![]() The application reflects the trend toward using advanced indexable hobs for higher AGMA-class work. For finishing, the respective parameters are 140 mm/min. The process is essentially climb milling. Cutting edges last for two complete parts and deliver an 80-rms surface finish to the roots of the shaft gear.Ī modified standard Chip-Surfer slotting tool from Ingersoll forms teeth in two passes at Allied Specialty Precision, reducing cycle time by 20 minutes. The change also eliminated a separate rough sawing operation and mid-cut stoppages to replace tools. The new process uses a 1.25DP Ingersoll single-start indexable hob on a Liebherr LC 2500 hobbing machine. On an 8 AGMA 66.5 " shaft gear, a mining equipment manufacturer reduced tooth-generation cycle time from 34 hours to 8.5 hours by switching from HSS shaping to indexable-insert hobbing. ![]() One case demonstrates many of these advantages. Moreover, many indexable tools or inserts can be replaced in the spindle, so chipmaking can resume in minutes with no touching off. That’s more than good enough for the vast majority of gear machining applications. They also routinely hold 0.0005 " (0.0127mm) repeatability to datum, axially and radially. Indexable mills, including form tools, significantly perform better than and outlast HSS ones. The potential to improve gear machining stems largely from advances in indexable-insert carbide tools that enable them to repeatably hold much closer tolerances than previously possible. Some are even completing the entire gear-teeth, keyways and hubs-with “one-and-done” machining processes on general-purpose CNC machining centers. In many cases, these progressive thinkers have also dispensed with special-purpose hobbing machines and machine-to-machine part transfers. Regrinding tools typically requires trafficking five expensive cutters through 5-week regrinding cycles just to keep a single process operating. ![]() They have also gotten off the tool regrinding carousel, a bottleneck that often delays deliveries. They are routinely tripling material-removal rates and tool life with no tradeoff in accuracy or surface finish. By applying indexable-insert tools, many have gained substantial competitive and cost advantages. More progressive gear makers tell a different story. Most still generate gear teeth with single-point, HSS shapers, rack cutters or hobs, believing that indexable-insert tools cost too much, can’t meet American Gear Manufacturers Association standards or are “not proven” enough. All images courtesy Ingersoll Cutting ToolsĪn operator at Allied Specialty Precision cutting a gear from 17-4 PH bar stock using an indexable tool.īy tradition, gear makers tend to be skeptical of new ideas. ![]()
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