Felsomat Corporation will feature gear honing technology with its Felsomat Power Speed Honing (Model FPSH) machine. The FPSH 180 is designed to be part of the Felsomat Flexline concept.
"The enhanced honing results from the FPSH beginning with the hobbing process performed by the FHC 180 hobbing machine," said a company spokesperson. "Next, the integration of the ALD SyncroTherm inline heat treatment process ensures reduced thermal distortion of the gears. In sum, this means less stock needs to be removed from the gear flanks, resulting in shorter gear honing cycle times. The FPSH can hone gears up to 160 mm diameter and module 0.5 - 4.0 mm. Stock removal between 40 - 80 microns on each flank is possible depending on the heat treatment deviation, and grinding burn is not a possibility due to the low cutting speed."
In addition to the FPSH, Felsomat's Flexline integrates the entire gear manufacturing process into one uninterrupted chain and is comprised of the following machine/processes:
Flex Turning Center FTC 180 (green turning)
The Flexline process begins with the Felsomat Turning Cell FTC 180, which is a twin spindle vertical machine suitable for high volume production of gear blanks. While one spindle is machining, internal automation unloads and loads the second spindle, reducing chip-to-chip time to 1 second.
Flex Hobbing Center FHC 180
The FHC 180 hobbing machine is also a twin spindle design with integrated chamfering and deburring on the second spindle while hobbing takes place on the primary spindle. Another feature is the ability to perform tooth chamfering between the roughing and finishing pass of the hobbing cutter, therefore eliminating a secondary burr from the chamfering process while not adding additional time to the total cycle time. This is useful for gears that are designed to be finish honed. The Flex Hobbing Center is also available as FHC 80 for smaller gears in automatic transmissions.
Flexline Integrated Heat Treatment
In association with ALD SyncroTherm, Felsomat has developed the capability to integrate the heat treatment process into the uninterrupted Felsomat Flexline Gear Manufacturing process. This new concept adapts from the traditional method of heat treating large batches to processing small batches or even individual gears. According to the company, this integrated process improves both productivity and quality in an environmentally friendly way.
Flex Turning Center FTC 180 (hard turning)
The FTC 180 twin spindle turning machine was specifically engineered for dry machining of hardened gears to reduce the cost of finish grinding with coolant. The massive machine base made of concrete, the short distances from Z-axis guide to spindle centerline, coupled with short precise ball screws and absolute measuring systems, enables a resolution of less than 1 micron in X and Z axes and achieving surface finish quality and tolerances that could only be achieved by grinding, according to the company.
Felsomat Laser Welding Cell FLW 180
Felsomat, in partnership with Trumpf, brings laser welding into the Flexline integrated gear manufacturing process. The Trumpf solid-state laser, together with Felsomat automation, allows welding of precise symmetrical rotating parts such as gears, planetary carriers, clutches and torque converters. Each machine integrated within the Felsomat Flexline system is also available as an individual standalone machine.
For more information contact:
Felsomat USA
1700 N. Penny Lane
Schaumburg, IL 60172
847-995-1086
info@felsomat.com
www.felsomat.com
IMTS 2014 Booth N-7040