For Gear, Spline & Rack Manufacturing

Transcription

1 For Gear, Spline & Rack Manufacturing INC

2 Advanced Technologies for Gear, Spline and Rack Manufacturing Standard s for Spline Applications Gear Milling System Advantages Super Fast Machining At least 50% less machining cycle time over other methods Carbide inserts with Semi Partial & Partial designed for single pass machining Long Tool Life Tough sub-micron grade coated inserts with up to 3 cutting edges igh Accuracy & Quality Machining No need for additional machining igh quality surface finish Shorter Delivery Times Standard spline application tools according to ANSI B9.1 available from stock Tailor Made Tailor made tools according to the customer's specifications Economical Solution Absolute price/performance advantage over existing technology igh Precision Machining for Tailor-made s For example: Gears: Up to Class 7 according to DIN 3962 and DIN 3967 or Class 11 according to AGMA Involute Splines: According to DIN 5480 or ANSI B92.1 Straight Side Splines: According to ISO 14 and DIN 5463; 5464 Simplified Machining Easy set-up and use on standard 3.5 axis CNC milling machines 2

3 CATALOG The Vardex Gear Milling Concept _ Page 4 Gear Milling System Page 6 GEAR MILLING INSERTS Gear Milling Tailor-made s Page 7 Gear Milling Standard s for Spline _ Page 8 TOOLOLDERS Toolholder - Weldon Shank for 1/4 U Page 10 Toolholder - Weldon Shank for 3/8 U _ Page 11 Toolholder - Shell Mill for 3/8 U Page 12 Toolholder - Shell Mill for 1/2 U Page 13 Toolholder - Shell Mill for 1/2 UT _ Page 15 Toolholder - Shell Mill for 5/8 U Page 16 Toolholder - Shell Mill for 5/8 UT _ Page 18 Gear Milling Toolholder - Disc Mill for 1/4 U Page 19 Gear Milling Toolholder - Disc Mill for 3/8 U Page 20 Solid Carbide Gear Milling Page 21 TECNAL DATA Recommended Grades and Speeds Page 22 Gear Milling Request Form _ Page 23 3

4 Advanced Technologies for Gear, Spline and Rack Manufacturing The VARDEX Gear Milling Concept Advanced milling tools with multi-flute indexable carbide grade inserts for super fast machining Offering a competitive alternative to the traditional ob system Tailor-made inserts and holders designed per customer application, with the exact required profile shape (evolvent, involute or any other profile) to be transferred to the component Major Applications GEAR SPLINE RACK VARDEX Gear milling tools are suitable for machining both straight and helical teeth covering modules from mm or DP VARDEX Spline milling tools are suitable for machining both involute or straight-sided profiles, covering modules from mm or DP 48/96-4/8 VARDEX Rack milling tools are suitable for covering modules from mm or DP

5 Toolholder Range End Mill Shell Mill Disc Mill Solid Carbide See pages See pages See pages See page 21-1/4", 3/8" Z "-1.42" - 3/8"U, 1/2"U, 1/2"UT, 5/8"U, 5/8"UT Z "-3.35" - 1/4"U, 3/8"U Z - 8, "-3.54" Tailor-made s for Gear, Spline and Rack Applications Tailor-made inserts for Gear, Spline and Rack See page 7 U Style 3 UT Style 1 Edge Standard s for Spline Applications Spline: According to Standard ANSI B92.1 See page 8 Spline 5

6 Gear Milling System Tailor Made s for Gear, Rack and Spline 4 1 U 2 T 3 E 4 DP 5 8/16 6 Z37 7 GM 8 VBX 9 210/ /4 3-3/8 4-1/2 5-5/8 2 - Style U - U Style 3 - T - Single None Application E - External 5 - Module or DP DP - Diametral Pitch M - Module 6- Module or DP 7 - Gear/ Spline Teeth 8 - Product Line 9 - Grade 10 - Special No. M DP Z... GM - Gear Milling VBX 210/... Standard s for Spline 5 1 U 2 3 E 4 DP 5 8/16 6 N7 7 Z GM 9 VBX /4 3-3/8 4-1/2 5-5/8 2 - Style U - U Style (Spline) 3 - None Application E - External 5 - DP DP - Diametral Pitch (for Splines) 6- Module/DP Range 7 - Milling Cutter No. 8 - Teeth Range Gear 9 - Product Line 10 - Grade 32/64-8/16 N1 - N8 Zmin 10 - Zmax 135 GM - Gear Milling VBX Weldon Shank Toolholders GM 1 E S W U / OR 32/64-24/ Product Line 2 - older Type Clamping System 5 - Shank Diameter 6 - Shank Style GM - Gear Milling E - End Mill 5 S - Screw 1.0", 1.25" W - Weldon Shank 7- Diameter [inch] 1.19" " 8 - Toolholder Overhang 1.97" " 9 - () 2-1/4 3-3/8 10- Style U - U Style 11 - Special older No. 215/... OR 11- DP Range 32/64-16/32 Shell Mill and Disc Mill Toolholders GM 1 S S U / OR 20/40-16/ Product Line 2 - older Type Clamping System 5 - Diameter [inch] GM - Gear Milling S - Shell Mill D - Disc Mill 3-10 S - Screw 1.73" " 6- Drive ole Diameter [inch].75", 1.0" /4 3-3/8 4-1/2 5-5/8 8 - Style U - U Style 9 - T - Single None Special older No. 215/... OR 10 - DP Range 32/64-8/16 6

