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Gear Honing:Characteristics & Specific applications
Matchless Machines & Technology
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What do we want in a Gear?Where-ever Gears are used, the characteristics
required are: Noise-less transmission at high speedsOptimization of powerWear resistance
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Why Gear Honing?The process of Gear Honing is ideally
suited for obtaining these characteristics.
By improving the surface finish and the quality of the Geometry of the Gear tooth, we can achieve interference free Gear performance with full contact between the two rolling surfaces.
This gives extremely smooth rolling of the Gear and thereby noiseless operation, excellent power transmission and low wear.
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What is Gear Honing?Gear honing is a hard finishing process similar
to hard shaving. The flanks of an external teeth gear and an
internal teeth honing ring are in rolling contact with a specified radial pressure at a low cutting speed.
The driven work-piece and tool spindles are crossed at a defined angle.
The superposition of the in-feed movements gives a resulting gliding movement running diagonally from tip to root of the tooth flank.
This produces a micro-cutting process with short cutting point engagement.
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Advantages of Gear Honing
Favorable surface texture reduces the noise emission in the transmission
Induced residual stresses in tooth flanks increase the bearing capacity
Low cutting speed prevents structure damages (burning)
New machines and tool systems achieve high stock removal rates and direct honing of hardened gears
Quick process and short floor to floor times are ideal for the quantity production
No limitations of gear size; from a small pinion to the final drive gear, all can be honed to perfection!
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Gear manufacturing as it once was
Green machiningGear forming (forging, sintering, …)
Green shaving
Heat treatement / Cleaning
Grinding Hard shaving
Gear honing
Finished gear
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Gear manufacturing today
Green machiningGear forming (forging, sintering, …)
Green shaving
Heat treatement / Cleaning
Grinding Hard shavingDirect-Honing
TM
Gear honing
Finished gear
Fässle
r G
ear
Hon
ing
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Workpiece- spindle
Workpiece
Honing ringTool-spindle
Pic: Fässler HMX 400
Kinematics of Gear Honing:
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Cutting veloc.
Axial veloc.
Radial veloc.
Surface structure
Distinguishing marks of gear honing
Pitch dia.PCD
Cutting velocities 1 … 10 m/s
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Fässler Technologies
Fässler Gear Honing
Hard Broaching
Dressing Technology
Tool design and manufacturing
Tech
nolo
gie
s
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Fässler HMX-400: 9-Axis
X In feed-Axis
Z1 Oscillation-Axis
A Cross angle adjusting-Axis
B1 Swivel-Axis
Z2 Headstock-Axis
B2 Headstock rotation-Axis
C1 Honing stone direct drive rotation-Axis
C2 Work piece 1 direct drive rotation-Axis
C3 Work piece 2 direct drive rotation-Axis
HM
X-4
00
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Comparison of Honed vs Ground GearsThe reason of the noiseless behavior of
honed gears is the surface structure. The ground surface in the transverse
plane of the gear looks like a saw. This causes vibrations and the gear is
loud. A honed surface in the transversal cut of
the gear looks smoother than the ground gear.
The vibrations are less.
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The Honing Process allows you to achieve:
Excellent surface finish and extreme small roughness values
Noiseless surface structure Extreme good wear behavior due to the induction of high
compressive residual stresses (1000 ... 1600 N/mm2). No thermal stresses; no changes of the material
microstructure; no grinding burn! No bias from the process Excellent profile and lead qualities (DIN 6 ... 2). Quite good correction of pitch errors and run out (DIN 6 ...
2). High process capability because of direct drive
technology Low tooling costs because long tool life of ceramic
bonded honing stones High stock removal possible Very economic finishing process - especially in mass
production
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HONING :TIME; COSTING AND ECONOMICS
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Cost comparison between various hard gear finishing processes
GreenShaving
DirectHoning™
CombiHoning
ProfileGrinding
GenerationGrinding
0%
50%
100%
150%
200%
250%
300%
350%
400%
cost [%]
Labour costTooling costMachine cost
Workpiece data:mn = 2z = 35alpha = 15°beta = 33°b = 15 mm
da = 91mm
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Cost comparison between various hard gear finishing processes
The preceding chart compares the manufacturing costs for a specific part for the different manufacturing methods.
This benchmarking was made from a well known gear box manufacturer.
The chart indicates that the cost of the green shaving are lowest.
The manufacturing cost for single direct honing is about 1.5 times higher, the costs for combi honing about 2.2 times higher.
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Comparison between various hard gear finishing processes
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Comparison between various hard gear finishing processes
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Comparison between various hard gear finishing processes
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Comparison between various hard gear finishing processes
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Honing : the superior hard finishing process….
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REASONABLE PRICE; INSTALLATION & COMMISSIONING SERVICES IN INR PAYMENT LOCALLY.
FREE SERVICE DURING WARRANTY AVAILABLE LOCALLY
POST WARRANTY AFTER SALES SERVICE AVAILABLE LOCALLY IN INR OR WITH INR PAYABLE AMC.
TECHNICALLY MOST ADVANCED DESIGN - TWIN SPINDLE - FASTEST CYCLE TIME 2-SPINDLE AND 2-HONING STONE CARRIER.
POSSIBILTY OF HONING 2 DIFFERENT GEARS. FAST SETUP CHANGE LOWEST RE-DRESSING FREQUENCY HIGHEST TOOL LIFE LOWEST TOOL COSTS
SPECIAL FEATURES & ADVANTAGESOF FASSLER - HMX
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In Conclusion….We are confident of our process and our
Machine!We have 3 machines successfully installed
at Bajaj for Honing gears of their premium 2 wheelers, and one to be installed shortly.
IF YOU ARE STILL GRINDING YOUR GEARS, YOU CAN GIVE US YOUR GEAR DRAWINGS.
WE WILL CARRY OUT HONING TRIALS AND DO A COMPARATIVE CASE STUDY FOR YOUR REFERENCE.
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THANK YOU!