Moving small- to medium-batch production from outsourced, dedicated hobbing operations to in-house, CNC multitasking machines helps job shops achieve quick turnarounds and flexibility in supplying splines for the heavy-vehicle industry. The men and women at Ford Sharonville have turned the art of gear making into a science. Inside Ford Sharonville Transmission: Producing 19 Million Gears a Year.How do you create products that are cost competitive and of the highest quality? Here are three approaches, one about a car manufacturer putting more emphasis on its capacity, one about a machine producer increasing efficiency through flowing parts, and one about a car maker assuring quality in production. According to the company, this feature has saved more than $200,000. The company can put a different kind of hob in the unit and switch to a different part fairly simply. Another benefit of the single setup is that scrap has been reduced from about 10 percent to 1.6 percent, greatly improving overall efficiency and the company’s bottom line.Īlong with the increased adjustment angle, Heimatec designed the custom hobbing tool to be interchangeable, which enables Gurecky to use different arbor sizes. Now, the company can machine precision parts on the CNC lathe using the custom hobbing unit in 8 to 10 minutes, start to finish.
The hobbing operation alone took one to two hours. Previously, the part would be turned on the lathe, then taken off and set up for a secondary hobbing operation. Completing more operations in one setup has been a major time saver for Gurecky.
#Dmg mori ellison code#
Heimatec and DMG Mori Ellison Technologies set up the hobbing attachment, wrote the program code and started cutting the 45-degree helical gears in a quarter of the time that it took in the past. So we increase the torque output by gearing down the tool.”
So if its 3,000 rpm into the tool, the tool only rotates at 1,500 rpm. “Many times, it’s a 1:1 ratio, and we go 2:1. “One of the things we do to help is increase the torque through a gear reduction,” Mr. The hobbing unit can run at 3,000 rpm and provide 63 Nm of torque. It also increases the performance of the hobs that do the cutting, he says. In turn, this structure provides the rigidity necessary to reduce backlash and increase tool life. Hansen says Heimatec’s hobbing units are designed with a strong bearing structure. When you’re turning at 45 degrees and milling at the same time, you tend to lose rigidity,” he says. You have to be concerned with the rigidity of the tool. “It’s a pretty difficult operation, and when you’re twisting that tool, there’s a lot of leverage. Rigidity is the key to tackling this difficult machining operation, he says. “As long as the machines can handle it, we can build a tool to do it.”Īfter a few months of testing, the tool was complete and ready to be put to work. According to Preben Hansen, president of Heimatec, lathes and their coordinating controls are more sophisticated these days, so a dedicated hobbing machine isn’t always necessary. Undaunted by the task, Heimatec said it could design a custom hobbing tool with ±45 degrees of adjustment to use in conjunction with the new machine. This was a problem because standard hobbing units only allow ☓0 degrees of helix angle adjustment due to loss of rigidity.
What made this particular application challenging was the fact that Gurecky needed to machine helical gears at a 45-degree angle.
#Dmg mori ellison install#
The company approached DMG Mori Ellison Technologies and decided to install its customized multifunctional NLX 2500SY/700 with the ability to hob gears. In late 2012, Gurecky President John Dorman decided it was time to purchase a CNC machine specifically for gear hobbing. For example, since buying its first DMU 50 ecoline from DMG Mori (Hoffman Estates, Ill.), the company has moved production from traditional vertical machining centers (VMCs) to the more versatile five-axis DMG Mori machines. To remain competitive, Gurecky constantly invests in advanced manufacturing equipment. The company produces multifaceted precision parts ranging from prototypes to mass production. Today, the company operates out of a 43,000-square-foot facility, serving the oil, gas and energy industries. (Prospect Heights, Ill.) was necessary to achieve a desired 45-degree helix angle. However, a custom hobbing tool from Heimatec Inc. of Rosenberg, Texas, decided to enhance its manufacturing operations by purchasing a machine that could act as a regular CNC lathe and machine helical gears at the same time. One way to meet this need is to accomplish more operations in one setup. As the competitive nature within a market increases, so does the need for increased productivity and throughput by handling the parts less.
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