JTEKT CORPORATION
e500H-GS
(Gear skiving package)
Gear production by compact type general purpose machine
JTEKT CORPORATION
e500H – GS (gear skiving package)
Improved productivity by high peripheral speed machiningImproved productivity by high peripheral speed machining
Integrated gear machining process into machining centerIntegrated gear machining process into machining center
Automatic programming function NCSFC & simple inputAutomatic programming function NCSFC & simple input
Reduced size and weightReduced size and weight
Pursuing high reliability and ease of usePursuing high reliability and ease of use
Evolution of skiving technologyEvolution of skiving technology
JTEKT CORPORATION
A method implementing gear machining by using the r elative speed generated by inclining the tool relative to the workpiece and rotating them synchronously
Actual cutting
speed V 3
Tool
Workpiece
Feed direction
Cross angle φ
Tool cutting speed: V1 200 m/minWorkpiece cutting speed: V2 170 m/minIndex angle (cross angle): φ 30°Workpiece torsion angle: β 0°
Tool cutting speed V 1
WorkpieceCutting
speed V 2
Actual cutting speed : V3 100 m/minV3=V1×SINφ/COSβ
This principle was proposed in Europe in the 1960 e ra, however the levelof engineering at the time was low, and practical u se was difficult.
What is the skiving method?What is the skiving method?
Machining principle of skiving method
JTEKT CORPORATION
Comparison of each gear cutting method
Hob cutting Shaper cutting Skiving cuttingBroach cutting
Outer gear
Inner gear
Shape
Principle
Accuracy
Cost
CT
Machining method
Meshes the workpieces
through rotation and feeds the tool to create the gear
Creates gear by rotating the pinion
cutter and workpiece at the specified
speed, then reciprocating
Creates gear by inclining the cutter and workpiece axis
and rotating synchronously at
high speed.
Cutting
performance
〇 〇
〇
○ 5 – 12 grades ○5 – 12 grades ○ 5 – 12 grades ○ 5 – 12 grades
〇
〇
×
〇
△ △(Special tool) ○○
△ ○○ ◎
Creates gear by withdrawing a tool with gear-shaped
blades arranged like a saw.
×
JTEKT CORPORATION
Merit of skiving
Inco
mpl
ete
gear
sha
pe
Hobbing Skiving
Inco
mpl
ete
gear
sha
pe
Size reduction of product
• Shortening of incomplete gear shape section
Contributes to size and weight reduction of the product
Size reduction
JTEKT CORPORATION
Merits of skiving
Improved productivity
5 times the cutting speed with high machining ability
Depends on feed axis.
Depends on rotating axis.
V: 100 - 300m/min
V: 40 - 60m/min
Gear shaper
Skiving
Recess section3 – 5 mm
Low product strength
High product strength
Skiving
Gear shaper
Improved product strength
No need for recess section
Contributes to improved product strength
JTEKT CORPORATION
Conventional
New technology
Lathe Hobbing Shaper Cham-fering Drilling
LatheHobbingmachine
Gear shaper Chamfering machine
Machining center
Skiving (gear cutting)Lathe Chamfering Drilling+
+ +
Machining process
Machining center
One chuck machining from lathing to gear cutting an d drilling
Machining equipment
Machiningprocess
Machiningequipment
Integrated gear machining processes to machining center
Merits of gear machining by machining centerMerits of gear machining by machining center
JTEKT CORPORATION
2005 Began skiving engineering development2006 Began production of gear parts
Established element/control/tool/machining technology
Internal gear
Sun gear
Coupling
30,000 sets/m
25,000 sets/m
25,000 sets/m
JTEKT initiatives in skiving
History of engineering developmentHistory of engineering development
2013 Skiving machining unite500H-GS released
Production resultsProduction results
JTEKT CORPORATION
We independently develop the engineering necessary for skiving and provide all equipment,
controls, tools and machining conditions.
