ESGI V4

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Company Profile

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 optimized 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, defense, 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 Rack Milling Cutters Master Gears Rotary Cutters Spline Rollers Shaper Cutters

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Technology & Infrastructure

Infrastructure 9 Axis Cnc Shaving Cutter Grinding Machine Cnc Hob Profile Grinding Machine Cnc Hob Sharpening Cnc Gear Analyzer

We at ESGI deploy state of the art manufacturing facilities backed by our fully equipped in-house 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 the world best companies combined with our strict incoming material inspection process ensures quality standards.

Industry Leading Raw Material Sourcing

State Of The Art Quality Control Cell

In-House Metallurgical Lab

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Technology & Infrastructure

Software ESGI has developed it’s own software’s for designing products with their abundant experience in manufacturing gear cutting tools for over two decades. We design & produce the tools to meet the varied requirements of customers We use simulation process for hobbing & shaving profiles to visualize the exact output

Our Plants ESGI is proudly nested in two geographical locations catering to the complete life cycle of gear cutting tools. Our head office complete with a 40,000 Sq feet state-of-the-art manufacturing facility is nested in Patiala, Punjab. Whereas our resharpening unit is located in Pune, the hub of automotive manufacturing in the country. Pune, Maharashtra Re-Sharpening Centre

Patiala, Punjab. Head Office & Manufacturing

10,000 Sq.Feet Manufacturing

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Value Added Services

Re-Sharpening Services

We at ESGI understand the importance of re-sharpening of tools to consistently obtain the desired results. We undertake the re-sharpening of Shaving Cutters at our mother plant and also at a dedicated facilities put up in Pune. Our mother plant serves for customer based in Northern, Eastern and Central India and our Pune plant serves the customers based in Western and Southern region.

Coatings Our tools are supplied with latest PVD coatings to enhance the life. We provide coatings as per customer requirement or application. PVD Coating increase the tool surface (and cutting edge) hardness, thus increase the cutting life obtained in each sharpening. 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

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Market Segments

Agricultural Equipment Cars

Engineering Vehicles Personal Transport

Scooters

Two Wheelers

Passenger Vehicles Commercial Vehicles

Three Wheelers

Truck / Lorry

Railways

Defense

Renewable Energy

Industrial

Construction Equipment

Our Customers Supply To

And Many More W W W. E S G I T O O L S . C O M

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Tool Applications

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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ESGI Hobs

Hob Nomenclature Total Length Cutting Length

TOOTH FLUTE

Hub Length Hub Face

A

DI

Hub dia

E OR

P.C.D

OUTSIDE DIA

RELIEF FACE

B

KEYWAY Bearing Face CUTTING TOOTH FACE

Recess

Standard Hob Tooth Profile Ao

R

R

GA

Hao

Pb

20°

Hao

Hao

H

R

H4

H4

H4

Pa Sn

Sn

Rr

Sn

Rr

Pre-shaving/pre-grinding With Pb - BP III

H4 Sn

Rr

Involute Spline Hob as per DIN 5480

Standard Finishing Hob BP II

Pre-shaving/pre-grinding Without Pb - BP III

Hao

20°

Rr

Hao Sn H4 H Pb R Ao Rr Ga

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= = = = = = = = =

Addendum Tooth Thickness Full Depth Protuberance Height Protuberance Amount Hob Tip Radius Protuberance Angle Root Radius Grinding Allowance

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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

Accuracy Class Upto Aaa As Per Din 3968 Range: Up To 25 Module Shoulder Clearance Type Bore & Shank Type Multi-gashes Multi-start Materials

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Standard Gear Hobs

Standard Hob Sizes Normal Module

Normal DP

Size (mm) 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

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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

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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Chain Sprocket 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 RS25 RS35 RS35 RS41 RS40 RS40 RS50 RS60 RS80 RS100 RS120 RS140 RS160

Outer Diameter

Overall Length

60 65 65 80 80 80 90 90 110 120 140 160 170

Overall Length

60 65 65 75 75 75 90 105 125 140 160 190 210

22

27 / 32

27 32 32 / 40 40

ASA Profile Pn Pn/2

Q

Pn/2

U

T

Q

G

°

215Â

G

17.5°

R

s

D

h1 35°

C H

17.5°

R

K

Ks

b d

F F

E

Ds

ASA Type 1 ( U Type ) Ordering Instructions 1. Standard of Chain ASA-1 ASA-2 DIN JIS-U JIS-S BS (ISO) 2. Chain pitch

ASA Type 2 ( S Type )

3. Chain number 4. Roller diameter 5. Bore size of hob

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Worm Gear Hobs

We manufacture worm wheel gear hobs which are bore type and shank type in single or multi start. ESGI worm gear hobs are available in topping or non-topping as per customer requirements.

Ordering Instructions • • • • •

Worm & Worm Wheel data Types of profiles: ZI, ZE, ZK, ZN, ZA In case of shank type, shank details Contact Ratio Please specify the contact pattern whether at entry or leaving side.

