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Company Profile About ESGI Tools
Profile Esgi tools pvt ltd – a leading tool manufacturing company set up in 1991 is renowned for its product in the precision Gear Cutting Tools industry, provides a comprehensive range of quality gear cutting tools to its customers with additional facilities of coating and re-sharpening. Here at Esgi the utmost importance is given to the quality of the product which lends an optimised performance and protracted life. Company’s prime focus is to look into the needs of entire automobile industry and therefore ESGI caters to all the mobility segments namely two wheelers, cars, commercial vehicles, tractors, agriculture and construction equipment, gear box, defence, railways, etc. and have developed tooling for most of the world’s best companies falling in the earlier defined segments.
Product Range
• Gear hobs • ES-Cut hobs • Gear Shaving cutters
• Master gears • Shaper cutters • Rack milling cutters
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• Rotary cutters • Spline rollers
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TECHNOLOGY BEHIND ESGI About ESGI Tools
Software ESGI has developed own software’s for designing with their abundance of experience gathered in years of manufacturing gear cutting tools. We design & produce the tools to meet the varied requirements of customers We use simulation process for hobbing & shaving profiles to visualise the exact output
Infrastructure ESGI deploys state of the art manufacturing facilities backed by our fully equipped metallurgical Laboratory, quality control cell with state of art inspection machines and equipments, manned by qualified personnel to check at every stage of manufacturing process of all products especially with a view to ensure adherence to our very strict specifications of quality standards.
We import raw material from some of the world best companies and strict incoming material inspection is undertaken to ensure the quality standards.
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INDUSTRIES WE SERVE About ESGI Tools
Agricultural Equipment
Cars
Engineering Vehicles Personal Trasport
Scooters
Two Wheelers
Passenger Vehicles Commercial Vehicles
Three Wheelers
Truck / Lorry
Railways
Defence
Reneuable Energy
Industrial
A Few of Our Clients we Serve
And Many More
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Tool Application About ESGI Tools
Sprockets
Large Gears Engine Gears
Straight Bevel Gears
Gearboxes
Transmission Gears
Pump Gears
Ring Gears
Racks
Slack Adjuster
Worm Gears
Shafts
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OPTIMISED PERFORMANCE SINCE 1991
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1. HOBS Hob Nomenclature And Standard Hob Tooth Profiles
A. Hob Nomenclature Total Length Cutting Length
TOOTH FLUTE
Hub Length Hub Face
A
DI
P.C.D
E
R BO
P.C.D
OUTSIDE DIA
RELIEF FACE
KEYWAY Bearing Face CUTTING TOOTH FACE
Recess
B. Standard Hob Tooth Profiles
R
R
R
GA
H4
H4
20°
Sn
Sn
Sn
Rr
Rr
Rr
Pre-shaving/pre-grinding With Pb
Pre-shaving/pre-grinding With Pb Hao Sn H4 H Pb R Ao Rr
Rr
H4
210Â
°
Hao
R
Sn
Hao
GA
20°
H4
Pb
Hao
Hao
H
Ao
Rr
Standard Finishing Hob
= = = = = = = =
Addendum Tooth Thickness Full Depth Protuberance Height Protuberance Amount Hob Tip Radius Protuberance Angle Root Radius
Involute Spline Hob
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1.1 TYPES OF HOBS Hobs
Range: up to 25 Module Accuracy Class upto AAA as per DIN 3968 Made in materials M35, ASP2030, ASP2052, S390 Bore & Shank type Multi-gashes Multi-start Shoulder Clearance type