Necessary engineering for skiving method
High speed/high rigidity workpiece axis• N=3,000 min-1 spec.• Compaction by built-in motor• Compatible with automatic hydraulic fixture
• Tool design based on JTEKT original gear creation theory
Optimum machining conditions• Selects the optimum machining conditions according to the customer’s product
TOYOPUC-MC70
Low resistance tool design
• High accuracy skiving control by high speed synchronization
• Simple programming function
Skiving
High speed/high accuracy gear cutting control
Element engineeringElement engineering Control engineeringControl engineering
Tool engineeringTool engineeringMachining engineeringMachining engineering
JTEKT CORPORATION
Largest possible chip drop port is secured directly under the cutting point.Bed structure does not accumulate chips.
Center trough
Pursuing high reliability and ease of use
This JTEKT machining center base has been installed in many parts production lines and is capable of:
High productivity• High speed
Rapid feed: 60 m/minATC : C-C 2.5 sec
Supporting multiple applications• Hydraulic fixture
Automation
High reliability• Chip processing ability• Structure is easy to maintain
[Correspondence to mass production]
JTEKT CORPORATION
Operator door opening up to the ceiling⇒ Well-litNo coolant drip
Machine structure and cover shape designed with consideration to
work easiness
Short distance from machinefront to pallet center.
⇒ Comfortable work posture
• No square and cumbersome protrusion • Easy to make line layout
Pursuing high reliability and ease of use
[Human-friendly cover shape]
JTEKT CORPORATION
B軸
C軸
High speed rotation lathing spindle unit
●e500H-GS Skiving machine
e500H-GS
Developed lathing spindle unit (3,000 min -1) with high speed and high rigidity
A axis
Enables both high load and low rising temperature by adoption of
large dia. ceramic balls.
Large dia. high ability bearing with high accuracy, high rigidity
and low rising temperature
Achieves torque full machining from low speed to high speed
(3,000 min -1) through adoption of constant torque servo motor.
High speed, high torque built-in motor
Achieved size reduction of total length through storage in the
hollow type spindle.
Hydraulic type draw bar compatible with auto chuck
(detachable)Achieved total length compact
distributor with air press. 2-port, hyd. 2-port and application of high
peripheral speed (3.9 m/s) seal.
JTEKT-made distributor with multi port correspondence to
high peripheral speeds
B axis
JTEKT CORPORATION
JTEKT CNC TOYOPUC-MC70
PLCTOYOPUC-PC10EL
Servo I/FMECHATROLINKⅢ
③ Multibus② Optimum program management
① High performance CPU
0 10000 20000 30000 40000 50000
整数演算
浮動小数点演算
メモリ
MC50
MC70
CPU benchmark (score) Measuring tool: CrystalMark Ver. 0.9.99.173 ALU value
10 times the performance ratio
Servo communication is not influenced by PLC communication and synchronization performance has been significantly increased.Gives priority to the important
processing that influence cycle time.
Achieves effective CNC processing.
Achieves high skiving accuracy with high calculation ability.
Cuts waste time and raises net rate.
CNC
TOYOPUC
MC70
PLC
Servo I/F
CNC
MC50
PLC
Servo I/F
Single bus Multibus
Communication speed : 4 times
Good
(Score)
CNC
TOYOPUC-MC70
JTEKT CNC achieving skiving principleJTEKT CNC achieving skiving principle Compared with conventional CNC MC50.
