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6 Axis-CNC Gear Chamfering Machine

KD250C

Tooth Chamfering by Woodpecker (Reciprocating) Motion Does Not Create Any Burrs or Swollen Edges on Gear Tooth Flanks

Max. Workpiece Diameter
250mm
Max. Module
6
  • Feature
  • Specifications
  • Catalog

Typical Parts Hobbed

・ Spur Gear
・ Helical Gear
・ Stepped Gear
・ Shaft Gear

In Response to the Increasing Demand for Gear Chamfering

Improvement in gear chamfering quality is required to extend the life of grinding wheels in final finishing processes such as gear honing or gear grinding.

Accordingly, Kashifuji has remodeled its mechanical KD1 Gear Chamfering Machine that had been manufactured and sold since 1976. The new machine is a complete NC machine. Previously, a gear with a Helix Angle with 20º or more degrees could not be processed on the original KD-1. The new machine allows chamfering by the woodpecker motion using a link mechanism. The upper and lower end surfaces can be chamfered in a single chuck. Kashifuji’s original chamfer cut process offers the new option for the gear chamfering process.

Chamfering Using Woodpecker Motion

The cutter's single stroke chamfers the acute angle side, obtuse angle side and tooth root, and the cutter shaves the part from the inside to the outside on the tooth flanks. Therefore, no secondary burr or swollen edges are created on the tooth flanks after chamfering. In addition, synchronous machining/chamfering of the cutter and the part’s gear teeth is performed by NC control. It is possible to meet detailed chamfering requirements such as chamfering of only the acute angle side and no chamfering of the tooth root etc.

Chamfering of Upper and Lower End Surfaces in a Single Chuck

Swiveling the cutter axis (A-axis) by ±180 degrees allows chamfering of the upper and lower end surfaces which allows both in a single part chucking.

Machining of Stepped Gears

With the woodpecker motion processing method, even stepped gears with small clearances between the two gear sections can be processed without interference. In addition, by using a multi-cutter holder (optional specification), chamfering can be performed even when the top and bottom gear specifications are different.

Kashifuji’s Reliable Design and Manufacture of Cutters

We design and manufacture the optimum cutter based on the gear specifications, tool specifications and required chamfering amount. A cutter made of High-Speed Steel contributes to reduce the running costs of the machine.

Chamfering Simulation Using the Dedicated Software

The amount of chamfer, chamfer shape, and cutter commonality can be checked on the operation panel screen.

Compatible with Automation (Optional Specifications)

Automation using a robot and auto loader is available.

Specifications

  • Specs

    Max. Workpiece Diameter

    250mm

    Max. Module

    6

    Max. axial feed travel

    350mm

    Max. Cutter head swivel

    ±180°

    Max. Cutter shift travel

    220mm

    Max. revolution of cutter, infinitely variable

    500rpm

    Max. revolution of work table

    100rpm

    Weight

    1,800kg

    Floor Space: Length x Width x Height

    1300×1572×1910mm

Product Catalog

You can download the PDF data of product catalogs by adding the desired catalog to the list and filling out the form at each download link.

Inquiries about This Product

We are dedicated to a fast response to your request, and will make every attempt to respond in a timely manner. Requests received on Holidays or Weekends will be handled on the next business day in most cases.

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Vertical Hob Machine

Changing Fixtures, Hob Cutters or Workpieces (manual loading) is far simpler and faster than in a horizontal hobber as compared to a vertical hobber. As the workpiece /fixture are positioned vertically, they are very easy to exchange and accurately mount. The Hob Head of a vertical hobber allows great accessibility to the work table/tooling area and peripheral equipment (auto loader, transfer unit etc.) can be added without reducing operability!

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Hand Scraped Guideways

Kashifuji hand scrapes the guideways on all its hobbing machines to create a platform that dampens and absorbs the intermittent cutting forces that are inherent to hobbing process. This feature allows many years of use while still maintaining superb hobbing accuracies.

Generally, machining has limited achievable accuracies due to friction created distortions and/or internal stress relief produced during the machining process. Variations of temperature and humidity during the machine process can also reduce accuracy. Kashifuji utilizes a hand scraped surface finish to assure highly accurate guideways that are not possible by any machining/grinding process.

