Both machines for “Power Skiving” offer additional machining technologies such as turning, drilling and milling in addition to the gear skiving process. This background also explains the FFG Group’s multiple path approach to machine development. The obvious advantage of “Power Skiving” can be found in process integration. Hardening distortions can be compensated by tool path correctionsīroad competence of machine and tool suppliers Soft and hard machining – Roughing and finishing Production of gears close to interfering contours (shaft shoulder) Product flexibility (quick changeover to other workpiece types, gear profiles, straight and helical gearing) Process flexibility (process optimization, retooling, path compensation, tools, cutting materials)ĭry machining possible, no need for cooling lubricant or oil (environment, costs) Lower total investment (no special foundations (broaching), periphery, operating and maintenance costs in the system)Įconomical machining due to short machining times (compared to gear shaping)
POWER SKIVING DMG PRODUCTS SERIES
However, for series production on a greenfield site, costs, quality and productivity must be assessed as a whole, and the evaluation matrix for Power Skiving can be even more advantageous.Įlimination of the loss of accuracy with multiple clamping in subsequent operations (quality improvement) – turning (as well as other operations) and gear cutting in one clampingįloor space-saving process due to less logistics space for subsequent machining In an isolated comparison of the machining scope for gear cutting, Power Skiving can keep up with broaching and gear shaping and only has to admit defeat to classical gear hobbing in terms of economy. The FFG Group therefore offers users the technology of Power Skiving on different machine concepts (MODUL gear cutting machine skiving with alternative machining processes, HESSAPP vertical turning machine for disc-type components with swivelling workpiece axis or the BOEHRINGER shaft turning centers with optional tool spindle). This eliminates a large part of the loading and unloading of the components, the intermediate transportation and the quality losses due to clamping faults in the subsequent machining processes. The main advantage of the above-mentioned process integration is that the components can be finished without or at least with fewer downstream machines. In recent years, skiving has made a quantum leap in industrial manufacturing with the availability of modern control technology for spindle synchronization, tool technology for high-performance cutting and a machine structure that meets the high demands for rigidity and dynamics. While the traditional alternative processes for gear machining such as broaching, gear shaping and gear hobbing are mainly used in technology-specific special machines, gear skiving can be applied on special machines and on modern 5-axis machining centers. The smaller the axis cross angle, the closer towards the interference contour can be machined. 30 to 50 %) in comparison to the likewise flexible gear shaping and the ability to apply the gearing close to an interfering contour (workpiece shoulder). Significant for the skiving process is the short machining time (approx. The cutting speed results from the rotational speeds of tool and workpiece in relation to the axis cross angle. In this way the tooth space is “peeled out” of the workpiece in several cuts. By superimposing a feed motion, both add to the movements to the feed speed and guide the cutting edge along the workpiece axis. With the coupled rotation of workpiece and tool, a relative movement of the cutting edge in the tooth space is thus created. The skiving process is characterized by the tool and workpiece axes arranged in a certain relationship to each other – the axis cross angle. In addition to traditional gear machining processes such as hobbing, gear shaping and broaching, skiving is a continuous machining process for soft and hard machining of internal and external gears.
“Power Skiving” makes a significant contribution to each of these aspects.
As with all manufacturing technologies, quality, cost optimization, flexibility and productivity are the top issues. The use of planetary gears for reduction or as a differential in the drive system also increases the demand for internal gears. With e-mobility, a market is now growing which demands high precision (low running noise), high power transmission (torque and speed) from the product and equally high product flexibility in volume production. Like electric mobility, the technology of power skiving has been known for more than 100 years and, with the availability of 5-axis machining centers, has found its way into individual and series production due to its convincing process flexibility.
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