangeable gears, as well as bevel gears and a toothed belt drive. The force is transformed to the drive shaft, which transfers the translational-reciprocal effect to the working tool spindle.
Circular feed is provided by a direct current electric motor through gear cylindrical elements. The main point on the spindle is transmitted through the worm gear to the ram. The feed can be changed by adjusting the speed of the motor.
Among other settings of gear shaping machines, the following aspects are distinguished:
- Division chain - used for kinematic interaction during rotation of the workpiece and tool.
- Node of the removal of the working part at idle - is carried out by rolling the caliper through an eccentric, traction, pusher and roller.
- Faster part rotation. This process is carried out through a chain from the motor to the cylindrical wheels. In this mode, part of the kinematics is deactivated by opening the pressure guitar elements.
- The system for setting the center distance. This distance is maintained by a thrust nut and a wedge-shaped slider. The position of the chain is adjusted by turning the nut on the adjustment screw.
- Manual control of the spindle drive is activated mechanically by turning the square through gears.
- System drive equipment to the upper position.
Preparation for work
Before starting the operation of the equipment, it is necessary to activate the opening circuit breaker, which is located on the side of the electrical cabinet. The remaining fixtures must be brought to the starting position:
- Set the table in the designated position.
- The slider of the plunging device must be in pre-working condition.
- The spindle moves to the upper position.
- An engagement wheel with a crown should be derived from the manual inclusion square.
Then the switches are switched to the "on" mode, after which the equipment is ready for operation.
Gear Shaving Machine 5V150
This universal unit is designed for cutting teeth on cylindrical gears of various gears with a diameter of up to 80 cm and a module of no more than 12 mm. The workflow is performed with a high speed steel mortising tool. It is in a vertical position and performs translational-reciprocal movements with synchronous run-in of the workpiece.
The cut part is fixed on the horizontal faceplate using a special mount. To control the runout of the product, the element can rotate in an accelerated mode, regardless of the table, which can move along the horizontal guiding parts of the core.
Features
The gear shaping machine, the purpose of which is discussed above, can provide such manipulations:
- Accelerated movement from an independent drive for example mounting to the starting position.
- Slow motion of mechanical type, allowing precise positioning of the workpiece and adjusting the depth of cut.
- Radial feed for inserting the mortising device into the part by a predetermined amount. In this case, the unit operates in a closed automatic mode.
- Achieving the same dimensions of the processed elements thanks to the automatic adjustment of the faceplate movements.
Characteristics of gear shaping machines 5V 150:
- The maximum diameter / module of the machined wheels is 100/12 mm.
- The maximum stroke / size of the mortising device is 200/200 mm.
- The distance between the axes of the slotter and the table is 700 mm maximum.
- The faceplate in diameter is 800 mm.
- The limits of radial / circular / double feeds are 5.4 / 1.5 / 188 strokes per minute.
- Acceleration of the hammering device / table - 3 / 1.7 revolutions per minute.
Model 5122
Gear shaping machines 5122 are also designed for cutting gear circles of a cylindrical type by rolling with a mortising tool. Aggregates are used in mass and single production.
Equipment Parameters:
- The maximum dividing size of the processed workpiece is 200 mm.
- Gear module - 5.
- The maximum width of the processed crown is 50 mm.
- The working surface of the table in diameter is 250 mm.
- Denomination of a cutter - 100 mm.
- Mass - 4.4 t.
- Overall dimensions - 2 / 1.45 / 1.96 m.
- Power plant capacity - 3 liters. from.
- The number of double strokes of the working part in one minute is 200/280/305/400/430/560/615/850.
Modification 5M14
The 5M14 universal mechanical gear shaping machine, like its analogues, is intended for cutting teeth of various types of cylindrical wheels. The hammering tip of the equipment has a small overrun, which allows you to cut gears into blocks. The working process is carried out by the method of rolling in a part with circular modular devices.
The unit has a vertical layout, the chiselling tool is made in the form of a gear wheel, the module of which is identical to the workpiece. During operation, the dolbyak receives translational-reverse movement and synchronous rotation around its own axis. At the beginning of the operation, the working part after each stroke moves relative to the axis of the workpiece in automatic mode. This process continues until the desired tooth height is reached.
Processing and stopping of equipment are carried out under the control of an automatic controller.
Unit parameters 5M14
Consider the technical characteristics of gear-shaping semiautomatic device:
- The size range of machined parts is 20-500 mm.
- The maximum width of the cut teeth with external gearing is 105 mm.
- The same indicator with internal gearing is 75 mm.
- Spindle travel - 125 mm to the maximum.
- The tilt angle of the teeth is up to 23 gr.
- The longitudinal movement of the caliper to the maximum is 50 cm.
- The distance between the ram and the table is from 45 to 170 mm.
- Double strokes of the mortising device - 124/179/265/400.
Below is a diagram and designation of the machine controls:
- Spindle of the chiselling tool.
- Coolant fluid flow regulator.
- Caliper Lock Nut
- Element of circular innings.
- Reversible handle.
- The screw for the longitudinal movement of the caliper.
- Start button.
- Stop key.
- Switch from setup mode to work stage.
- Local light switch.
- Knob for push.
- Radial feed block.
- Turn on radial clutch.
- The main switch.
- Square for manual drive.
- The bar for the reference mechanism.
As you can see, the unit in question has a fairly reliable and understandable design, while it is characterized by high performance and versatility in use.