Memory
Integer calculation
Floating decimal point calculation
JTEKT CORPORATION
Simple programmingSimple programming
JTEKT CNC TOYOPUC-MC70
NCSFC
Flow display possible to understand the flow of machining
Gear data
Workpiece teeth amount
Teeth torsion angle [ ° ]
Module [mm]
Material dia. [mm]
Outer/inner teeth Outer: 1 Inner: -1
Tool data
Tool amount
Tool torsion angle [ ° ]Tool dia. [mm]
Cutting condition
Cutting width [mm]
Margin [mm]
Cross angle [ ° ]
Cutting speed [m/min]
Tool feed amount [mm]
Y axis travel speed [mm/min]
XZ axes return travel speed [mm/min]
Part axis rotation dir. CW: 1 CCW: -1
Offset angle offset dir. add: 1 subtract: -1
Simple programming through input of gear data and tool data cutting
condition to the screen
JTEKT CORPORATION
High speed rotation lathing spindle compatible with automatic hydraulic fixture
Lathing function by machining center
Second spindle function (lathing spindle)Second spindle function (lathing spindle)
Can lathe using machining center by equipping the high-speed lathing spindle
JTEKT CORPORATION
JTEKT developed the skiving tool in-house
Cutter
Workpiece
Workpiece
Tool designing
Machining simulation
Optimization
Tool path
Tool blade shape
Tool to be fabricated
Skiving tool
Machining accuracy
Calculates cutting resistance
Skiving tool
JTEKT CORPORATION
Evolution of skiving engineering
High accuracy• Tool position compensation reducing machining errors
・ Highly functional skiving tool design engineering reducing cutting resistance
・ Arbitrary tooth shape of inner and outer teeth and tooth trace shape control
Evolution of simulation engineering and control engineeringEvolution of simulation engineering and control engineering
JTEKT CORPORATION
外歯 内歯
・歯車種類
・対象ワークサイズ φ30~φ220mm φ50~φ200mm
・最大モジュール
・ワーク材質
・加工精度(参考)
平歯車・内歯歯車・ハスバ歯車・スプライン
全長100mm以下
鉄系材料(焼入前)
JIS N7級相当
2.5
Target workpieces
Range of target workpiecesRange of target workpieces
Outer teeth Inner teeth
Gear type
Target workpiece size
Largest module
Workpiece material
Machining accuracy (reference)
Gear type
Spur gear / internal gear / helical gear / spline
Total length 100 mm or less
Ferrous materials (before hardening)
Equivalent to JIS grade N7
JTEKT CORPORATION
Example of high productivityExample of high productivity
Conventional
Now
Lathe Hobbinemachine
Shaper Machining center
Machining center
Deburring machine
・Machining accuracy (m 2.4)・Machining time
m 2.4: 30 sec.Tooth trace: 3.8 µm JIS grade N4
Tooth shape: 12.8 µm JIS grade N7
Equipment expense
Equ
ipm
ent c
ost
Production volume: 4,500/month
m 1.0: 10 sec.
【Machining results】
【Effect】
Side gear
Module 2.4Outer teeth
Module 1Inner teeth
Material: SCM415Size: Φ81 × 41 mm
Machining example ①
Machining expense
Mac
hini
ng c
ost
70% reduction
【Workpiece】【Workpiece】
70% reduction
Conventional ConventionalNow Now
JTEKT CORPORATION
Example of large module (M 3.5)Example of large module (M 3.5)
Workpiece O.D.: Φ98.5 mmModule: 3.5Material: SCM415
Internal gear component
60
420
(Shaper) (Skiving)
Cutting speed: 150 m/minFeed: 0.15 mm/rev
Machining time: 80 sec.
【Workpiece】
【Effect】
【Machining conditions】
Machining example ②
85%削減
Conventional Now
85% reduction
JTEKT CORPORATION
Example of high accuracy machiningExample of high accuracy machining
Machining example ③
Test piece
Material: SCM440Size: Φ190 × 20 mmMachined part: Internal teeth
(Module 1.15)Enlarged image of internal teeth
Tooth shape accuracy
Tooth trace accuracy
Machining specifications
Module (mm)
No. of teeth
Pitch circle dia.
Helix angle ( ° )
Helix direction
Machining time (sec.)
Tooth shape accuracy (µm)
Tooth trace accuracy (µm)
Machining results
Right
JTEKT CORPORATION