Gear-manufacturing systems

Gear-manufacturing systems

December 4, 2019

German Machine Tools of America

Ann Arbor, Michigan – GMTA, the North American distributor of Profilator, has added new machines using process modules it already supplies. Profilator is suitable when customers require complex machining processes to be carried out effectively, efficiently, and with high precision.

Today, an operator working on a modern machine expects a flexible manufacturing process, short cycle times, and reduced investment and running costs. Profilator offers polygon and face slot machining; gear tooth pointing, chamfering, and deburring; gear and spline cutting; shifter stop machining; and scudding.

Polygon turning is for castle teeth machining on automotive gearbox parts. The rotating cutterhead is synchronized with the workplace spindle and a front face coupling is produced with the carbide insert arrangement and the transmission ratio. With additional inserts on the same cutter head, the part can be deburred.

Gear tooth pointing allows the pointing tower to be used in both rotative and indexing modes. Settings and corrections are made through the new Ergo Control SIMPS (Profilator Simplified Integrated Machine Programming System).

Chamfering and deburring splines, gear wheels, and shafts on the Profilator uses the ZEM series gear deburring machines. This vertical, single spindle gear deburring machine offers clear advantages over conventional deburring machines.

Gear cutting is used both for the Profilator rotative gear cutting with inserts and for hobbing. Through the application of Schlagzahn tools and carbide inserts, customers achieve the most economical manufacture of splines, gears, involute gears and front face gears. The shifter stop is synchronized so that the tool machines each tool flank.

Scudding can be used for a wide range of symmetrical gear applications as well as non-symmetrical gear or profile applications such as belt pulleys and synchronize gears. The same machine can be used for internal and external scudding.

Profilator developed the S-type machine. This is a compactly and modularly designed, vertical single spindle pick-up gear cutting machine. Machines in the S Series are better than broaching and most applications feature a dry machining process. All machine components are designed for especially high static stiffness and optimal dynamic behavior. Furthermore, the machine’s twin spindle arrangement speeds up the process considerably. A control panel and a media container are installed on the rear of the machine bed.

The workplace flow direction is variable. S-type machines are available in three sizes, namely Profilator S-150, Profilator S-250, and Profilator S-500. Profilator S-150 has a part diameter up to 150mm, while Profilator S-250 and S-500 have a part diameter up to 250mm and 500mm, respectively.