KOEPFER Gear Hobbing Machines
Truly extreme gear shapes can be produced on KOEPFER gear hobbing machines as well. However, unlike the less extreme forms, these shapes cannot usually be defined in a mathematically simple way. Complex calculations and formulas are required. “In these cases, the software needs to be adapted for each application. Naturally we make our expertise available to our customers for this purpose,” said Manuel Hofmeier.
which in turn require non-circular gears. They are much more cost-effective to produce than, for example, an electronic direct drive with variable speed control. This realization still has to get through to developers in many industries, of course. As that occurs, we are very well placed with our technology,” said development engineer Manuel Hofmeier in conclusion. TECHNICAL DATA
“Ultimately, our machines make standardized volume production
Module, max.
of any convex contour feasible. It‘s a whole new dimension of
Workpiece diameter, max.
gear hobbing.”
Hobbing length, max.
It will therefore come as no surprise that the gearing experts at EMAG KOEPFER believe their new technology has very strong
Workpiece length, max.
market potential. There are, for instance, many applications in
Hobbing width, max.
the machinery industry or in logistics where alternating torques
Shift distance
are required within one system or where the transmission of power is irregular. “Our methods ultimately make it a lot easier to develop the mechanical solutions required for these tasks,
Main spindle: Speed, max. Hobbing speed, max.
K 160 mm
2,5 90 / 140
mm
200 / 480
mm
300 / 1,000
mm
250
mm
160
1/min
4,000
1/min
5.000
in in
in in in
rpm rpm
3.5 / 5.5
8 / 19
12 / 39.5
10
EMAG Salach GmbH SALACH Austrasse 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-820 E-mail: info@salach.emag.com
LEIPZIG Pittlerstrasse 26 04159 Leipzig Germany Phone: +49 341 4666-0 Fax: +49 341 4666-114 E-mail: info@leipzig.emag.com
AUSTRIA Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com
FRANKFURT Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245-0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com
MUNICH Zamdorferstrasse 100 81677 München Germany Phone: +49 89 99886-250 Fax: +49 89 99886-160 E-mail: info@muenchen.emag.com
DENMARK Horsvangen 31 7120 Vejle Ø Denmark Phone: +45 75 854854 Fax: +45 75 816276 E-mail: info@daenemark.emag.com SWEDEN Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com
6.5
4,000
5.000
HUNGARY Gerenda u. 10. 1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com CZECH REPUBLIC Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com
02.2016 · © Copyright EMAG · Printed in Germany
“Extreme” gear shapes can be manufactured as well
Manufacturing Systems for Precision Metal Components
POLAND ul. Prusa 9F / 1 50-319 Wrocław Poland Phone: +48 728 389 989 Fax: +48 601 371 353 E-mail: info@poland.emag.com
Market Companies
SPAIN EMAG Máquinas Herramienta S.L. Pasaje Arrahona, no 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info@emh.emag.com ITALY ZETA EMAG Srl Viale Longarone 41/A 20080 Zibido S.Giacomo (MI) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-21 E-mail: zetaemag@emag.com
GREAT BRITAIN EMAG (UK) Ltd. Chestnut House, Kingswood Business Park Holyhead Road, Albrighton Wolverhampton WV7 3AU Great Britain Phone: +44 1902 37609-0 Fax: +44 1902 37609-1 E-mail: info@uk.emag.com RUSSIA EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moskau Russia Phone: +7 495 28709-60 Fax: +7 495 28709-62 E-mail: info@russia.emag.com USA EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com
MEXICO EMAG Mexico Colina de la Umbria 10 53140 Boulevares Naucalpan Edo. de México Mexico Phone: +52 55 5374266-5 Fax: +52 55 5374266-4 E-mail: info@mexico.emag.com BRAZIL EMAG do Brasil Ltda. Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP, Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com INDIA EMAG INDIA Pvt. Ltd. Technology Centre, No. 17/G/46-3, Industrial Suburb, 2nd Stage, Yeshwantpur, Bangalore 560022 India Phone: +91 80 42544400 Fax: +91 80 42544440 E-mail: info@india.emag.com
CHINA EMAG (China) Machinery Co.,Ltd. Building A3 & B7 Cangneng Europe & America Technology Park No. 8 Loujiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com KOREA EMAG Korea Ltd. Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong, Joongwon-gu, Seongnam City Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com JAPAN TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com
KOEPFER GEAR HOBBING MACHINES Subject to technical changes.
