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 Gear honing Finished gear Hard shaving Gear manufacturing today Green machining Gear forming (forging, sintering, …) Green shaving Fässler Gear Honing Heat treatement / Cleaning Grinding Hard shaving Direct-Honing TM Gear honing Finished gear Kinematics of Gear Honing: Honing ring Toolspindle Workpiece Workpiecespindle Pic: Fässler HMX 400 Distinguishing marks of gear honing Axial veloc. Cutting veloc. Radial veloc. Surface structure Cutting velocities 1 … 10 m/s Pitch dia. PCD Technologies Fässler Technologies Fässler Gear Honing Hard Broaching Dressing Technology Tool design and manufacturing Fässler HMX-400: 9-Axis X In feed-Axis Z1 Oscillation-Axis A Cross angle adjusting-Axis B1 Swivel-Axis HMX-400 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 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 Tooling cost Machine cost 300% 250% 200% cost [%] 150% 100% 50% 0% Green Shaving Direct Honing™ Combi Honing Profile Grinding Generation Grinding Workpiece data: mn = 2 z = 35 alpha = 15° beta = 33° b = 15 mm da = 91mm 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. Comparison between various hard gear finishing processes Comparison between various hard gear finishing processes Comparison between various hard gear finishing processes Comparison between various hard gear finishing processes Honing : the superior hard finishing process…. SPECIAL FEATURES & ADVANTAGES OF 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 TIME 2-SPINDLE AND 2HONING 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. THANK YOU!