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September 2015

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Two New Gear Shaping Heads at Gear Expo 2015



For Platform 2 (LSE/LFS 200 to 500) and Platform 3 (LSE/LSF 600 to 1600) machines, Liebherr Gear Technology is introducing at Gear Expo, Booth 1809, a smaller shaping head option which facilitates electronically controlled machining of spur and helical gear teeth.

"The smaller SKE 120 shaping head enables users to machine a considerably wider range of components on our Platform 2 and Platform 3 gear-shaping machines. We are thus better able to meet contract manufacturers' gear-cutting requirements," said Dr. Hansjörg Geiser, Manager Development and Design Gear Cutting Machines at Liebherr-Verzahntechnik GmbH, about the new shaping head for the LFS/LSE range of gear shaping machines.

The new SKE 120 shaping head with highly dynamic rotary drive and moveable shaping head slide occupies less space at a stroke length of 120 mm. The design engineers used the space gained to enlarge the stroke position travel range on Platform 2 machines. The SKE 120's stroke position travel range, at 650 mm on Platform 2 machines, is more than twice as large as that of the SKE 240, which is 300 mm. The same applies to Platform 3 machines where the difference is 350 mm. Even 900 mm are feasible if raised column slides are used. The shaping spindle is hydrostatically mounted and channeled.

Some workpieces require a longer stroke length (for wider teeth), while others require a wider stroke position travel range (longer workpieces with correspondingly higher gear teeth). The optionally available NC swivel column slide, which lets operators produce conical gear teeth at a shaping spindle angle of between -1° and +12°, has been optimized to achieve a higher degree of rigidity. If NC swivel column slides are not used, the shaping spindle angle can be adjusted by up to +/- 0.45° using a cam.

The direct-drive electronic lead guide provides users with latitude and flexibility. They only need enter a helix angle of between 0° and 45° and the control system calculates the rest. The new SKE 120 shaping head differs primarily from the larger shaping head with electronic lead guide, SKE 240, by a smaller stroke length, hence the name. The crank drive features automatic mass counterbalance, which is designed to ensure optimum concentricity. The spindle itself has a somewhat narrower design than the SKE 240, which has a positive impact on interference conditions.

"SKE 120 and SKE 240 shaping heads featuring the electronic lead guide provide contract manufacturers with a range of new opportunities," said a company spokesperson. "For example, frequent workpiece changeovers are easier."

To be able to machine different helix angles on gears, the motion of the shaping head must replicate the gear's helix angle. This can be performed by a mechanical lead guide. A manual changeover from mechanical lead guides becomes obsolete. Set-up times are shortened because where an electronic lead guide is used only the shaping tool needs to be changed, if at all.

An added benefit is that customers do not have to invest in multiple lead guides. Furthermore they are not dependent on the control's processing time, which makes them even more flexible. Added opportunities are provided in combination with the stroke position adjustment detail.

"A further requirement was the ability to manufacture efficiently and to optimum quality, in addition to the flexible range of workpieces," said the spokesperson. "Therefore, the process itself is very productive, given the high number of strokes at 1,200 double strokes per minute. This unique figure is based on a highly dynamic drive mechanism combined with effective control technology at optimum rigidity."

Liebherr developed its Type LSE range of machines based on its proven LFS machines. Besides the option of using electronic lead guides, these machines also enable users to correct helix angles. Tooth flank angular deviation (fh) can be corrected simply and precisely when setting up the shaping machine.

Furthermore it is possible to retain the helix angle for subsequent tempering. For even better quality, um corrections can be undertaken: the machine achieves tooth flank quality grade 4 as per DIN3962-2.

Along with increased quality and flexibility requirements, materials have also changed. For example, the tensile strength of workpieces to be shaped has increased substantially. The LFS/LSE machines have been designed to shape high-strength materials.

Liebherr has already applied the results of internal tests in this segment using appropriately configured and coated replaceable cutting inserts to industrial applications and put these in practice. The choice of high-alloy substrates with correspondingly efficient coatings demonstrates that machining performance and tool service lives can be enhanced.

For more information contact:

Liebherr Automation Systems Co.

1465 Woodland Drive

Saline, MI 48176-1259

734-429-7225

info.lgt@liebherr.com

www.liebherr.us

www.liebherr-emo.com

GEAR EXPO 2015 Booth 1809

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