FlexChamfer: Maximum flexibility for deburring and chamfering gears

The FlexChamfer technology can easily deburr and chamfer external gears as well as cluster gears and gears with interfering contours during the machining process.

FlexChamfer

Economical deburring and chamfering even for small batch sizes

As power density increases, more focus is being placed on machining the face edges of gears. Innovative chamfering technologies are required in order to achieve the quality requirements and precise chamfer shapes that are demanded. One promising technology is the precise ChamferCut process, which produces the exact chamfer shape. However, conventional chamfering technologies reach their limits with small batch sizes and difficult component geometries. Particularly in the case of cluster gears, ChamferCut cannot machine all the gear positions.

The patent-pending FlexChamfer process is ideally suited for small batch sizes, both for simple and difficult workpiece geometries. In contrast to ChamferCut, which has its strengths in larger batch sizes, FlexChamfer allows flexible and cost-efficient production even for small and medium batch sizes. The universal milling cutters used are cost-effective and can be changed quickly and easily without the need for time-consuming retooling. This means that even small batches can be processed very economically.

NEW

Unique: Sequential chamfering with FlexChamfer for the new BKD gear hobbing machine platform.

With the optionally integrated FlexChamfer unit, the new generation of gear hobbing machines ranging from 800 mm to 6,000 mm offers a unique solution that enables chamfering directly after the main gear machining process – in the same setup and without additional reclamping. This eliminates additional part handling and machining steps while reducing non-productive time.

CNC-controlled machining with commercially available end mills also enables the flexible implementation of different chamfer geometries, rotary chamfers and corrections directly via the machine control.

FlexChamfer therefore combines gear machining and chamfering in one continuous process – a solution for which there is no comparable technology on the market.

Sequential chamfering in action

Highlights

The advantages of FlexChamfer at a glance

CNC-controlled refinement of chamfering with carbide milling cutters
Generation of variable chamfer shapes with standard catalogue tools
Especially suitable for external gears with or without interfering contour, as well as shafts and internal gears
Can be used in hobbing, shaping and skiving machines
Takes place during machining (depending on the cycle time for gear cutting)
Ideal for small and medium batch sizes
Quick set-up and changeover
Wet and dry machining

Video

The LHGearTec user interface: maximum user friendliness

With the LHGearTec software, the system constantly guides the operator when entering workpiece and tool data, and when corrections to the workpiece are being made. Entering parameters for the FlexChamfering is also quick and easy. For additional assistance, the system visualises the process.

Low tool investment: cost-effective chamfering solution for small batch sizes

Unlike the workpiece-specific tools used with many other chamfering technologies, the FlexChamfer process uses a universal milling cutter that is available as catalogue stock. This eliminates the expensive manufacturing and long delivery times of custom tools. The use of standard tools also makes the FlexChamfer process more flexible, as it is possible to react quickly to changing requirements.

Applications: chamfering with FlexChamfer

Short setup and changeover times for higher productivity and flexibility in chamfering and deburring

The FlexChamfer process excels with short setup and changeover times. Thanks to CNC technology where all axes can be positioned, tools can be changed in under a minute. This makes production more flexible and different workpieces can be machined quickly without long changeover times. This feature makes FlexChamfer particularly suitable for making prototypes or small batches where frequent changeovers are required. The short setup and changeover times can reduce production time and thus increase productivity.

FlexChamfer can be used for various technologies:

Gear hobbing

Liebherr has manufactured highly productive gear hobbing machines for decades. With its wide range of machine types, Liebherr can serve the needs of customers from a wide variety of industries from automotive to wind turbine manufacturers.

Gear hobbing machines

Gear shaping

Liebherr gear shaping machines are used in special applications. We design individual manufacturing solutions for our customers.

Gear shaping machines

Gear skiving

With Liebherr gear skiving machines, you get the process, tools and machine including tool changer and automation from a single source.

Gear skiving machines

Versatility for wet and dry machining

No compromises: deburr and chamfer all types of gears with ChamferCut and FlexChamfer

ChamferCut and FlexChamfer complement each other perfectly as precise gear chamfering processes. ChamferCut is particularly suitable for mass production, as it can produce large quantities with precise chamfering in a short time. FlexChamfer, on the other hand, is ideal for machining small batch sizes and difficult component geometries. The two processes can be combined on one machine, so there is no need to compromise. The combination allows a flexible response to different jobs for efficient production and top quality.