Gear cutting tools

Gear cutting tools

Focus on quality

Gear cutting tool product range

Liebherr offers a comprehensive range of gear cutting tools, many years of experience in gear manufacturing, and the highest level of product quality down to the smallest detail. We are a reliable partner offering innovative developments and durable tools.

Our product range is in demand from customers all over the world. In addition to tool calculation, design and production, Liebherr offers all its customers excellent after-sales service. This includes sharpening and coating gear cutting tools as well as reconditioning CBN grinding tools at our electroplating shop.

Get an overview of our extensive portfolio on this page:

Skiving tools
Shaper cutters
Wafer & solid wafer
Rolling racks & rolling dies
Shaving cutters

Roller deburring tools & rolling chamfering discs
Master gears
CBN grinding tools
Tool reconditioning
Component and contract manufacturing

Skiving tools

PM-HSS and carbide skiving cutters

Tools made of powder-metallurgical high speed steel (PM-HSS) are inexpensive to purchase, but are more prone to wear.
Due to the raw material and manufacturing process, tools made of solid carbide are more expensive to purchase and recondition. Because they are relatively expensive, using them is only worthwhile for high production numbers or higher-strength materials.

conical and cylindrical tools

Conical and cylindrical tools have different axis alignments. The relief angle of a conical skiving tool is determined by its design and is usually centered, while a cylindrical skiving tool requires additional tilting or an off-centered position. The control system of the Liebherr gear skiving machines (LK) controls both tool types.

Interaction of tool, technology and machine: skiving³

Field tests have clearly shown that the key to success is mathematical control of the tools and the process, as well as coordination of the technology, tool, and machine. This has been proven during customer trials.

Optimal tool design

Ideal technological design for every gear
Accurate profile calculation taking account of the crossed axis angle and cutting face offset
Avoidance of collisions especially for internal gears
Optimal cutting and clearance angles for the entire process

Advantages of gear skiving

Two to five times faster than gear shaping
One to two quality grades better than gear shaping
Excellent single indexing quality at the workpiece
Tool life similar to gear shaping
Available tool designs: conical and cylindrical
Process-optimized tool design
Tools available in PM-HSS and carbide (also with indexable inserts)
Dry skiving possible
Pressure angle and lead modification possible

01/04

liebherr-gear-cutting-tools-shaping-cutters

Shaper cutters

Shaper cutters are available as disc, bell, shank and hollow bell types. PM materials and highest-quality carbides are used.

The shape, designs and coatings are optimized and customized according to the gear cutting tasks.

Stock shaper cutters in bell, shank and disc designs for various modules and pressure angles can be delivered at short notice for standardized basic tooth profiles such as DIN 3972, DIN 5480, DIN 5482 and DIN 8197.

If required, semi-finished disc-type shaper cutters are available, from which we can manufacture express shaper cutters for special gear cutting tasks at very short notice.

Wafer cutters

The wafer cutter is a coated disposable tool that represents the optimum tool condition comparable to a non-helical shaper cutter. The thin, coated wafer disc is clamped in a special wafer holder and mounted just like a shaper cutter on the shaper cutter holder of the shaping machine.

Advantages

Maximum process reliability, since process parameters are fixed
Economical in series production
No wear-related profile changes on the workpiece, since the tool is not resharpened
Very simple machine adjustment (reduced setup time)
Always fully coated tools in use
Machine does not need to be adjusted after wafer change during one lot of workpieces

Solid wafer cutters

Solid wafer cutters are used when a constant workpiece profile is required, thus reducing the usable tool height. Solid wafer cutters are available for any kind of spur or helical gear, with the optimum coating for each application. The solid wafer cutter has the same advantages as the wafer cutter even when used for smaller batch sizes.

In special cases solid wafer cutters can also be manufactured with different teeth for up-shaping and/or down-shaping processes.

01/03

Rolling racks

Rolling racks are manufactured for special customer requirements and are generally used for manufacturing splines.

Rolling racks are available up to the following maximum values:

Module 1.6
Length 1500 mm
Width 350 mm
Height 90 mm

Rolling dies

Rolling dies are generally used for manufacturing conical gears, such as for push sleeves with internal or external gears. These can be used as single, single in a dual configuration or as sets. Rolling dies can have one flank or multiple flanks depending on the requirements. The rolling dies are available with hobbed or ground teeth depending on the required gear quality.

Subject to special manufacturing guidelines, our rolling dies have the longest possible tool life.

Versions: hobbed or ground

01/02

Shaving cutters

Shaving cutters are available for all standard gear shaving processes in hobbed, preground or fully ground quality.