FRANCE NODIER EMAG Industrie 2, Parc des Fontenelles 78870 Bailly France Phone: +33 130 8047-70 Fax: +33 130 8047-69 E-mail: info@nodier.emag.com
STANDARDIZING THE PRODUCTION OF NON-CIRCULAR GEARS
The dynamic axes of the KOEPFER gear hobbing machine, type 160, are perfectly synchronized for non-circular machining. This is achieved with new machine software.
www.emag.com
Manufacturing Systems for Precision Metal Components
KOEPFER Gear Hobbing Machines
KOEPFER GEAR HOBBING MACHINES: Standardizing the Production of Non-Circular Gears Non-circular gears are making headway in many areas of application – in machines, engines, and pumps they ensure perfectly tuned irregular power transmission. This allows the replacement of expensive direct drives used to control the changes in power transmission electronically. The demanding production of the non-circular components does present a challenge, however. Currently the methods used, including EDM or gear shaping, are usually relatively expensive. The key question is, how can the components be produced more flexibly and more efficiently? The gear hobbing specialists at EMAG subsidiary KOEPFER have an innovative answer. Their new process makes it possible to machine mathematically definable non-circular contours on a standard hobbing machine for significant reductions in production costs.
Another practical application of non-circular gears can be found in the automotive industry. They are used in an engine‘s timing assembly to prevent or compensate for undesirable oscillations. They do so by generating a kind of counter-oscillation in the system. As early as the 1980s oval bicycle chainrings provided improved power transmission when pedaling. Pump motors also benefit from non-circular gears, to cite another example. They help to adapt the flow of the pumped fluid perfectly to the overall system. As their popularity increases, the search for an efficient way of manufacturing non-circular gears is being stepped up. Currently the complex geometric shapes are often still manufactured by
Circular gears are not always the best solution for transmitting
to be very slow, but the stroke of the tool before and after
power in a machine or engine – on the contrary: in some areas
should be as fast as possible. This safeguards the quality of the
of application, the resulting regular transmission of power even
produced components while shortening the production cycle.
causes problems or adverse side effects. For instance, when
Non-circular gears are ideal for producing this continuously
deep drawing a component, the stroke motion of the drawing
recurring, irregular motion relatively easily and, above all, with
machine needs to be quite irregular: The drawing action has
high precision.
EDM, sintering, or shaping. However, this incurs relatively high costs, especially at small and medium unit volumes – due to the need for new tools, for example. These methods are also relatively inflexible. Users are looking for solutions that make it possible to
Non-circular gears are making headway in many areas of application – in machines, engines, and pumps where they ensure perfectly tuned irregular power transmission. The quality of the finished gearing is comparable to that of standard circular gears. Even particularly complex shapes can be machined.
respond quickly to changing requirements in gear production – from circular gears to non-circular gears and back again.
Standard gear hobbing machine in action From this perspective, machining by hobbing is an attractive alternative. This standardized process is highly precise and flexible. Non-circular machining does, however, pose a special challenge: “The non-circular form of the blank makes it necessary to continuously correct the position of the hob during the cutting process. But this can, of course, be done with the dynamic axes of a modern gear hobbing machine. What‘s
»» In the case of sharply eccentric contours, the blank itself will already be oval in shape. It is first measured in the machining area of the machine, and then the machine‘s axes are synchronized to the position of the component. Next, the hobbing process starts. »» Alternatively there is the option of taking an initially round blank and milling it to create an oval contour, for example. This is, however, only possible if the desired shape is not too eccentric.
important is the perfectly synchronized control of those axes,”
In both cases, the machining process is carried out with
said Manuel Hofmeier from KOEPFER, pinpointing the essence
perfectly synchronized and dynamic machine axes. The
of the challenge. The hobbing experts at the EMAG subsidiary
hob follows the exact contour around the component. The
have developed a new solution which can be used as needed
procedure ensures that the teeth are cut in precisely the
on all standard 160 and 300 machine types with the current
shape required.