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1.1 TYPES OF HOBS Hobs
Types • • • • • • • • • • • • • • •
STANDARD gear hobs Pre shaving hobs Pre grinding hobs Pre skiving Hobs Shank type hobs Stub and fellow stub hobs Involute spline hobs Parallel / straight spline hobs Chain sprocket hobs Serration hobs Timing pulley hobs Worm hobs Chamfer hobs and cutters Special hobs Hurth milling cutters
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1.2 STANDARD GEAR HOBS Hobs
Standard Hob Sizes Normal Module
Normal Dp
Size OD
1 - 1.25 1.5 - 1.75 2 - 2.25 2.5 - 2.75 3 - 3.5 3.5 3.75 4 4.5 5 5.5 6 6.5 7 8 9 10 11 12 13 14 15 16 18 20 22 24 25
24 - 20 18 - 14 12 - 11 10 - 9 8 7 6 5.5 5 4.5 4 3.5 3 2.65 2.5 2.25 2 1.75 1.5 1.25 1
50 55 60 70 70 80 80 90 90 100 100 110 110 110 120 125 140 160 160 170 180 180 200 220 240 250 250 270
OAL 50 55 60 65 70 75 75 80 85 90 95 100 110 115 130 145 160 175 190 200 210 220 230 250 270 270 300 300
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Bore 22 22 22 22 27 27 27 27 27 27 32 32 32 32 32 32 32 40 40 40 40 40 40 50 50 50 50 50
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1.3 CHAIN SPROCKET HOBS Hobs
Roller Chain Sprocket Hob Chain Pitch Roller Diameter 6.35 (1/4") 9.525 (3/8") 9.525 (3/8") 12.7 (1/2") 12.7 (1/2") 12.7 (1/2") 15.875 (5/8") 19.05 (3/4") 25.4 (1") 31.75 (1.1/4") 38.1 (1.1/2") 44.45 (1.3/4") 50.8 (2")
3.3 3.3 5.08 6.35 7.77 (Agriculture) 7.95 (Standard) 8.5 (Motorcycle) 10.16 11.907 15.875 19.05 22.225 25.4
Hob Specifications ASA I, II Chain
Outer Diameter
RS25 RS35 RS35 RS41 RS40 RS40 RS50 RS60 RS80 RS100 RS120 RS140 RS160
Overall Length
60 65 65 80 80 80 90 90 110 120 140 160 170
60 65 65 75 75 75 90 105 125 140 160 190 210
Overall Length 22
27 / 32
27 32 32 / 40 40
ASA Profile Pn
Type 1
U
Pn/2
Q
Pn/2 T
Q
G
°
215Â
17.5° K
G
R s
D
h1 C
H
35°
F
17.5° Ks
R
b d
F
E
Ds
Ordering Instructions 1. Standard of Chain ASA-1 ASA-2 DIN JIS-U JIS-S BS (ISO)
3. Chain Number 4. Roller Diameter 5. Bore size of Hob
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1.4 PARALLEL OR STRAIGHT SPLINE HOBS Hobs
Dimension Details Spline Dimensions
Hob Dimensions TYPE 1 Outside Ø
60 80 100 110 140 80 100 110 -
Overall Length
60 75 95 115 170 75 90 115 -
Bore Ø
22 27 (26.988) 32 (31.75) 40 (38.1) 27 (26.988) 32 (31.75) -
N
6 8 10 -
TYPE 2
Minor Ø
Major Ø
Width
23 26 28 32 36 42 46 58 56 62 78 82 36 36 42 50 52 56 62 72 82 92
26 30 32 36 40 46 50 14 62 68 18 88 6 40 46 9 58 62 68 78 88 98
6 6 7 8 8 10 12 0.4 14 16 18 20 6 7 8 9 10 10 12 12 12 14
Chamfer Ammount
.3 .4 .4 .5 -
N
6 8 10 -
Minor Ø
Major Ø
Width
11 13 16 18 21 23 26 28 32 36 42 46 52 56 62 72 82 32 36 42 46 52 56 62 10 82 92
14 16 20 22 25 28 32 34 38 42 48 54 60 65 72 82 92 32 42 48 54 60 65 72 72 92 102
3 3.5 4 5 5 6 6 7 8 8 10 12 14 14 16 18 20 6 7 8 9 10 10 12 82 12 14
Chamfer Ammount
0.3 0.4 0.5 0.4 0.5 -
Ordering Instructions 1. Outside Diameter with tolerance 2. Root Diameter with Tolerance 3. Spline width with Tolerance
4. Number of Splines 5. Component Drawing
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2. GEAR SHAVING CUTTERS Introduction
Our designs and technology ensure the compatibility of the shaving cutters with the pre-shaved tool for superior contact and to achieve the required true involute form diameters of the gears.
• • • •
Plunge Underpass Diagonal Conventional
Thickness up to 60mm PCD from 150 to 260mm Range from 1.5 to 8 Module Available in material M2/M3/ASP2023 Facilities to make all types of profiles like Tip Relief or Root Relief or both, ‘K’ profile, lead crowning or any customised profile.
