Reworking & smoothing machines for gears

The smoothing process is an independent machining process to remove or level uneven surfaces and damages oft the gear (100% finishing).

The gear smoothing machine consists of the main components such as smoothing station 1 and 2, infeed and outfeed belts and electrical cabinet.


Reworking station:
Removal of protruding material by rolling with a diamond-coated smoothing wheel ("reworking wheel").

This process is also particularly suitable for processing noise-tested rework parts, i.e. for eliminating "nicks" on the tooth contact surface without applying high deformation forces.

A subsequent brushing process ensures a clean workpiece surface before the workpiece is sent to station 2 (conventional three-wheel smoothing for finishing).

Smoothing station:
The smoothing station consists of a total of three smoothing wheels (simultaneous three-wheel machining) with an axial oscillation unit. The easily replaceable smoothing wheels are arranged in a triangle around the workpiece.


Depending on the type and requirements of the workpiece, reworking and smoothing stations can be operated jointly or independently of one another and on an individual scale. In principle, it is advisable to let the workpiece run through both machining processes in order to achieve an optimal result.

Properties:


  • Removal or reduction of tooth damage up to 0.2mm in size possible in seconds without changing the flank shape and tooth geometry.
  • Mandrel-free system - low tool costs
  • "Whole-tooth contact" in various predefined flank areas thanks to three-way smoothing wheels.
  • Automatically oscillating smoothing wheels and workpiece guides for effective smoothing of crowned and / or conical gears.
  • Easily convertible to a different component type thanks to:
    - Exchange of smoothing wheels
    - Selection of the component on the operator panel
    - Replacement of the jaw inserts of the gripper (if necessary)
    - Replacement of the clamping bolts (if necessary)
  • Max. Changeover time: 15 min
  • High overall efficiency of the system due to the removal or reduction of tooth flank damage in seconds, including when using the oscillating movement.
  • Optimal adaptation of the working conditions to the workpiece through:
    - Stepless setting of the processing parameters such as contact force (smoothing pressure), smoothing speed, smoothing time and oscillation frequency
    - Optional use of the lubrication system (for dry or wet processing)
    - The oscillation movement can be switched on and off
  • Long tool life and gentle machining of the workpiece through the use of a cooling-lubricating combination integrated in the machine control.
  • Low coolant and lubricant consumption thanks to the use of a minimum quantity cooling and lubricating system, high environmental compatibility.
  • Short overall lead times
  • The system can be easily interlinked with any production line.

Excerpt from customer test series

The picture shows considerable fluctuations in the time signal, resulting from a very uneven and damaged surface - strong noise development when unrolling.

Classification of the specimen as "reworking part to reject part"
Reworking part
Part not ok
Part ok after reworking and smoothing process
Result
  • As far as possible removal of the above material - "polished" surface on all teeth
  • Significant flattening of the time signal curve
  • Significant improvement in noise behavior. Due to their smooth surface structure, parts run much more smoothly.
  • A high proportion of the previously noise-tested reworking parts reached the OK part level after the 1st smoothing process.