GEAR Machining SolutionGEAR Machining Solution 齿轮加工 方案

| Ravindra Pudasaini | 行业应用经理 | 20170524

Gear Types 齿轮类型

G i t ti hi t h i t t th th t h ith th t th d t

Automotive Gears （汽车齿轮）

Gear is a rotating machine part having cut teeth that mesh with another toothed partin order to transmit torque

Gear Categories Industrial Gears （工业齿轮）Gear Categories齿轮分类

Industrial Gears （工业齿轮）

Special Gears （特种齿轮）Special Gears （特种齿轮）

Gear Industries Breakdown 各类型齿轮产量比例

Industrial GearsIndustrial Gears工业齿轮 22%

汽车齿轮Automotive Gears 64%

Special Gears 特种齿轮14%

Gear can be applied in 18 30 areas of each car

Source: GM Company

Gear can be applied in 18~30 areas of each car

• Automotive Gears: Power Train & Auto Axel Assembly. All Types of Auto and Motorcycle Gears

• Industrial Gears: Various Types of Gears. Industrial Transmission. Metallurgy, Mining, Cement, Marine, Aviation, Chemical Industry, Railway, Light Industry, Textile, Wind Power etc

• Special Gears: Machine Tools, Cutting Tools, Power Tools, Measuring Equipment, Testing Equipment For Manufacturing and assembly configuration gearing

Market Status and Size 市场情况

In 2016, Value of 230 Billion RMB Gears are produced and China becomes the No 1 in the world with the average growth of 18 %the No 1 in the world with the average growth of 18 %

China Gear production can be divided into three stages by reviewing30 Years history30 Years history

Motorcycle Gear : 20 Billion RMB Leading Growth (摩托车齿轮） Automotive Gear : 130 Billion RMB Leading Growth （汽车齿轮）g （汽车齿轮） Wind Power Gear: 200 Billion RMB Leading Growth （风电齿轮）

Currently China has 300 Gear Companies among them 150 Companies have y p g psales revenue more than 100 million

In future the growth comes from listed Industries and Estimated Value is 300 Billion RMB 未来发展方向 Automatic Robot: （自动化机器人）

S （高铁）

l 4

High Speed Train: （高铁）

Transmission Parts 传动部件

齿轮箱外壳 Gear Box Housing

不同类型的齿轮Different Types 不同类型的齿轮Different Types of Gear (Spur, helical, Internal)

轴Shafts

差动齿轮箱 Diff ti l C 差动齿轮箱 Differential Case

正，螺旋，偏轴伞Straight, Spiral, Hypoid

Gear Problem and Solution齿轮加工的问题和解决方案

Oil Mist & Smoke in Work AreasOil Mist & Smoke in Work Areas工作区域内的油雾和油烟 Excessive Heating of Tools & Work Pieces

刀具和加工工件的过热

Chips Carried into Zone

Milling CutterChips Dragging back into Work piece 铁削带回到加工工件

Cutting Chips

Gear Manufacturing Processes and Cost Involved齿轮制造与其成本分配

FinishingMaterials 材料

10%

Finishing 精工 5%

Heat Treating 热处理 30%

Machining 机加工 55%

Gear Machining齿轮加工

Gear Teeth Cutting : Difficult Operations粗加工 高粘度的切削油

Milling 铣齿

Hobbing 滚齿

粗加工： 高粘度的切削油 Shaping 插齿

Broaching 拉齿

Gear Machining 齿轮加工

Sh i 梯齿

Gear Finishing : Light Operations精加工：低粘度的切削油

Shaving 梯齿

Grinding 磨齿

Skiving 修齿g

Honing 珩磨

Gear Teeth Cutting 粗加工

Gear Shaping 插 齿ECOCUT HFN 32 LEGear Shaping 插 齿ECOCUT HFN 32 LE

Gear Milling 铣齿ECOCUT HFN 32 LE, ECOCUT 632 LE

Gear Hobbing 滚齿ECOCUT HFN 32 LE ECOCUT 632 LEECOCUT HFN 32 LE , ECOCUT 632 LE

Gear Broaching 拉齿ECOCUT 628 LE, ECOCUT 8532 LE

Gear Tooth Finishing 精加工

G G i di 磨齿 CBN P fil G i di 成形磨齿Gear Grinding 磨齿 CBN Profile Grinding成形磨齿Generating Grinding 大平面齿磨

ECOCUT HSG 211 LE, ECOCUT HFN 13 LE UNI, ECOCUT HFN 16 LE

Gear Honing珩磨 外 磨 内 磨 Gear Shaving梯齿Gear Honing珩磨 External外珩磨 internal内I珩磨 Gear Shaving梯齿