control system – only their software needs to be modified. The machine is then fully prepared for non-circular machining. “That is the critical point. In the past, we have created customer-
EMAG KOEPFER GmbH, Global Headquarters
Klaus Zandomeni EMAG KOEPFER GmbH
specific one-off solutions for non-circular machining. Now we
“Our approach has major advantages especially for
have a standardized solution. The mechanical components
small and medium volume production.”
of the machines do not need to be modified for it,” confirmed Hofmeier.
“The user takes a few minutes to set up the standard machine for the non-circular component, and can then produce a few
CONTACT EMAG KOEPFER GmbH
Perfectly synchronized machine axes
Siederstrasse 49 · 78054 Villingen-Schwenningen · Germany Phone: +49 7720 99689-0 · Fax: +49 7720 99689-201 E-mail: info@emag.com · Internet: www.emag.com
The machining process is carried out with perfectly synchronized and dynamic machine axes. The hob follows the exact contour around the component.
initial prototypes, for example. The user could then return to high volume production of some other gear. The geometric
The user simply enters the mathematical data of the required
data of the oval component is stored in the control system
contour into the software. The rest of the procedure depends
from that point on. Other methods cannot provide this kind of
on the component.
immense flexibility.”
KOEPFER Gear Hobbing Machines
Truly extreme gear shapes can be produced on KOEPFER gear hobbing machines as well. However, unlike the less extreme forms, these shapes cannot usually be defined in a mathematically simple way. Complex calculations and formulas are required. “In these cases, the software needs to be adapted for each application. Naturally we make our expertise available to our customers for this purpose,” said Manuel Hofmeier.
which in turn require non-circular gears. They are much more cost-effective to produce than, for example, an electronic direct drive with variable speed control. This realization still has to get through to developers in many industries, of course. As that occurs, we are very well placed with our technology,” said development engineer Manuel Hofmeier in conclusion. TECHNICAL DATA
“Ultimately, our machines make standardized volume production
Module, max.
of any convex contour feasible. It‘s a whole new dimension of
Workpiece diameter, max.
gear hobbing.”
Hobbing length, max.
It will therefore come as no surprise that the gearing experts at EMAG KOEPFER believe their new technology has very strong
Workpiece length, max.
market potential. There are, for instance, many applications in
Hobbing width, max.
the machinery industry or in logistics where alternating torques
Shift distance
are required within one system or where the transmission of power is irregular. “Our methods ultimately make it a lot easier to develop the mechanical solutions required for these tasks,
Main spindle: Speed, max. Hobbing speed, max.
K 160 mm
2,5 90 / 140
mm
200 / 480
mm
300 / 1,000
mm
250
mm
160
1/min
4,000
1/min
5.000
in in
in in in
rpm rpm
3.5 / 5.5
8 / 19
12 / 39.5
10
EMAG Salach GmbH SALACH Austrasse 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-820 E-mail: info@salach.emag.com
LEIPZIG Pittlerstrasse 26 04159 Leipzig Germany Phone: +49 341 4666-0 Fax: +49 341 4666-114 E-mail: info@leipzig.emag.com
AUSTRIA Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com
FRANKFURT Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245-0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com
MUNICH Zamdorferstrasse 100 81677 München Germany Phone: +49 89 99886-250 Fax: +49 89 99886-160 E-mail: info@muenchen.emag.com
DENMARK Horsvangen 31 7120 Vejle Ø Denmark Phone: +45 75 854854 Fax: +45 75 816276 E-mail: info@daenemark.emag.com SWEDEN Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com
6.5
4,000
5.000
HUNGARY Gerenda u. 10. 1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com CZECH REPUBLIC Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com
02.2016 · © Copyright EMAG · Printed in Germany
“Extreme” gear shapes can be manufactured as well
Manufacturing Systems for Precision Metal Components
POLAND ul. Prusa 9F / 1 50-319 Wrocław Poland Phone: +48 728 389 989 Fax: +48 601 371 353 E-mail: info@poland.emag.com
Market Companies
