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| DMU 125 FD duoBLOCK® complete machining on 5-axis universal milling machines with B-axis and integral milling/turning table. |
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With a modular gearMILL performance package consisting of standard machine, standard tools, measuring module and special gearMILL gear-cutting software, DMG has recently included a product in its range which enables common gear wheels to be produced efficiently and above all cost effectively with any tooth profile, with both soft and hard machining, while maintaining short delivery times. The suitability of the system has already been shown in practice by the manufacture of larger precision bevel gear sets with Zyklo-Palloid® teeth (Zyklo-Palloid® is a registered trademark of Klingelnberg AG).
As well as the soft gearMILL intelligence, the 5-axis machines of the duoBLOCK® and gantry ranges from DECKEL MAHO Pfronten lie at the centre of this success. They enable both individual items and medium sized batches to be produced. In addition, milling/turning machines enable the integrated manufacture of rotating solid bodies to which gearing is to be applied as well as complete pinion shafts. With its modular gearMILL system for manufacturing gears on universal machines, DMG is accordingly entering a domain which has previously been ruled by out-and-out specialists. The initial impetus for this demanding technology project arose from practical requirements where, for many years, cost-bedeviled users repeatedly placed orders for very special sample machining – including the complete production of gear wheels and especially the manufacture of spiral bevel gears. Excellent results were quickly achieved using NC programs provided by customers. The DMG 5-axis machines achieved the required surface quality even on hardened tooth flanks. Only the geometrical data for the tooth gaps presented a challenge which had to be solved – and which in the meantime has been successfully overcome.
With a high degree of customer orientation and technical manufacturing expertise in 5-axis technology, DECKEL MAHO has developed its own gearMILL software from experience with sample machining. This was initially used to prepare geometrical information from special gear software for further processing in a CAD/CAM system. In a further step, the Pfronten engineers then developed an additional gearMILL software module which completely calculates the tooth gap geometry based on gear data, and from this generates optimum 5-axis manufacturing control programs for DECKEL MAHO universal machines.
In contrast to conventional CAD/CAM systems for simultaneous 5-axis machining, the new DECKEL MAHO software does not calculate the milling paths and tool orientation by approximating the tool to a curved surface which is spatially curved on all sides. Instead, it calculates them directly and with mathematical accuracy. Only as a result of this gearMILL maneuver has it now become possible to generate technologically optimum tools for practical implementation on standard DECKEL MAHO 5-axis machines.
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