Gear Grinding Machines – Diamond and CBN Tools

1 gear Grinding Machines Diamond and CBN ToolsReishauer Generating gear Grinding Reishauer AGIndustriestrasse 36, 8304 Wallisellen, Switzerland +41 44 832 22 11 GrindingGeneratingGrindingFormGrindingDi CtiCtiGenerating GrindingForm GrindingDiCtiCtiDis-ContinuousContinuous Dis-ContinuousContinuous Reishauer AGNovember 2015 Page 2 gear GrindingGear GrindingGeneratingGrindingFormGrindingDi CtiCtiGenerating GrindingForm GrindingDiCtiCtiDis-ContinuousContinuous Dis-ContinuousContinuous Reishauer AGNovember 2015 Page 3 gear GrindingRZ 410, 2010 FlexibleRZ 410, 2010 FlexibleRZ 60 / 160 / 260 / 360from 2012 Automotive, TruckRZ 60 / 160 / 260 / 360from 2012 Automotive, Trucko0uto ot e,uco0uto ot e,ucRZ 630, 630, 800, 2007 Printing MachinesRZ 800, 2007 Printing MachinesRZ 1000, 2007 Wind PowerRZ 1000, 2007 Wind PowerRZ 550, 2010 FlexibleRZ 550, 2010 Flexible Reishauer AGNovember 2015 Page 4 Reishauer gear GrindingIndustrial MachinesPrinting MachinesWind PowerWind PowerFlexibleFlexibleSetupquick-change of OperatorAutomatic setting of all axis positionsandautomaticpositioningofthedia mond toolOperatorandautomaticpositioningofthe Diamond tool, the Grinding wheel andthe automatic dressing of thegrinding wheel and Grinding of thefirst workpiece.

2 Reishauer AGNovember 2015 Page 5 Productivity Reishauer AGNovember 2015 Page 6 ProductivityNoise ReductionMinimized waivinessin profile directionMinimized vibration and frequencyin drive systemSpecific profile-and lead modificationLNS(Low Noise Shifting) Reishauer AGNovember 2015 Page 7 FunctionalityNoise ReductionLNSLNS (Low Noise Shifting) Reishauer AGNovember 2015 Page 8 FunctionalityStatistically shortened waviness in axial direction (Low NoiseLow Noise Shifting LNSdirection (Low Noise Shifting) Yesterday:Today:generating Grinding withoutLNSial directionYesterday:ial directiongenerating Grinding with LNSY esterday:AxProfile directionAxProfile directionToday:andorgenerating Grinding withoutLNSH oninggenerating grindingwithLNSH oningHoning Reishauer AGNovember 2015 Page 99ge e at g gd gt outSHoninggenerating Grinding withLNSH oningHoningFunctionalityMi i i d ib tiNoise ReductionMinimized waivinessin profile directionMinimized vibration and frequencyin drive systemLNS(Low Noise Shifting) Reishauer AGNovember 2015 Page 10 FunctionalityWaiviness and Ghost Frequency Macro-waviness Ghost frequencies = Winkel_Sekunde P_Px = Ordnung (Bezugsfrequenz) = Winkel_Sekunde P_Px = Ordnung (Bezugsfrequenz)808590951001051101151201 2513013514014515015516016517017518018519 0195200 Ordnung (Bezugsfrequenz) 14:35:45 Abt.)

3 0672, Masch-Messung, Masch: 73996m Mess-Nr: 00002, n= 1/min, Schlichthub,todayLimitImproved by:- Fine balancing- Defined number of Grinding wheel starts-Increased machine stiffness Reishauer AGNovember 2015 Page 1111-Increased machine stiffnessFunctionalityNoise ReductionMinimized waivinessin profile directionMinimized vibration and frequencyin drive systemSpecific profile-and lead modificationLNS(Low Noise Shifting) Reishauer AGNovember 2015 Page 12 FunctionalityProfile modificationProfile with tip relief Reishauer AGNovember 2015 Page 1313 FunctionalityOption:Line Dressing Reishauer AGNovember 2015 Page 14 Line DressingTopological Dressing of Profilecrowningtip and root reliefprofile angle Reishauer AGNovember 2015 Page 15 Line DressingDiamond ToolsDiamond ToolsDiamond Roll Set 1-startDiamond Profile RollDid F ll P fil R llDid DblTDi kModule - 5 Module 5 (10) Diamond Full Profile RollDiamond Double TaperDiskDiamond Radius Form RollDiamond Dressing ToolsOtdit123 Module 5 (10)Outerdiameter123 mmOuter diameter 160 mmBore diameter 52 mm Reishauer AGNovember 2015 Page 16 DressingChange of pressure angle modifications and corrections separate for:left flankrigth flank Reishauer AGNovember 2015 Page 1717 DressingLead modification Reishauer AGNovember 2015 Page 1818 FunctionalityConstant Contact Pattern Reishauer AGNovember 2015 Page 19 FunctionalityLead modification Reishauer AGNovember 2015 Page 20 FunctionalityPast.