Rack Milling Cutters

We produce special form cutters for cutting Racks, Serrations and Splines. These cutters are produced in single or multiple rows with straight or spiral flutes with very close tolerances. • • • •

Range from 1.5 to 6 module Diameter from 50mm to 200mm Length from 20mm to 220m Accuracy class up to AAA

• Manufactured in latest PM & conventional machines • Supplied with all types of coatings

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ES-Cut HOBS for High Speed Cutting ESGI has introduced ES-Cut series hobs for high speed wet and dry cutting giving multiple benefits. Esgi has identified and shortlisted special high performance materials from all around the world after conducting extensive trials.

Up To

Up To

191%

76%

Life Increase

Time Saving

Benefits • • • • •

Reduces cycle time. Increase in parts per sharpening. Lesser Inventories. Fewer Variables for smooth production. Increase in plant capacity at no additional investment on land, machinery and manpower. • Reduced cost per component

Characteristics • • • •

Suitable for high volume components Range up to 7 module Suitable for dry and wet cutting Made in bore and shank type

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Worm Gear Hobs

Dimension Details Other

Machine and Cutting data

Hob Data

Component Data

Particulars Normal Module Normal PA Number of Teeth Face Width Spur/Helical Pre-Finish/Finish Component Hardness Hob Material Coating Type Hob Size Number of Threads Flutes Straight/Helical Machine Make Dry/Wet Pieces per Stack No. of Passes Cutting Speed (m/mt) Axial Feed (mm) Chip thickness (mm) Feed Marks (mm) Cutting Time seconds) Parts per Sharpening Time Saving 2Life Increase

ES-Cut

1.75 Mod 20 35 10.4 SPUR Finish 170-210 BHN

Other

ES-Cut

2.25 Mod 22.5 40 14 SPUR Pre-Shaving 170-210 BHN

Other

ES-Cut

3.0 MOD 20 28 10 SPUR Pre-Shaving 160-200 BHN

Other

ES-Cut

4.0 Mo 20 50 38.5 HEL 10째 Pre-Shaving 190-210 BHN

MACH-7

ES-65

ASP2052

ES-80

ASP2030

ES-65

ASP2052

ES-65

AlCroNA

AlCroNA

Futura

AlCroNA

Futura

AlCroNA

AlCroNA

AlCroNA

70*180*32

70*180*32

70*140*32

70*140*32

70*110*32

90*150*32

3

4

3

3

1

2

2

1

17

17

16

17

12

19

17

15

Straight

Helical

Helical

Helical

Straight

Straight

Straight

Mitsubishi Dry 5 1 1 157 210 1.6 1.4 0.174 0.209 0.0033 0.0026 43 27 7000 15000 -37% 114%

Liebherr Wet 1 1 160 1.4 0.188 0.0032 27 4500

1 300 1.4 0.188 0.0032 14 7000

-48% 56%

Mitsubishi Wet 2 1 1 80-85 130 2 2 0.23 0.199 0.0039 0.0022 180 44 1100 3200 -76% 191%

100*180*40 90*180*32

Helical

Liebherr Dry 1 2 85/100 2.5/1 0.202 0.00648 253 727

1 1 130 3 0.138 0.0105 150 1030

-41% 42%

We provide various grades of material are available depending on the type of machines, components and volumes. Following materials are recommended based on their cutting capacity. Mat ES-40 ES-65 ES-80

Mod 1.75 1.75 1.75

Rcd. Cutting speed 150-175 m/mt 175-210 m/mt 275-300 m/mt

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Parallel or Straight Spline 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 Amount

.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 Amount

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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Gear Shaving Cutters

Our designs and technology ensure the compatibility of the shaving cutters with the per-shaved tool for superior contact and to achieve the required true involute form diameters of the gears. Specifications • • • • •

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 customized profile.

Types • • • •

Plunge Underpass Diagonal Conventional

Master Gear Cutters

Specifications • • • • •

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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Shaper Cutters

Specifications • • • • • • • •

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

Rotary Cutters

Rotary cutters are used for cutting Straight Bevel Gears. • • • •

Made for G 104 & G 102 Made in 'T' and 'U' Types Material M2 and ASP2023 Also Supplied with PVD Coating

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Spline Rollers

Spline rollers are used for cutting involute shafts and splines. Made from special materials these rollers are used on highly specialized machines.

The ESGI Advantage Some ConďŹ dence Building Line Here Or Some Facts & Figures

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Technical Notes & Guidelines

Types Of Hobbing Climb Cutting

Quick hob wear Prolonged comma

Conventional Cutting

Hob wear

Less hob wear

Basic shape of chip

Shorter comma

Lower

Cutting speed

Good

Hob performance

No ( Not on CNC machine ) Regular

Backlash Table feed

Higher Poor Yes Jumpy

Component profile

Good

Lower

Productivity

Higher

Preferred

Helical Gear

-

Poor

Large Gears

Gear Type

Small Gear

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.

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Technical Notes & Guidelines

Cycle Time 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

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

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.

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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Technical Notes & Guidelines

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 Amount

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.

Eect of Sharpening Errors on Gear ProďŹ le Hob Run Out

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Resulting Gear Profile

1120


“ The past, like the future, is indefinite and exists only as a spectrum of possibilities ” Stephen Hawking



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