SPAIN EMAG Máquinas Herramienta S.L. Pasaje Arrahona, no 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info@emh.emag.com ITALY ZETA EMAG Srl Viale Longarone 41/A 20080 Zibido S.Giacomo (MI) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-21 E-mail: zetaemag@emag.com
GREAT BRITAIN EMAG (UK) Ltd. Chestnut House, Kingswood Business Park Holyhead Road, Albrighton Wolverhampton WV7 3AU Great Britain Phone: +44 1902 37609-0 Fax: +44 1902 37609-1 E-mail: info@uk.emag.com RUSSIA EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moskau Russia Phone: +7 495 28709-60 Fax: +7 495 28709-62 E-mail: info@russia.emag.com USA EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com
MEXICO EMAG Mexico Colina de la Umbria 10 53140 Boulevares Naucalpan Edo. de México Mexico Phone: +52 55 5374266-5 Fax: +52 55 5374266-4 E-mail: info@mexico.emag.com BRAZIL EMAG do Brasil Ltda. Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP, Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com INDIA EMAG INDIA Pvt. Ltd. Technology Centre, No. 17/G/46-3, Industrial Suburb, 2nd Stage, Yeshwantpur, Bangalore 560022 India Phone: +91 80 42544400 Fax: +91 80 42544440 E-mail: info@india.emag.com
CHINA EMAG (China) Machinery Co.,Ltd. Building A3 & B7 Cangneng Europe & America Technology Park No. 8 Loujiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com KOREA EMAG Korea Ltd. Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong, Joongwon-gu, Seongnam City Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com JAPAN TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com
KOEPFER GEAR HOBBING MACHINES Subject to technical changes.
FRANCE NODIER EMAG Industrie 2, Parc des Fontenelles 78870 Bailly France Phone: +33 130 8047-70 Fax: +33 130 8047-69 E-mail: info@nodier.emag.com
STANDARDIZING THE PRODUCTION OF NON-CIRCULAR GEARS
The dynamic axes of the KOEPFER gear hobbing machine, type 160, are perfectly synchronized for non-circular machining. This is achieved with new machine software.
www.emag.com
Manufacturing Systems for Precision Metal Components
KOEPFER Gear Hobbing Machines
KOEPFER GEAR HOBBING MACHINES: Standardizing the Production of Non-Circular Gears Non-circular gears are making headway in many areas of application – in machines, engines, and pumps they ensure perfectly tuned irregular power transmission. This allows the replacement of expensive direct drives used to control the changes in power transmission electronically. The demanding production of the non-circular components does present a challenge, however. Currently the methods used, including EDM or gear shaping, are usually relatively expensive. The key question is, how can the components be produced more flexibly and more efficiently? The gear hobbing specialists at EMAG subsidiary KOEPFER have an innovative answer. Their new process makes it possible to machine mathematically definable non-circular contours on a standard hobbing machine for significant reductions in production costs.
Another practical application of non-circular gears can be found in the automotive industry. They are used in an engine‘s timing assembly to prevent or compensate for undesirable oscillations. They do so by generating a kind of counter-oscillation in the system. As early as the 1980s oval bicycle chainrings provided improved power transmission when pedaling. Pump motors also benefit from non-circular gears, to cite another example. They help to adapt the flow of the pumped fluid perfectly to the overall system. As their popularity increases, the search for an efficient way of manufacturing non-circular gears is being stepped up. Currently the complex geometric shapes are often still manufactured by
Circular gears are not always the best solution for transmitting
to be very slow, but the stroke of the tool before and after
power in a machine or engine – on the contrary: in some areas
should be as fast as possible. This safeguards the quality of the
of application, the resulting regular transmission of power even
produced components while shortening the production cycle.
causes problems or adverse side effects. For instance, when
Non-circular gears are ideal for producing this continuously
deep drawing a component, the stroke motion of the drawing
recurring, irregular motion relatively easily and, above all, with
machine needs to be quite irregular: The drawing action has
high precision.
