CLC 200 HC
- Module, max.: 3 / 5 mm | 0 / 0 in
- Workpiece dia., max.: 250 mm | 10 in
- Workpiece length, max.: 300 mm | 12 in
Hobbing on the CLC 200 HC – Machine concept for the highest gear quality
Machine concept of the CLC 200 HC
The CLC 200 HC is based on a consistently rigid machine design. The central element is a stationary, direct-drive workpiece table combined with a similarly direct-drive gear hobbing head. By completely eliminating mechanical gear trains between the drive and the machining point, transmission errors are minimized and high positioning and repeatability accuracy are achieved.
The workpiece is clamped using the chuck on the workpiece table with a counterholder. Depending on the workpiece requirements, the component can be supported from above either with a center point or with a swinging pressure bell. This design ensures a very rigid setup, low vibrations, and consistent tooth quality throughout the entire machining process.
The Mineralit machine base, with its excellent vibration damping effect, forms the basis for stable processes—even at high chip capacities up to module 5.
Hobbing and chamfering in a single setup
A key feature of the CLC 200 HC is the integration of the chamfering and deburring process directly into the gear hobbing process. Gear hobbing takes place on one side of the setup, while deburring and chamfering are performed on the opposite side. Both processes utilize the same workpiece clamping setup, eliminating the need for phasing entirely.
The first pass begins with the gear cutting. At the same time, deburring takes place on the underside of the workpiece. After the hob is retracted, the upper gear teeth are chamfered. This is followed by the second hobbing pass, while the chamfering is completed cycle time-concurrently with the main machining time.
This two-pass process ensures that no burrs remain in the flank line direction. It is precisely these small material burrs that are often the cause of problems in subsequent hard finishing operations in conventional processes, as they lead to increased wear on grinding wheels or honing rings after hardening.
Advantages of the 2-pass method in gear hobbing
Two-pass gear hobbing offers decisive advantages over the single-pass process for the entire process chain:
After the second cut, the flanks are free of burrs, which reduces material removal during the grinding or honing process. At the same time, the risk of tool damage during hard finishing is significantly reduced. The service life of grinding wheels and honing rings increases, dressing intervals are extended, and the process costs of downstream operations are sustainably reduced.
Measurements show very high quality consistency with tight tolerances in profile and flank line deviation. The consistent gear quality reduces variations in the series production process and increases process reliability, particularly in automated lines.
Models for automotive and industrial applications
The CLC 200 HC is available in two versions to optimally meet different market requirements.
Automotive applicationsIn the automotive version, the machine is designed for modules up to 3. A high-speed gear hobbing head with up to 6,000 rpm enables short cycle times while maintaining high surface quality. This version is specifically tailored for high-volume production and short cycle times. | Industrial applicationsThe industrial version covers modules up to 5/6 and operates with higher torques on the hobbing head and workpiece table. It is particularly suitable for larger tooth profiles, robust components, and applications with increased chip volume. |
Both variants feature direct-drive, water-cooled axes and an identical basic mechanical structure, ensuring a high degree of process stability.
Machine Features
The CLC 200 HC supports all common gear hobbing tools, including HSS variants, coated tools, and carbide cutters. The machine is designed for both dry and wet machining.
Systems such as Artis or Montronix can be integrated for process monitoring to reliably detect tool conditions, process forces, and machining anomalies. Operation is handled via a modern CNC control system with a user-friendly HMI that supports both machine setters and operators in series production.
Automation for short non-productive times
The CLC 200 HC is consistently designed for series production. A gantry automation system can be directly integrated. Loading and unloading time is approximately four seconds.
By combining gear hobbing, deburring, and chamfering in a single setup, not only is the number of machines in the line reduced, but so is the logistical effort between the individual process steps.
Advantages CLC 200 HC
- Hobbing and chamfering in a single setup
- 2-pass hobbing process with integrated leveling Deburring/chamfering
- Direct drives on the hobbing head and workpiece table
- Highly rigid workpiece clamping with counterholder
- Short non-productive times and high productivity
- Mineral cast iron bed with high damping capacity
Workpieces
The Right Manufacturing Solution for Every Workpiece
Gear shaft
Gear wheels (e-bikes)
Regardless of whether they are made of plastic or metal, EMAG solutions can be used to manufacture a wide variety of gear wheels. Thanks to the wide range of technologies available at EMAG, we can…
Gear with synchronising wheel
One look at a typical gearwheel shows the machining challenges involved. Even a small wheel with integrated synchronous gear is a relatively complex construction.
Hobbing gears
The increasing number of automobile gears, especially as automatic transmissions are developed with 10-gear systems, allow cars to run for longer periods of time within optimal rpm ranges, thus…
Planetary Gears
Technologies
Complex Manufacturing Systems from a Single Source thanks to a High Range of Technologies
Flexible, highly productive, highly accurate - as a continuous gear production process, hobbing is indispensable in many industries, as it allows any…