ECOCUT HFN 5 LE, ECOCUT HFN 10 LE , ECOCUT HSG 211 LE RATAK MSN 121 A/H

Gear Problem and Solution齿轮加工的问题和解决方案

Oil Mist & Smoke in Work AreasOil Mist & Smoke in Work Areas工作区域内的油雾和油烟 Excessive Heating of Tools & Work Pieces

刀具和加工工件的过热

Chips Carried into Zone

Milling CutterChips Dragging back into Work piece 铁削带回到加工工件

Cutting Chips

Gear Problem and Solution齿轮加工问题和解决方案

油烟/油雾问题OIL MIST PROBLEMS

Oil Mist in Air 空气中的油雾

Oil in Machines & Floor 机床和地面上的油雾

Operators Breathing in Oil Mist操作工吸入油雾

原因Causes Evaporation and Misting Properties 选用的矿油属于高挥发，高油雾类

High Pressure Supply System Spraying on to High RPM High Pressure Supply System Spraying on to High RPM Cutting Tools 高压喷射，高速加工

Shearing of Oil Molecules into Smaller Particles 油分子的剪切力油分子的剪切力

SOLUTION 解决方法

Use of LE Mineral Oils 使用低挥发矿物油产品，LE 技术产品Use of LE Mineral Oils 使用低挥发矿物油产品，LE 技术产品

Use of PLANTOCUT Natural Ester Oils使用天然酯类油

Success Stories -Tractor Company 成功案例

美国福特汽车 厂美国福特汽车工厂Ford New Holland Tractor Manufacturer

>Above 10000 Employees, 10,000员工.ECOCUT 628 LE i d f G h bbi G Sh i G Sh i d B hiECOCUT 628 LE is used for Gear hobbing, Gear Shaping, Gear Shaving and BroachingReduced oil Consumption by 35 %. Increased Workers SafetyECOCUT 628 LE 用于滚齿，插齿，拉削。油耗降低35 %，提高车间安全性。

35 00040,00045,000

(Kg/Year) 70 00080,00090,000

(USD)

15,00020,00025,00030,00035,000

30,00040,00050,00060,00070,000

05,000

10,00015,000

Before ECOCUT 628 LE

After ECOCUT 628 LE

Savings0

10,00020,000

,

Before ECOCUT 628 LE

After ECOCUT 628 LE Saving Cost 628 LE 628 LELE

Major Technical Features- Vegetable Oils --Over Look天然原材料的合成酯

环境

天然原材料的合成酯

Environment 环境

• Reduction of Waste• Recycling is possible

Safety 安全

• Flash Point HigherL l ibilit li it Hi hRecycling is possible

• Lower emission• Lower explosibility limit : Higher

Technique 技术Costs 成本

• Smaller diversity of products

Technique 技术

• Reduction of Waste• Recycling is possible

• Process safety• Lower maintenance accessory

• Lower emission• High Load Carrying Ability

GLEASON Machine Tools Approval 机床厂家认证

LIEBHERR Machine Tools Approval 机床厂家认证

KAPP Machine Tools Approval 机床厂家认证

GLEASON Machine Tools Approval 机床厂家认证

KLINGELNBERG Machine Tools Approval 机床厂家认证

Gear Box Housing 变速器外壳

Material: Aluminum Alloy

材料：铝合金

Operation: Turning, Milling, Drilling, Tapping,

Reaming

加工：车削、铣削，钻孔、攻丝，铰孔

ECOCOOL 1030 S

ECOCOOL 3030 SECOCOOL 3030 S

ECOCOOL 318ECOCOOL 318

FUCHS Cutting Fluid Benefits 福斯切削液的优势福斯切削液的优势

Cutting Fluid proven long life, almost maintenance free coolant because:应用证实 使用寿命更长 更易于维护应用证实，使用寿命更长，更易于维护

Proven excellent bio-stability and maintenance free product

卓越的生物稳定性， 较长的使用寿命，无需维护。

Proven excellent cleaning performance and excellent coolant for all types of metal machining

优异的清洗性能 非常适用于黑色和有色金属加优异的清洗性能，非常适用于黑色和有色金属加工

Proven excellent Aluminum Alloy staining control ability.

杰出的铝合金抗腐蚀能力杰出的铝合金抗腐蚀能力。

Proven excellent Hard Water Stability.

优秀的耐硬水稳定性 甚至在1000ppm硬水中也不会分层优秀的耐硬水稳定性。甚至在1000ppm硬水中也不会分层。

Proven very low foaming Behavior. Ideally suited for modern CNC machines which have

higher coolant pressures (>50 bars) and high flowrate .g p ( ) g

泡沫性能较好。是现代CNC机床（高压高流量）的理想冷却液

Thank you very muchThank you very much for your attention.