The smaller the axis cross angle, the closer towards the interference contour can be machined. 30 to 50 %) in comparison to the likewise flexible gear shaping and the ability to apply the gearing close to an interfering contour (workpiece shoulder). Significant for the skiving process is the short machining time (approx. The cutting speed results from the rotational speeds of tool and workpiece in relation to the axis cross angle. In this way the tooth space is “peeled out” of the workpiece in several cuts. By superimposing a feed motion, both add to the movements to the feed speed and guide the cutting edge along the workpiece axis. With the coupled rotation of workpiece and tool, a relative movement of the cutting edge in the tooth space is thus created. The skiving process is characterized by the tool and workpiece axes arranged in a certain relationship to each other – the axis cross angle. In addition to traditional gear machining processes such as hobbing, gear shaping and broaching, skiving is a continuous machining process for soft and hard machining of internal and external gears. “Power Skiving” makes a significant contribution to each of these aspects. As with all manufacturing technologies, quality, cost optimization, flexibility and productivity are the top issues. The use of planetary gears for reduction or as a differential in the drive system also increases the demand for internal gears. With e-mobility, a market is now growing which demands high precision (low running noise), high power transmission (torque and speed) from the product and equally high product flexibility in volume production.
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Harish Maniyoor, Sandvik Coromant global product manager for automotive, says the customer reported increased process stability and considerably improved component quality.Like electric mobility, the technology of power skiving has been known for more than 100 years and, with the availability of 5-axis machining centers, has found its way into individual and series production due to its convincing process flexibility. In that case, the customer reduced the time-consuming shaping process it was using to make gear components from low-alloy 16MnCr5 by opting for Sandvik Coromant’s CoroMill 178 for power skiving.
One Sandvik Coromant customer in the automotive segment achieved a 90% reduction in machining time through the use of power skiving tools. Manufacturers can also benefit from increased design precision and flexibility. A single set-up greatly improves machine utilization and total profit - based on Sandvik Coromant’s own findings, a 20% increase in machine utilization can provide a 10% higher gross profit margin. As the process combines hobbing and shaping, power skiving enables machining of a whole component in a single, multi-tasking machine rather than several machines. The intersecting angle between the tool and gear axis affects the revolution speed and greatly benefits productivity.
Power skiving is a continuous rotary cutting technique where the tool meshes with the gear under production. In the face of all these challenges, Sandvik Coromant recommends looking to power skiving, which has particularly benefited gear manufacturing in the automotive industry, and recommends its PrimeTurning concept. Scenarios like the ongoing COVID-19 pandemic also introduce challenges to the shop floor, such as unpredictable demand and the need to maintain productivity with fewer workers at any one time. Manufacturers must cost-effectively meet these requirements while maximizing machine uptime and reducing cycle times.
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You will also learn how to maximize productivity during this inside look into Hwacheon’s automatic workpiece changer, the perfect solution for mass production. In this digital demo, Jeong Hoon highlights many of the benefits the D2-5AX provides when machining complex shapes and parts. AUTOMATION SOLUTIONS FEATURING HWACHEON'S D2-5AX AND AUTOMATIC WORKPIECE CHANGER This places pressure on manufacturers to machine smaller and more precisely engineered components with increased design flexibility. Today’s industrial robots must not only fit into increasingly small spaces, dedicating as much “manufacturing real estate” as possible to production, but also be lighter with reduced inertia and the ability to perform more exact movements with optimal speed and efficiency. Robots now factor into a range of industries, from automotive and aerospace to the food industry and pharmaceuticals - yet all of these sectors have common requirements. This was a 12% increase from 2018 and a historic high. The overall number of industrial robots operating in factories worldwide grew to 2.7 million in 2019, according to the 2020 World Robotics Report by the International Federation of Robotics (IFR). Power Skiving Enables Smaller, Precise Robotics Machining | BY EVAN DORAN, MODERN MACHINE SHOP
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