Hand Scraping is a finish processing method that makes the guideways extremely accurate with an ideal flatness and straightness by manually removing metal in extremely small amount (1~3 micro meters) by the use of a hand tool called a "Scraper". This hand tool has a carbide tipped single edge blade with a blunt angle. This tool is used to relieve the surface tension (create numerous, evenly distributed small, shallow dips or reliefs) in the guideway surfaces. Scraping produces a very flat surface, and the "shallow divots" retain oil which creates smooth sliding surfaces while reducing wear.

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Hand scraping is a labor intensive process. The guideway surfaces are painted with a “dye” then rubbed with a reference straight edge, the dye collects on the highspots. The highspots are then removed by “hand scrapping”. This process (applying dye, rubbing & scrapping) is continually repeated until approximately 30% of the guideway surface is “relieved” producing ~70% bearing surface. This process produces an extreme flatness.

Hand scraping is referred to as a "Master's Skill". Kashifuji's skilled craftsmen are able to make accurate micro-meter scraping marks compensating for variations caused by material or temperatures changes. The "scraping pattern" produced, is often referred to as an "art form", and is unique to each craftsman. It takes many years of tedious, difficult work to acquire the experience & skill to become an accomplished Kashifuji "Scraper".

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Zero Backlash Table(Work Table Backlash Eliminator)

Kashiufji designed and developed a hydraulically controlled split worm Work Table Backlash Eliminator.

This device creates a Zero Backlash condition for the work table under all cutting conditions. The backlash eliminator suppresses work table vibrations assuring smooth and highly accurate work table rotation. The rotational accuracy of the work table will not degrade with use, as the device is self-adjusting (maintenance-free).

The backlash eliminator allows consistency in hobbing accuracies especially when hobbing large pitch gears, hobbing with a carbide skiving hob cutter and opposite hand hobbing (lead angle of a hob cutter is opposite of the helix angle of the part).

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Automation

Numerous styles and types of auto loaders, conveyors or part stockers are available for automatic part transfer. All loader design are labor saving and increase efficiency.

Basic 2-Arm Auto Loader(KN80, KN152)

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Basic Ring Loader
(KE201/251、KA220/400)

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Transfer Example for Flat Gears

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Transfer Example for Flat Gears

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Transfer Example for Shaft Gears

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Transfer Example for Shaft Gears

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In-machine chamfering unit (optional specifications)

<Stock removal process using a chamfering cutter>
The use of an auto part loader device enables chamfering and deburring during the hobbing process. By effectively using the open space of the machine and by making the chamfering tool axis and the deburring tool axis independent, it is easy to change / adjust the tooling from the machine front operation side. In addition, the combination of hobbing, chamfering and deburring reduces the line length and cycle time.

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By installing a chamfering device underneath the hob head, it is possible to chamfer the part in the tooling area after hobbing and deburr the part in the open space. Additionally, the secondary burrs caused by deburring can be removed by re-hobbing. The removal of secondary burrs prevents the tooth flanks from getting damaged due to the hardened secondary burrs in the finishing processes such as gear grinding or honing, contributing to improved tool life. The combination of hobbing, chamfering and deburring reduces the line length. Also, it is possible to process a shaft gear.

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<Milling Method by tracing using a carbide rotarty end mill>
The use of an auto part loader device enables chamfering during the hobbing process. Using the machine open space effectively, the rotating carbide end mills lightly touch the rotating part allowing chamfering for both top and bottom ends of the part. Chamfering is possible using the same rotarty end mill even if the part type is chgangred.

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Hard Hobbing

Hard Hobbing is a finish hobbing process for hardened gears.

There are two kinds of Hard Hobbing processes that use carbide hobs. One is "Finish Hobbing" in which hardened gears are "finished" after the initial tooth cutting. The other is "Hardened Solid Gear Hobbing" where hardened solid gear blanks are finished hobbed.

Kashifuji has developed an Auto Part Orientation Device utilizing a special non-contact sensor that quickly and accurately orientates gear teeth to the hob tool.

Finish Hobbing

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Hardened Solid Gear Hobbing

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Auto Part Orientation Device

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Programming

Programs are created by only inputting part gear data, hob data and cutting conditions. After the completion of the programs, hobbing will be automatically performed by selecting the part number.
Optional crowning, relieving and/or taper hobbing cycles are easily performed. Simple and easy-to-operate hobbing programs are available for a wide variety of production situations, from mass production to special prototype hobbing.

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