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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.
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.
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.
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 both wet and dry machining. This makes it suitable for chamfering and deburring in a wide range of applications.