Gear Honing - Matchless Machines and Technology

Report
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?
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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
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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
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Fässler Gear Honing
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Hard Broaching
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Dressing Technology
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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.
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The Honing Process allows you to achieve:
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Excellent surface finish and extreme small roughness values
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Noiseless surface structure
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Extreme good wear behavior due to the induction of high compressive
residual stresses (1000 ... 1600 N/mm2).
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No thermal stresses; no changes of the material microstructure; no
grinding burn!
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No bias from the process
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Excellent profile and lead qualities (DIN 6 ... 2).
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Quite good correction of pitch errors and run out (DIN 6 ... 2).
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High process capability because of direct drive technology
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Low tooling costs because long tool life of ceramic bonded honing
stones
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High stock removal possible
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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.
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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
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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.
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THANK YOU!

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