Professional Documents
Culture Documents
MICHIAKI HASHITANI* 1
YUKIHISA NISHIMURA* 1
MASAKATSU FUJITA* 1
YOSHIKOTO YANASE* 1
MASANOBU MISAKI* 1
It is a never-ending theme for motorcycle and automobile manufacturers, for whom the Machine Tool Division of
Mitsubishi Heavy Industries, Ltd. (MHI) manufactures and delivers gear cutting machines, gear grinding machines
and precision cutting tools, to strive for high precision, low cost transmission gears. This paper reports the recent
trends in the automobile industry while describing how MHI has been dealing with their needs as a manufacturer of
the machines and cutting tools for gear production.
process before heat treatment. A gear shaping machine,
however, processes workpieces such as stepped gears and
internal gears that a gear hobbing machine is unable to
process. Since they employ a generating process by a
specific number of cutting edges, several tens of microns
of tool marks remain on the gear flanks, which in turn
causes vibration and noise. To cope with this issue, a
gear shaving process improves the gear flank roughness
and finishes the gear tooth profile to a precision of microns while anticipating how the heat treatment will
strain the tooth profile and tooth trace. After heat treatment, it was usual only to finish the portion of the gear
that accommodates a bearing.
Material
Material
Turning
Turning
Gear
cutting
Gear
cutting
Heat
treatment
Shaving
Hard
turning
Complete
Hard
turning
Complete
Material
Turning
Gear
cutting
Material
Turning
Gear
cutting
Material
Turning
Gear
cutting
Heat
treatment
Gear
shaving
Hard
turning
Gear
grinding
Hard
turning
Gear
grinding
Hard
turning
Gear
honing
Complete
Gear
honing
Complete
Complete
.
..
.
.
.
.
.
.
O
50
Ti
N
0
100
Ti oxide
Composition (%)
Composition (%)
100
Al oxide
50
N
AI
O Ti
Quantity machined/cutter
re-sharpening
5 080
6 000
4 280
5 000
4 000
2 440
3 000
2 000
1 000
0
Other make
of cutter
Broach
Hobbing
machine
Gear shaping
machine
Chamfering Shaving
Heat
machine
machine treatment
SE25A
ME20
GT06R (Hobbing +
Chamfering + Rolling)
Cylindrical
grinding machine
Gear
grinding machine
Production cylindrical
grinding machine
Generating gear
grinding machine
PD32
ZE15A
PD23
ZE24A
General-purpose
cylindrical grinding
machine
Form gear
grinding machine
Synchronous gear
shaving machine
Helical guide-less
gear shaping
machine
SD25
ST25
RD23
ZG400
SC40
ST40
RD32
ZG1000
RC45
Shaving cutter
grinding machine
GD30
FS30A
GD50
GB63
SC63
GB100
SC100
Synchronous gear
honing machine
FE30A
SD15
GD20
Gear
honing machine
ZS25A
ZA30A
GBH18
Tools
Spline
broach
Shaving
cutter
Workpiece specifications
1.4
Module
Gantry loader
Control box
installed on
left side of
machine lessens
machine width.
Gantry loader
can be installed later.
Control box
34
Number of teeth
25 mm
Face width
o
17.5
Pressure angle
o
Helix angle
22.5 RH
Tool specifications
Type
Solid hob
Outside diameter
58 mm
Starts
4
Flute
16
Coating
Machining parameters
Machining method
Climb cut
Hob rotational speed
1 370 min-1
Cutting speed
250 m/min
Axial feed rate
2.0 mm/rev
Cycle time
14.3 s
Electricity
cost
0.9
0.8
0.09
Coolant
cost
0.6
0.55
0.5
0.3
0.2
After machining
45% reduction
1
0.06
0.7
0.4
Before machining
Cutting
tool cost
0.85
Electricity
cost 0.04
Coolant Cutting
cost 0
tool cost
0.51
0.1
0
Conventional machine
GE hobbing machine
4
4
4
4
MEAN 3
TIP
FFA
FA
4
0
3
2
4
0
4
4
2
1
BIAS
FF: F
total profile
deviation
4.0X
ROOT
FF
L1
L2
L3
10
L4
10
MEAN 0
TIP
FFA
FA
3
7
3
6
3
9
3
8
3
7
BIAS
FA: FH profile
slope deviation
JIS class N6
BOTTOM
FQ
R1
R2
R3
R4
4
4
4
4
BIAS
FQ: F
profile form
deviation
BOTTOM
total helix
deviation
JIS class N4
4.0X
FH
FQA
4
1
4
2
3
2
4
2
4
2
MEAN 4
FFA: FF
500X
TIP
FQ
L1
L2
L3
L4
MEAN 1
BIAS
TIP
FH
FQA
-3
2
2
1
1
2
-1
2
0
1
4
Workpiece specifications
2.5
Module
Machining parameters
Stroke speed
(min-1)
40
600/1 000
Cp=3.13
20
Cutting speed
(m-min-1)
Number of teeth
2.8
Diameter
(mm)
75
15
Radial feed
(mm/str)
0.009/0.01
Spur gear
Cycle time
90s
Helix angle
30
40/66
10
0
-10
-20
-30
-40
10 15 20 25 30 35 40
Quantity
Figures 1
1 and 12 show case examples of machining
11
by SE25A. Restricting vibration results in stable, favorable machining accuracy. The thermal deformation that
could be a problem with dry cutting remains low while
the over ball diameter during continuous machining is
also stable. As with the GE15A, the SE25A is also capable of both dry and wet cutting.
