In depth: Eliminating the physical shifting axis on the G 160 Gear Grinding Machine

In depth: Eliminating the physical shifting axis on the G 160 Gear Grinding Machine

The Samputensili G 160 gear grinding machine is ideal for automotive gear manufacturing applications requiring high efficiency, low maintenance, reliability and fast production. One of the key features of the machine is the elimination of the physical shifting axis. Threaded grinding wheels need to be shifted along the axis between workpieces to create a “clean” grit. Additionally, they need to be shifted during grinding. This creates a diagonal path rather than straight axial motion. Current gear grinding machines use a physical Y-axis below the grinding spindle to accomplish this. However, there are serious space constrains to design this Y-axis as compact as possible with high stiffness. Having said that, this Y-axis is carrying the highest load created by the generating grinding process in its direction of motion.

The concept behind the G 160 gear grinder takes this issue head on. Rather than, stiffening the Y-axis on the grinding head, the design of the G160 completely eliminates this axis. This not only removes the “weak spot”, but instead of stacking (4) axes (radial (X), axial (Z), swivel (A), and shifting (Y), only (3) axes are stacked onto each other (Y, Z, A) before reaching the grinding spindle. When compared to other gear grinding machines, this increases the rigidity of the system, which in turn, enhances productivity and grinding quality. Because the traditional shifting axis is physically not present, the interpolation of the Z and Y-axes is simulating the motion of this shifting axis, referred to as the virtual shifting axis. Both axes are not constraint in space and thus are large, strong, and very rigid. This patented machine concept ensures the best production times on the market.

Finally, no additional axis is needed to perform the dressing cycle. The dresser is mounted on the X1 axis slide next to the workpiece spindle, so that the efficient and dynamic motion of the linear motor can also be used to fine-tune the geometry of the grinding wheel and the corresponding gear. It enables topological changes of the gear flank at a quality that has not been seen before. Having the dresser located on the same slide as the workpiece-spindle makes it insensitive to thermal or any other type of changes.

Automatic Transmission Planetary Pinion

Number of teeth

z

23

Normal module

m

1.356 mm

Normal pressure angle

α

17°30’00”

Helix angle

β

18°51’43”

Face width

b

20.6 mm

Nominal stock per flank

q

0.08 mm

 

 

Roughing Pass

Finishing Pass

 

No. of Starts

5

5

 

Axial Feed Rate

0.67

0.25

mm/rev

Grinding speed

80

80

m/s

Idle Time

1.0

5.1

sec

Part Change

1.0

1.0

sec

Dressing Part

0.7

0.7

sec

Total Cycle Time

10.7

10.7

sec

Learn more about the Samputensili G 160 Gear Grinding Machine: http://bit.ly/2G7egUW