Chamfering to measure

With the LCD 300 ChamferCut, Liebherr now offers a standalone solution for chamfering with the increasingly popular ChamferCut process. At the EMO 2013 trade fair, Liebherr debuted an integrated machine orientated around the automotive industry, offering hobbing and chamfering with the ChamferCut process simultaneous with prime time operation. In 2014, the portfolio was extended to include an LC 300 ChamferCut for components up to 300 millimetres in diameter. It soon became apparent that there was a demand for a pure chamfering machine as well. To meet these requirements, Liebherr has now developed the autonomous ChamferCut machine. The LCD 300 ChamferCut can be deployed to enhance an existing machine park, to replace existing chamfering machines or assemble new lines.

The fundamental idea is speed and simplicity

The basic idea for the solution was clear: “This machine should be easy to operate and work as quickly as possible”, explains Dr Hansjörg Geiser, head of gear cutting machine development & design. With the LCD 300 ChamferCut chamfering machine, workpiece clamping for chamfering can be geometrically optimised and smaller tools can be used. This achieves additional variance and broadens the area of use. Thanks to this technology and the fast tooling times, an LCD 300 ChamferCut machine can perform the same work as about two to three milling machines.

The result is a machine with extremely fast tooling times and optimised workpiece clamping. The operator can input and adjust data for the ChamferCut process with ease via CNC axes. New software has been developed for the user interface. This is orientated around the adjustment sheets of the FETTE ChamferCut tools. With graphic support and examples for adjustment corrections, the user can find his way around in no time. An intuitive guide simplifies machine operation.

The machine is loaded automatically using the trusted ring loader principle, though the use of robots or a gantry as an alternative loading system is also possible. This provides flexibility for inclusion in the automation process, for example via a plastic chain conveyor.

Cost effective and outstanding results

Compared with pressurised deburring and chamfering with end mills, chamfering with ChamferCut is becoming more and more popular as the machining costs with this method are the lowest. The special tools have a very long service life and easy to regrind. Precision chamfering with repeat accuracy, combined with long service lives speak in favour of the ChamferCut process. Little wonder, therefore, that the significance of chamfering with ChamferCut has grown in recent years. Chamfering is especially popular owing to the high level of quality associated with passenger vehicle and commercial vehicle manufacturers as well as in gearbox and engine manufacture: “In these areas of industry, the expectations are naturally very high”, explains Hansjörg Geiser. “As gearboxes become more and more compact in their design, special requirements in chamfering quality arise that can be fulfilled particularly well with the ChamferCut process on Liebherr machines.”

Good reasons for chamfering with Liebherr ChamferCut units:

  • High chamfering speeds (short cycle times)
  • No reduction in milling length
  • Geometry of hob and ChamferCut can be selected freely
  • Rigid clamping system during hobbing, adapted device for chamfer cutting
  • Very small diameters possible (> 30 mm) with broad application possibilities
  • High quality and precise chamfer forms
  • Trouble-free chamfering of root of tooth
  • Very long service life even with dry machining
  • No needle chips
  • Adjustment via CNC axes with simple tooling
  • Lowest tool costs with chamfering by comparison
  • Tools can be reground easily
  • User-friendly data input