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2.1 MASTER GEARS Gear Shaving Cutters
• • • • •
Range from 1.5 to 8 Module PCD from 95 to 200mm Thickness up to 70mm Accuracy class IV as per DIN 3962 Material M2
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2.2 SHAPER CUTTERS Gear Shaving Cutters
• • • • • • • •
Range from 1.5 to 10 Module PCD from 75 to 200mm for Disc & Hub Type PCD starts form 15mm for Shank Type For Internal & External gears Spur Profiles like Semi-topping & pre-shaving Accuracy class ‘AA’ & ‘A’ as per DIN1829 Material M35/ASP2030/ASP2052/390
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2.3 ROTARY CUTTERS 2.4 SPLINE ROLLERS Gear Shaving Cutters
Rotary cutters are used for cutting Straight Bevel Gears.
• Made in 'T' and 'U' Types • Material M2 and ASP2023 • Also Supplied with PVD Coating
Spline rollers are used for cutting involute shafts and splines. Made from special materials these rollers are used on highly specialised machines.
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3 TECHNICAL NOTES AND GUIDELINES 3.1 Types of Coatings & Hobbing
A. Types of PVD Coatings Tin
Used for conventional hobbing machines
AlCroNA
For high speed wet cutting CNC hobbing machine
AlCroNA pro
For high speed dry and wet cutting CNC hobbing machine
B. Types of Hobbing Climb Cutting
Conventional Cutting
Less hob wear
Hob wear
Shorter comma
Basic shape of chip
Quick hob wear Prolonged comma
Higher
Cutting speed
lower
Good
Hob performance
Poor
Yes ( Not on CNC machine ) Jumpy
Backlash Table feed
No Regular
Good
Component proďŹ le
Lower
Productivity
Higher
Preferred
Helical Gear
-
Large Gears
Gear Type
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Poor
Small Gear
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3 TECHNICAL NOTES AND GUIDELINES 3.2 Types of Coatings & Hobbing
C. Hob RPM Depending upon the cutting speed requirement, RPM can be calculated by following formula
RPM =
V x 1000 πxD
V : Cutting speed in meter/minute D: Diameter of Hob in mm.
D. Cycle Tme Cycle Time (t) can be calculated by using following calculations
RPM =
ZxL RPM x f x i
Z: Gear Teeth L: Hob Travel Length RPM: Hob Revolution f: Feed (mm/ work piece revolution) I: No. of Starts
E. Hob Shift Most important part of Hobbing operation is to use the optimal life of Hob by uniformly distributing the wear amount. This is achieved by shifting the Hob in axial direction by using following calculations
Straight M x π x i Flute Hob = N x Cos (LA) M: Module
Helical M x π x I x Cos (LA) Flute Hob = N
i: No. of starts LA: Lead angle of Hob N: Number of Flutes
F. Effect of sharpening errors on gear profile • • • •
Positive rake angle produces Gear Tip plus (minus pressure angle) Negative rake angle produces Gear Tip minus(plus pressure angle) Convex rake angle produces thinner gear teeth on middle of the profile Indexing error produces irregular profiles.
G. Hob Setting Angle • •
When hand of Hob & Work piece are same, then setting angle shall be β-γ When hand of Hob & Work piece are opposite, then setting angle shall be β+γ Β : Gear Helix Angle γ : Hob Lead Angle
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3 TECHNICAL NOTES AND GUIDELINES 3.2 Types of Coatings & Hobbing
H. Hob Wear Amount For better cutter efficiency, Hob wear should not be increased beyond following limits and should be sharpened quickly for better results.
Module
Max Wear Ammount
1 to 2 Module
0.20 mm
3 to 4 Module
0.25 mm
5 to 6 Module
0.30 mm
6 to 8 Module
0.40mm
Periphery Wear Due to prolonged use of chipped edge and Flank wear. Crater Wear Wear on the cutting face due to excessive feed rate. Chipping / Gauging When Crater extends to Cutting edge, it gets chipped off Normal Wear Desirable mode of hob wear after cutting substantial parts.
I. Hob Mounting Errors Hob Run Out
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Resulting Gear Profile
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ESGI Tools Private Limited B-6, Focal Point, Patiala (Punjab) -147004 India 000+91 175 2233991 to 94 esgi@esgitools.com www.esgitools.com CIN: U28939PB1998PTC021017
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