4.3 Gear shaving machine FE30A
Figure 13 shows the newly developed model FE30A.
Reviewing the column and saddle structures using FEM
analysis improved their rigidity. The operation panel
has a large color graphics display to ensure easier operation and maintenance. The feature for monitoring
the spindle load currents helps to establish the machining parameters. In addition, data entry on the NC
screens alone allows tapers and the crowning amount to
be corrected. Figures 14 and 15 illustrate the principle
and actual data samples, respectively.
4.4 Gear grinding machines
Grinding gears after heat treatment to reduce vibration
and noise from transmission gears and improve final accuracy is drawing attention. As the E series gear grinding
machines, MHI has developed models ZE15A/24A3 to meet
these needs. These machines have the following features.
Face width
Face width
Cutter
Cutter face
Distance
between d'
centers
Taper
Workpiece
Workpiece
width
c
d
d'
b'
b
b'
Face width
c'
a'
Face width
Conventional
crowning method
Guide rail
With table at center
Center of oscillation
Allowable table feed length
With table at extreme right end
Machining example
Data
entry
(mm)
Crowning
Taper/crowning
Amount of crowning
0.0
0.0
0.03
0.03
Axis A compensation
0.0
0.02
0.0
0.0
0.0
0.02
Amount of taper
0.0
0.0
Gear specifications
o
Module 3, number of teeth 31, pressure angle 20 ,
helix angle 20o (RH), outside diameter 105 mm, face witdth 40 mm
Dressing parameters
Grinding wheel revolution speed 70 min-1
Dresser revolution speed 3 260 min-1
Dressing time: 3 minutes 43 seconds
Tooth profile error
Grinding parameters
Grinding wheel revolution speed 2 580/3 800 min-1,
axial feed 0.8/0.4 mm/rev,
radial depth of cut 0.25/0.8 mm, climb/conventional
Tooth lead error
JIS class N1
500X
ROOT
MAX MIN
FQ
TIP
FH
FQA
4.0X
ROOT
MAX MIN
FQ
TIP
0
5
-2
5
5
L1
0
6
5
R2
0
5
-2
5
5
L2
0
6
1
5
1
1
5
R3
0
5
-1
5
5
L3
0
6
2
5
1
1
4
R4
0
5
0
5
5
L4
0
6
2
5
5 0
MEAN 5
-1
5
5 0
MEAN 6
1
5
-1
2
1
1
-1
1
-1
1
0
1
MEAN 1
L1
0
R2
0
2
1
-1
L2
1
R3
0
2
2
-1
L3
2
R4
0
2
2
-1
1
MEAN
BIAS
0
0
2
2
-1
L4
1
1
2
0
BIAS
FH
FQA
TOP
5
R1
1
1
2
-2
TOP
JIS class N1
1.0X
BOTTOM
MAX MIN
FQ
FH
FQA
1
5
-1
1
0
2
BOTTOM
MAX MIN
FQ
FH
FQA
2
R1
500X
Cycle time:
78 seconds
BIAS
BIAS
0.5
Right 0.5
Right -14
-14.0
-2.7
Aiming at
-2.7-10=-12.7
Aiming at
-2.7+3=0.3
0.5
m)
Left 0.5
Left -12.3
-0.9
Aiming at
-0.9+1=0.1
-12.3
Aiming at
-0.9-10=-10.9
Spindle motor
Crank
Crank
ST25CNC
Spindle motor
Spindle
Pinion cutter
Servomotor
for helix
angle control
8
6
4
2
0
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Almost no pitch accuracy improvement.
5. Conclusions
As a comprehensive manufacturer of gear processing
systems producing both machine tools and cutting tools,
MHI has developed the dry cutting system, E series
machine gear grinding machines, among others, while
anticipating the future trends of the automobile industry. While continuing to develop product systems that
anticipate the need of customers, MHI is also willing to
offer the comprehensive services including remote monitoring of production lines, implementation of pre-services
and enhancing production support systems.
References
(1) Hashitani, Dry Cutting System and Gear Finishing Process,
Japan Society for Abrasive Technology Special Symposium
2004.1.19
(2) Kage et al., Dry Hobbing of Gear, Japan Society of Mechanical Engineers Mechanical Engineering Congress Review 2003
VIII p.177
(3) Hashitani et al., ZE15A Gear Grinding Machine for economical hard gear finishing of quiet, small gears, Mitsubishi Heavy
Industries Technical Review Vol.42 No.2 (2005)
(4) Nabekura et al., The Synchronous Gear Shaving Machine
Aimed at Low-Noise Gear, Mitsubishi Juko Giho Vol. 39 No.4
(2002)
Masakazu Nabekura
Michiaki Hashitani
Masakatsu Fujita
Yoshikoto Yanase
Yukihisa Nishimura
Masanobu Misaki