4 Lead modificationToday on all Reishauer Machines possible,tomorrow requested from R&D Reishauer AGNovember 2015 Page 21 FunctionalityRoot and Lead Load CapacityCompressiveConstant contactModifications Compressive residual stress Constant contact pattern due to accuracy of profile, lead and pitchModifications specific to load conditionslead and pitchRoot load capacityFlank load capacityRoot load capacityFlank load capacity Reishauer AGNovember 2015 Page 22 FunctionalityDefined Root GrindingNot allowed because ofProtuberance requiresDefined root radiusFull form grindingae= Stock allowance per flanc St k lli thtgrinding stepexcellent pre machining Reishauer AGNovember 2015 Page 23a e= Stock allowance in the rootFunctionalityCompressive Residual StressCompressive residual stress in tooth flank Flankstress in tooth flank FlankCompressive residual30 30 RootCompressive residual stress in tooth root Root Reishauer AGNovember 2015 Page 24 FunctionalityCompressive Residual Stress-400-2000s ES/MP a-1000-800-600-400 Residual stress-400-300-200-1000al stress ES/MPa from surface [mm] from surface [mm] Residua0a-500-400-300-200-100sidual stress from surface [mm]

5 Res Reishauer AGNovember 2015 Page 25 Functionality Reishauer AGNovember 2015 Page 26 Standard and Polish Ground GearToolingReishauerProcessDevelopmentTo olingThe Reishauer-Superfinishing use one Grinding worm for the total Grinding operation as Grinding tool . The Grinding wheel is divided in two zones with different ProcessDevelopmentThe geometry of the Grinding wheel isThe geometry of the Grinding wheel is done with standard Reishauerdressing Tools and the same dressing technology used for generating Grinding Reishauer AGNovember 2015 Page 27 Reishauer-Superfinishing Reishauer AGNovember 2015 Page 28 Polish GrindingPrinzipleResultsReishauerProcess DevelopmentStandard-generating grindingMaterial fraction left flankResultsReishauer mMaterial fraction right flank With removal of the material peak the material fraction of the superfinished surface increase. Reishauer AGNovember 2015 Page 29pReishauer Polish GrindingGear load bearing capacityGear wear behaviour Reishauer AGNovember 2015 Page 30 Abbott Material Ratio CurveSpecial Profile Reishauer AGNovember 2015 Page 31 Functionalityfully shapedtooth tipfully shapedfully shapedrootinvolutes Reishauer AGNovember 2015 Page 32 FunctionalityInspection offull shapeInspection ofinvolute area Reishauer AGNovember 2015 Page 33 FunctionalitySpecial ApplicationWithout negative crowning bad pattern Reishauer AGNovember 2015 Page 34 Special ApplicationProfile Grinding Reishauer AGNovember 2015 Page 35 Special ApplicationProfile Grinding Dressing Condition Reishauer AGNovember 2015 Page 36 Special ApplicationHardnessMaximum Hardness 62 HRc(740Hv)Maximum Hardness 62 HRc(740 Hv) Hardness over HRc 62.

6 -Difficult / impossible to grindHigh risk for cracks-High risk for cracks-High risk for burning Reishauer AGNovember 2015 Page 37 Pre Work ConditionQualityPklit b ttthDIN 10 Pre-work quality better then DIN 10 RtdAl t dPit hEb tt th DIN9 Runoutand Accumulated Pitch Error better the DIN 9Fp and Fr less then 100 m Reishauer AGNovember 2015 Page 38 Pre Work Condition Reishauer AGNovember 2015 Page 39 REISHAUER GENERATING Grinding