In many ways, the production of large components presents a particular challenge in manufacturing. Used in commercial vehicles, large transmission, or wind power, these parts are large – making them difficult to handle and slowing down production speeds. Adding to the production challenge is the additional technological requirements being placed on the parts, as well as the demand for improved reliability and precision, with decreased costs per piece. All of which needs to be achieved while improving process speeds.
Maximum flexibility is required for gear production. EPS steering is a good example: Production planners for this application are looking for machines that can efficiently and completely cut an EPS steering gear including steering pinion, worm gears, and screws. The HLC 150 H horizontal gear cutting machine from EMAG KOEPFER is the perfect solution for this.
Gear cutting and deburring
The gear-cutting specialists have developed a complete solution that covers every aspect of the process: It features all relevant gear cutting technologies including chamfering. Components with toothing up to module 3 and up to 500 millimeters in length can be completely finished. For a transmission shaft, for example, gear hobbing for rough-machining is the first step, followed by press deburring, and a second hobbing step for finishing.
High-quality gear cutting guaranteed
With this machine, customers also benefit from many upgraded technical details. For example, the large axis center distance of up to 130 millimeters, and the powerful 28 kW cutter head ensure flexibility and efficiency. During the milling operation, the cutter head, with its very rigid suspension, always moves completely. This guarantees that the hobbing process is always very smooth and precise. Decreasing unit costs are also ensured by energy-efficient hydraulic units. Furthermore, the quick-clamping system makes it possible to change tools very quickly, minimizing unproductive downtime’s.
The HLC 150 H horizontal gear cutting machine by EMAG KOEPFER is the perfect complete solution for workpieces up to module 3 with a maximum length of 500 mm. It not only features all relevant gear cutting technologies such as gear hobbing, skiving, screw milling and worm skiving, it also includes press deburring and chamfering integrated into the machining area. As a result, an extremely wide range of workpieces can be finished without burrs – including gear and anchor shafts, steering pinions, planetary gears and worm gears.
High-quality gear cutting
Component quality and process reliability are ensured, first by the cutter head. It has a very rigid suspension, and always moves completely during the machining operation. The shift axis is based on the interpolation of two axes. This results in a large swivel angle for the cutter head, and a large shift path at the same time. This process is why the gear hobbing runs very smoothly and high gear cutting quality is guaranteed. Another important feature is the ability of the chips to fall downward freely, preventing chip build-up. For chip discharge, various solutions are available including scraper-belt or permanent-magnetic conveyors – with the option of a deep-bed filter with magnetic pre-separator drum for ferromagnetic materials, non-ferrous metals, and plastic.
Lower costs in gear cutting
The HLC 150 H also reduces costs in many ways: Its frequency-controlled hydraulic units are very energy-efficient. Next, the media supply is only activated when required. Furthermore, the quick-clamping system and easy accessibility of the machine allow changing of all tools in a very short time.
Integrating into lines by automation
Not least, the HLC 150 H includes a largely modular automation system: Lighter components up to 3 kg are handled by an integrated high-speed gantry loader with rotating twin gripper. For heavier workpieces up to 10 kg a V-shaped linear gripper is available. The machine can be integrated into a complete EMAG production line at any time.