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BLEND OF KISSsoft AND 5-AXIS MACHINE FOR MACHINING OF
SPIRAL BEVEL GEARS
PRESENTED BY
Shailesh V SGeneral Manager – ManufacturingSAN ENGINEERING AND LOCOMOTIVE Co. LTD.,BANGALORE
Engineered & built to last
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TOPICS COVEREDTOPICS COVERED
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ABOUT SAN ENGG AND LOCO Co. LTD.ABOUT SAN ENGG AND LOCO Co. LTD.
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ABOUT SAN ENGG AND LOCO Co. LTD.ABOUT SAN ENGG AND LOCO Co. LTD.
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KEY ELEMENTS OF LOCOMOTIVEKEY ELEMENTS OF LOCOMOTIVE
Following is the list of few key elements required for locomotive assembly
• POWER PACK SYSTEM
• TRANSMISSION
• FINAL DRIVE GEAR BOX • WHEEL - AXLE & HORN GUIDE ASSEMBLY • MAIN FRAME
• BOGIE Engineered & built to last
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POWER PACK SYSTEM
The power generated in the diesel engine is transmitted to transmission through Flexible coupling & cardan shaft & from transmission to the final drives through cardan shaft. Final drives which are mounted directly on axle will drive the bevel gear mounted on axle which in turn drives the wheel fitted on axle end.Accessories like Engine cooling fan, alternator, engine mounted compressor, lubricating pump, water pump & fuel pump will take the drive directly from engine through belt drive or gear drive.
Engineered & built to last
KEY ELEMENTS OF LOCOMOTIVEKEY ELEMENTS OF LOCOMOTIVE
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GENERAL ARRANGEMENT OF LOCOMOTIVE
(VIEW SHOWN WITH VULKAN COUPLING)
31014170
0231014170
NTS
07.05.10
POWERPACKARRANGEMENT
FUEL TANK
RAIL LEVEL
REV
1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE. 5) * INDICATES NO SEPARATE DRAWINGS.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.3) WORK TO COARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS WITHOUT TOLERANCE.2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.
DRG. NO.
COMPANY LTD.SAN ENGG. AND LOCOMOTIVE
DATE
SCALE
APPD.
CHKD.
TRCD.
DRN.
BANGALORE - 560 048
D
C
B
A
654321
654321
D
C
B
A
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL.
DRG. NO.
Engineered & built to last
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FINAL DRIVE WHEEL AND AXLE ASSEMBLY
Engineered & built to last
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• Teeth generation on bevel gear and pinion was done at dedicated bevel gear generator at our Mysore plant.
• Bevel gear and pinions generated by this process requires to be manufactured in pairs .
• Each pair is checked for contact pattern in soft condition.
• Finally this pair has to be lapped before taking for final assembly.
Engineered & built to last
PROCESS OF BEVEL GENERATION
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GEAR CUTTING MACHINE AT SAN-MYSORE
Engineered & built to last
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VIDEO OF GEAR CUTTING ON BEVEL GENERATOR MACHINE
Engineered & built to last
Video Mysore
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LIMITATIONS OF BEVEL GENERATOR
• Maintaining each bevel pair identification till completion of all processes is a tedious procedure.
• No interchangeability possible during assembly.
• Replacement of spares during overhauling of final drives is difficult as both gear and pinion needs replacement even if any one is damaged.
• Extra operation of soft checking & lapping required to ensure contact pattern between gear and pinion.
Engineered & built to last
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NEED FOR 5 AXIS MACHINE
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FLOW CHART OF GEAR CUTTING PROCESS
KISS soft parasolid model of gear
Model imported to Siemens NX 10
Block creation indicating raw material
Operation split to rough, semi finish and finish
Tool selection
Program generation through iterations
Post processing of programs
Cut one tooth & program prove out
NOT OK
Cut balance teeth
Program transfer & dry run on machine
Check for dimensional and geometric accuracies
OK
Engineered & built to last
Check for job collision and tooth profile
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• Parasolid model of bevel gear and pinion generated using KISSsoft is imported through SIEMENS NX10 programming software.
• Blocks are created around the model indicating the material which is to be machined.
• Cutting process is split into roughing , semi finshing & final finishing of flange,hub & blend.
• Tools are selected based on minimum spacing betweentooth .
Engineered & built to last
PROCESS OF PROGRAM GENERATIONPROCESS OF PROGRAM GENERATION
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PROCESS OF PROGRAM GENERATION
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PROCESS OF PROGRAM GENERATION
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GEAR CUTTING VIDEO
Engineered & built to last
Video Variaxis
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PINION CUTTING VIDEO
Engineered & built to last
Video Integrex
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ADVANTAGES OF 5 AXIS MACHINING
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Other components machined on 5 axis machines
HOUSING COVER Engineered & built to last
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Other components machined on 5 axis machines
OUTPUT FLANGE PINION SHAFT
Engineered & built to last
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Other components machined on 5 axis machines
SECONDARY CONTROL PUMP HOUSING Engineered & built to last
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Other components machined on 5 axis machines
PUMP IMPELLEREngineered & built to last
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Other components machined on 5 axis machines
PRIMARY SHAFT Engineered & built to last
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Other components machined on 5 axis machines
TURBINE WHEEL FLANGE Engineered & built to last
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Other components machined on 5 axis machines
GUIDE WHEEL FLANGE Engineered & built to last
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Other components machined on 5 axis machines
PUMP IMPELLER Engineered & built to last
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Other components machined on 5 axis machines
OUTPUT FLANGEEngineered & built to last
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LIMITATIONS OF 5 AXIS MACHINES
• Machining of gears with modules lesser than 6 mm is difficult as tool procurement is difficult .
• Need for extra modelling and CAM programming software for gear teeth machining.
Engineered & built to last
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Thank you