The following types and limit ranges are available:

Module 0.5 to 12.7
Helix angle up to 45°
Maximum tool diameter 305 mm
Maximum tool width 65 mm
Slotting: straight or spiral, also available with positive front rake angle
Root shape: milled or drilled

Regrinding diagrams for optimum sharpening of the tools are available on request. Shaving cutters reduce grinding times in hard fine machining.

liebherr-gear-cutting-tools-rolling-deburring-discs

Roller deburring tools

Rotary chamfering/deburring cutters are used for creating chamfers on the workpiece using the generating method. Rotary chamfering/deburring cutters are available with an additional smoothing wheel to minimize bulging on the faces of the workpiece.

There are different chamfering types such as:

Parallel
Comma-shaped
Parallel with chamfer at the tooth root surface

These are also available for workpieces with beveled faces.

The tools are supplied already adjusted and can be used for chamfering gears with the same gear data and the same face width, provided there is no risk of collision with the workpiece contour.

The option of reversing the rotary chamfering/deburring discs guarantees economical tool use.

When the rotary chamfering/deburring discs reach their wear limit, the discs can be reversed and very quickly set up again so that the tool can be re-used.

Rolling chamfering discs

Flexible rolling chamfering discs are used when the workpiece gear data are identical but the face widths are different. They can be supplied in sets, or if necessary with holders for a specific face width.

As with the rotary chamfering/deburring cutters, the chamfers on the workpieces can be parallel, comma-shaped or parallel with chamfers at the tooth root surface.

The rolling chamfering discs can be designed for wet or dry machining. An additional coating extends the already long tool life even further.

01/03

Master gears

Master gears are manufactured up to quality level 3 as per DIN 3962 and are supplied with a test certificate.

The following gauge types are available:

Master gears
Plug gauges
Ring gauges

Plug and ring gauges can be supplied as Go and No Go gauges.

CBN grinding tools

CBN grinding tools are available as grinding worms and as profile grinding discs with an electroplated CBN coating. The coating is customized for the specific machining requirements. The tools are mainly used for grinding involute gears with the highest possible quality requirements in mass production.

The following types of grinding worm are available:

Roughing and finishing worm
Mono-finishing worm
Combination worm with profile grinding disc

The following types of profile grinding disc are available:

Roughing profile grinding discs
Finishing profile grinding discs
Mono, duo or trio

Our tool specialists manufacture the tools to the highest precision for maximum process reliability in gear grinding.

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Customized grinding tools

Profile grinding discs for:

Spline shaft profiles

Slot and surface grinding discs for:

Fixing and indexing slots
External cylindrical grinding

Cup discs for sharpening:

Shaper cutters with stepped cutting face
Shaper cutters with conical cutting face
Gear hobs

Grain sizes

Grinding worms B76 - B251
Profile grinding discs B35 - B301

01/02

Tool reconditioning

Sharpening and coating of gear cutting tools

Liebherr after-sales service offers sharpening and coating of gear tools. Our satisfied customers are happy to use this well-established service.

You can rely on the experience of the tool manufacturer for sharpening and coating your tools.

ISO 9001:2015

Our high quality standards prompted us to implement the international standards for quality management systems in our tool manufacturing as long ago as the 1990s. The benefits of this can be seen in the high degree of customer satisfaction and are highlighted by the success of our products in the market. Therefore, our goal is to continually improve our quality management system.

liebherr-gear-cutting-tools-resurfacing-cbn-tools

Reconditioning of CBN grinding tools

Highly qualified specialists will recondition your grinding tools at our in-house electroplating shop.

After the tools are inspected, the tool body is ground if necessary, all in a very short time and at an attractive price. Thorough quality control at every process step ensures consistently high tool quality.

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Component and contract manufacturing

We will produce workpieces to customer specifications, either as series production parts or as prototypes. Our plant operates a wide range of different CNC gear cutting and gear testing machines, all of the latest generation. Gear hobbing, gear shaping and gear grinding machines feature quick-conversion automation systems. The existing range of tools allows us to cover practically all commonly encountered gear types.

External and internal gears and shafts: Max. Ø 500 mm – module 0.3 – 12 mm
Spur / helical or tapered: Max. Ø 500 mm – till module 12 – ± 45°
Herringbone gears: on request

Liebherr-Verzahntechnik GmbH is ISO 9001:2015 certified.

liebherr-gear-cutting-tools-component-manufacture

Wide product range and short delivery times

Possible range of parts

Gears
Shaft gears
Couplings
Sprockets
Worms
Worm wheels
Components, including assembly

High vertical integration through modern machinery

We manufacture your workpieces on state-of-the-art gear cutting machines. As well as internal and external cylindrical grinding machines, there are turning and gear cutting centers at our plants. We also ensure very high quality with our Liebherr gear measurement machines and 3D measuring instruments.

01/02

Stock tools

Find the right gear cutting tool with just a few clicks

Liebherr offers a wide range of high-quality shaper cutters.
We have disc, shank and bell cutters in stock.
Simply order them using the inquiry form in this catalog.