EDM, sintering, or shaping. However, this incurs relatively high costs, especially at small and medium unit volumes – due to the need for new tools, for example. These methods are also relatively inflexible. Users are looking for solutions that make it possible to
Non-circular gears are making headway in many areas of application – in machines, engines, and pumps where they ensure perfectly tuned irregular power transmission. The quality of the finished gearing is comparable to that of standard circular gears. Even particularly complex shapes can be machined.
respond quickly to changing requirements in gear production – from circular gears to non-circular gears and back again.
Standard gear hobbing machine in action From this perspective, machining by hobbing is an attractive alternative. This standardized process is highly precise and flexible. Non-circular machining does, however, pose a special challenge: “The non-circular form of the blank makes it necessary to continuously correct the position of the hob during the cutting process. But this can, of course, be done with the dynamic axes of a modern gear hobbing machine. What‘s
»» In the case of sharply eccentric contours, the blank itself will already be oval in shape. It is first measured in the machining area of the machine, and then the machine‘s axes are synchronized to the position of the component. Next, the hobbing process starts. »» Alternatively there is the option of taking an initially round blank and milling it to create an oval contour, for example. This is, however, only possible if the desired shape is not too eccentric.
important is the perfectly synchronized control of those axes,”
In both cases, the machining process is carried out with
said Manuel Hofmeier from KOEPFER, pinpointing the essence
perfectly synchronized and dynamic machine axes. The
of the challenge. The hobbing experts at the EMAG subsidiary
hob follows the exact contour around the component. The
have developed a new solution which can be used as needed
procedure ensures that the teeth are cut in precisely the
on all standard 160 and 300 machine types with the current
shape required.
control system – only their software needs to be modified. The machine is then fully prepared for non-circular machining. “That is the critical point. In the past, we have created customer-
EMAG KOEPFER GmbH, Global Headquarters
Klaus Zandomeni EMAG KOEPFER GmbH
specific one-off solutions for non-circular machining. Now we
“Our approach has major advantages especially for
have a standardized solution. The mechanical components
small and medium volume production.”
of the machines do not need to be modified for it,” confirmed Hofmeier.
“The user takes a few minutes to set up the standard machine for the non-circular component, and can then produce a few
CONTACT EMAG KOEPFER GmbH
Perfectly synchronized machine axes
Siederstrasse 49 · 78054 Villingen-Schwenningen · Germany Phone: +49 7720 99689-0 · Fax: +49 7720 99689-201 E-mail: info@emag.com · Internet: www.emag.com
The machining process is carried out with perfectly synchronized and dynamic machine axes. The hob follows the exact contour around the component.
initial prototypes, for example. The user could then return to high volume production of some other gear. The geometric
The user simply enters the mathematical data of the required
data of the oval component is stored in the control system
contour into the software. The rest of the procedure depends
from that point on. Other methods cannot provide this kind of
on the component.
immense flexibility.”
Manufacturing Systems for Precision Metal Components
KOEPFER Gear Hobbing Machines
KOEPFER GEAR HOBBING MACHINES: Standardizing the Production of Non-Circular Gears Non-circular gears are making headway in many areas of application – in machines, engines, and pumps they ensure perfectly tuned irregular power transmission. This allows the replacement of expensive direct drives used to control the changes in power transmission electronically. The demanding production of the non-circular components does present a challenge, however. Currently the methods used, including EDM or gear shaping, are usually relatively expensive. The key question is, how can the components be produced more flexibly and more efficiently? The gear hobbing specialists at EMAG subsidiary KOEPFER have an innovative answer. Their new process makes it possible to machine mathematically definable non-circular contours on a standard hobbing machine for significant reductions in production costs.
Another practical application of non-circular gears can be found in the automotive industry. They are used in an engine‘s timing assembly to prevent or compensate for undesirable oscillations. They do so by generating a kind of counter-oscillation in the system. As early as the 1980s oval bicycle chainrings provided improved power transmission when pedaling. Pump motors also benefit from non-circular gears, to cite another example. They help to adapt the flow of the pumped fluid perfectly to the overall system. As their popularity increases, the search for an efficient way of manufacturing non-circular gears is being stepped up. Currently the complex geometric shapes are often still manufactured by
Circular gears are not always the best solution for transmitting
to be very slow, but the stroke of the tool before and after
power in a machine or engine – on the contrary: in some areas
should be as fast as possible. This safeguards the quality of the
of application, the resulting regular transmission of power even
produced components while shortening the production cycle.
causes problems or adverse side effects. For instance, when
Non-circular gears are ideal for producing this continuously
deep drawing a component, the stroke motion of the drawing
recurring, irregular motion relatively easily and, above all, with
machine needs to be quite irregular: The drawing action has
high precision.
