Combining power skiving and turning for complex gears

For many gear manufacturers, power skiving is getting very interesting, and not without reason, since the technique is much faster than shaping and more flexible than hobbing and broaching. However, for many years, the technique was considered quite complex. Against this backdrop, Emag says that its new development is a game changer.

Firstly, with the VSC 400 PS, the operator makes only a few data entries, making power skiving very simple. Secondly, the VSC 400 PS can be equipped with up to four power skiving tools and six turning tools. As a result, the user can produce even complex components in a single clamping operation that is fast and controlled.

For example, the machine with its two spindles, which can hold up to two power skiving tools each, can produce up to four different types of external and internal teeth using four tools. A big advantage is that the gear tooth positions match perfectly to each other at the end of cycle, made possible by the single clamping operation and no change-over. The customary step of measuring the first tooth cutting pass (prior to cutting the second) is no longer needed.

Direct drives in the main and milling spindles keep the axes synchronised during the machining processes. Additionally, the rigid B axis allows a large variety of axis crossing angles. This is essentially the setting angle of the tool, which always tilts slightly with respect tothe component. It is this tilt that makes the actual cut possible. A value between 15°and 25° is common, but Emag has also successfully implemented power skiving processes with an angle up to 45°.
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