EDM, sintering, or shaping. However, this incurs relatively high costs, especially at small and medium unit volumes – due to the need for new tools, for example. These methods are also relatively inflexible. Users are looking for solutions that make it possible to
Non-circular gears are making headway in many areas of application – in machines, engines, and pumps where they ensure perfectly tuned irregular power transmission. The quality of the finished gearing is comparable to that of standard circular gears. Even particularly complex shapes can be machined.
respond quickly to changing requirements in gear production – from circular gears to non-circular gears and back again.
Standard gear hobbing machine in action From this perspective, machining by hobbing is an attractive alternative. This standardized process is highly precise and flexible. Non-circular machining does, however, pose a special challenge: “The non-circular form of the blank makes it necessary to continuously correct the position of the hob during the cutting process. But this can, of course, be done with the dynamic axes of a modern gear hobbing machine. What‘s
»» In the case of sharply eccentric contours, the blank itself will already be oval in shape. It is first measured in the machining area of the machine, and then the machine‘s axes are synchronized to the position of the component. Next, the hobbing process starts. »» Alternatively there is the option of taking an initially round blank and milling it to create an oval contour, for example. This is, however, only possible if the desired shape is not too eccentric.
important is the perfectly synchronized control of those axes,”
In both cases, the machining process is carried out with
said Manuel Hofmeier from KOEPFER, pinpointing the essence
perfectly synchronized and dynamic machine axes. The
of the challenge. The hobbing experts at the EMAG subsidiary
hob follows the exact contour around the component. The
have developed a new solution which can be used as needed
procedure ensures that the teeth are cut in precisely the
on all standard 160 and 300 machine types with the current
shape required.
control system – only their software needs to be modified. The machine is then fully prepared for non-circular machining. “That is the critical point. In the past, we have created customer-
EMAG KOEPFER GmbH, Global Headquarters
Klaus Zandomeni EMAG KOEPFER GmbH
specific one-off solutions for non-circular machining. Now we
“Our approach has major advantages especially for
have a standardized solution. The mechanical components
small and medium volume production.”
of the machines do not need to be modified for it,” confirmed Hofmeier.
“The user takes a few minutes to set up the standard machine for the non-circular component, and can then produce a few
CONTACT EMAG KOEPFER GmbH
Perfectly synchronized machine axes
Siederstrasse 49 · 78054 Villingen-Schwenningen · Germany Phone: +49 7720 99689-0 · Fax: +49 7720 99689-201 E-mail: info@emag.com · Internet: www.emag.com
The machining process is carried out with perfectly synchronized and dynamic machine axes. The hob follows the exact contour around the component.
initial prototypes, for example. The user could then return to high volume production of some other gear. The geometric
The user simply enters the mathematical data of the required
data of the oval component is stored in the control system
contour into the software. The rest of the procedure depends
from that point on. Other methods cannot provide this kind of
on the component.
immense flexibility.”
KOEPFER Gear Hobbing Machines
Truly extreme gear shapes can be produced on KOEPFER gear hobbing machines as well. However, unlike the less extreme forms, these shapes cannot usually be defined in a mathematically simple way. Complex calculations and formulas are required. “In these cases, the software needs to be adapted for each application. Naturally we make our expertise available to our customers for this purpose,” said Manuel Hofmeier.
which in turn require non-circular gears. They are much more cost-effective to produce than, for example, an electronic direct drive with variable speed control. This realization still has to get through to developers in many industries, of course. As that occurs, we are very well placed with our technology,” said development engineer Manuel Hofmeier in conclusion. TECHNICAL DATA
“Ultimately, our machines make standardized volume production
Module, max.
of any convex contour feasible. It‘s a whole new dimension of
Workpiece diameter, max.
gear hobbing.”
Hobbing length, max.
It will therefore come as no surprise that the gearing experts at EMAG KOEPFER believe their new technology has very strong
Workpiece length, max.
market potential. There are, for instance, many applications in
Hobbing width, max.
the machinery industry or in logistics where alternating torques
Shift distance
are required within one system or where the transmission of power is irregular. “Our methods ultimately make it a lot easier to develop the mechanical solutions required for these tasks,
Main spindle: Speed, max. Hobbing speed, max.
K 160 mm
2,5 90 / 140
mm
200 / 480
mm
300 / 1,000
mm
250
mm
160
1/min
4,000
1/min
5.000
in in
in in in
rpm rpm
3.5 / 5.5
8 / 19
12 / 39.5
10
EMAG Salach GmbH SALACH Austrasse 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-820 E-mail: info@salach.emag.com
LEIPZIG Pittlerstrasse 26 04159 Leipzig Germany Phone: +49 341 4666-0 Fax: +49 341 4666-114 E-mail: info@leipzig.emag.com
AUSTRIA Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com
FRANKFURT Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245-0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com
MUNICH Zamdorferstrasse 100 81677 München Germany Phone: +49 89 99886-250 Fax: +49 89 99886-160 E-mail: info@muenchen.emag.com
DENMARK Horsvangen 31 7120 Vejle Ø Denmark Phone: +45 75 854854 Fax: +45 75 816276 E-mail: info@daenemark.emag.com SWEDEN Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com
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HUNGARY Gerenda u. 10. 1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com CZECH REPUBLIC Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com
02.2016 · © Copyright EMAG · Printed in Germany
“Extreme” gear shapes can be manufactured as well
Manufacturing Systems for Precision Metal Components
POLAND ul. Prusa 9F / 1 50-319 Wrocław Poland Phone: +48 728 389 989 Fax: +48 601 371 353 E-mail: info@poland.emag.com
Market Companies
SPAIN EMAG Máquinas Herramienta S.L. Pasaje Arrahona, no 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info@emh.emag.com ITALY ZETA EMAG Srl Viale Longarone 41/A 20080 Zibido S.Giacomo (MI) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-21 E-mail: zetaemag@emag.com
GREAT BRITAIN EMAG (UK) Ltd. Chestnut House, Kingswood Business Park Holyhead Road, Albrighton Wolverhampton WV7 3AU Great Britain Phone: +44 1902 37609-0 Fax: +44 1902 37609-1 E-mail: info@uk.emag.com RUSSIA EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moskau Russia Phone: +7 495 28709-60 Fax: +7 495 28709-62 E-mail: info@russia.emag.com USA EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com
MEXICO EMAG Mexico Colina de la Umbria 10 53140 Boulevares Naucalpan Edo. de México Mexico Phone: +52 55 5374266-5 Fax: +52 55 5374266-4 E-mail: info@mexico.emag.com BRAZIL EMAG do Brasil Ltda. Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP, Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com INDIA EMAG INDIA Pvt. Ltd. Technology Centre, No. 17/G/46-3, Industrial Suburb, 2nd Stage, Yeshwantpur, Bangalore 560022 India Phone: +91 80 42544400 Fax: +91 80 42544440 E-mail: info@india.emag.com
CHINA EMAG (China) Machinery Co.,Ltd. Building A3 & B7 Cangneng Europe & America Technology Park No. 8 Loujiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com KOREA EMAG Korea Ltd. Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong, Joongwon-gu, Seongnam City Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com JAPAN TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com
KOEPFER GEAR HOBBING MACHINES Subject to technical changes.
FRANCE NODIER EMAG Industrie 2, Parc des Fontenelles 78870 Bailly France Phone: +33 130 8047-70 Fax: +33 130 8047-69 E-mail: info@nodier.emag.com
STANDARDIZING THE PRODUCTION OF NON-CIRCULAR GEARS
The dynamic axes of the KOEPFER gear hobbing machine, type 160, are perfectly synchronized for non-circular machining. This is achieved with new machine software.
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