7 Gear Milling Tailor-made s External Circular Pitch L L Module = Pitch / π DP = 25.4 / Module U Style - 3 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. Based on the required customer application, VARDEX designs and supplies tailor-made inserts to suit a specific Module / DP as well as the exact number of teeth used on the component. Tailor-made s for Gear, Spline and Rack Applications UT Style - 1 Edge Application Module Diametral Pitch (DP) Gear L /4 U /8"U 16 3 Toolholder GME4S100W U215/... GM0SD U215/... GME3S125W U215/... GMS4S U215/... GMD8SD U215/... Page Rack /2"U 22 3 GMS4S U215/... GMS5S U215/ /2"UT 22 1 GMS6SD UT215/ /8"U 27 3 GMS3S U215/... GMS4SD U215/ /8"UT 27 1 GMS6SD UT215/ /96; 40/80; 32/64; 24/48 1/4 U 11 3 GME4S100W U215/... GM0SD U215/ Spline /40; 16/32 3/8"U 16 3 GME3S125W U215/... GMS4S U215/... GMD8SD U215/ /24; 10/20; 8/16 1/2"U 22 3 GMS4S U215/... GMS5S U215/ /12; 5/10 1/2"UT 22 1 GMS6SD UT215/ /16; 6/12 5/8"U 27 3 GMS3S U215/... GMS4SD U215/ /10; 4/8 5/8"UT 27 1 GMS6SD UT215/

8 Gear Milling Standard s for Spline External Circular Pitch L ANSI B92.1 Standard U Style - 3 According to Standard ANSI B92.1, there are 7 different diametral pitches available, ranging: DP32/64 to DP8/16. For each DP, there are 8 different types of inserts to select, according to the number of teeth on the spline. Standard s for Spline Applications 1/4"U.43" 3/8"U.63" L Inch Diametral Pitch (DP) DP32/64 DP24/48 DP20/40 DP16/32 EDP (VBX) Milling Cutter No. Z - Range of Teeth on Gear 2UEDP32/64Z10-11N1GM N UEDP32/64Z12-13N2GM N UEDP32/64Z14-16N3GM N UEDP32/64Z17-20N4GM N UEDP32/64Z21-25N5GM N UEDP32/64Z26-34N6GM N UEDP32/64Z35-54N7GM N UEDP32/64Z55-135N8GM N UEDP24/48Z10-11N1GM N UEDP24/48Z12-13N2GM N UEDP24/48Z14-16N3GM N UEDP24/48Z17-20N4GM N UEDP24/48Z21-25N5GM N UEDP24/48Z26-34N6GM N UEDP24/48Z35-54N7GM N UEDP24/48Z55-135N8GM N UEDP20/40Z10-11N1GM N UEDP20/40Z12-13N2GM N UEDP20/40Z14-16N3GM N UEDP20/40Z17-20N4GM N UEDP20/40Z21-25N5GM N UEDP20/40Z26-34N6GM N UEDP20/40Z35-54N7GM N UEDP20/40Z55-135N8GM N UEDP16/32Z10-11N1GM N UEDP16/32Z12-13N2GM N UEDP16/32Z14-16N3GM N UEDP16/32Z17-20N4GM N UEDP16/32Z21-25N5GM N UEDP16/32Z26-34N6GM N UEDP16/32Z35-54N7GM N UEDP16/32Z55-135N8GM N Toolholder GME4S100W U32/64-24/48 GM0SD U32/64-24/48 GME3S125W U20/40-16/32 GMS4S U20/40-16/32 GMD8SD U20/40-16/32 (66673) (66675) (66676) (66678) (66677) Page

9 Gear Milling Standard s for Spline (con't) External Circular Pitch L ANSI B92.1 Standard U Style - 3 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. Standard s for Spline Applications 1/2"U.87" L Inch Diametral Pitch (DP) DP12/24 DP10/20 5/8 U 1.06 DP8/16 EDP (VBX) Milling Cutter No. Z - Range of Teeth on Gear 4UEDP12/24Z10-11N1GM N UEDP12/24Z12-13N2GM N UEDP12/24Z14-16N3GM N UEDP12/24Z17-20N4GM N UEDP12/24Z21-25N5GM N UEDP12/24Z26-34N6GM N UEDP12/24Z35-54N7GM N UEDP12/24Z55-135N8GM N UEDP10/20Z10-11N1GM N UEDP10/20Z12-13N2GM N UEDP10/20Z14-16N3GM N UEDP10/20Z17-20N4GM N UEDP10/20Z21-25N5GM N UEDP10/20Z26-34N6GM N UEDP10/20Z35-54N7GM N UEDP10/20Z55-135N8GM N UEDP8/16Z10-11N1GM N UEDP8/16Z12-13N2GM N UEDP8/16Z14-16N3GM N UEDP8/16Z17-20N4GM N UEDP8/16Z21-25N5GM N UEDP8/16Z26-34N6GM N UEDP8/16Z35-54N7GM N UEDP8/16Z55-135N8GM N Toolholder GMS4S U12/24-10/20 GMS5S U12/24-10/20 GMS3S U8/16 GMS4S U8/16 (66679) (66680) (66681) (66682) Page

10 Toolholder - Weldon Shank for 1/4 U D L2 L3 L1 L1 L Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s L L1 D Dimensions inch (max) 1/4 U 3 GME4S 100W U Z Screw Torx Screwdriver SN2T (70036) K2T (70227) Spline Toolholders For Standard Spline s EDP Dimensions inch L L1 D 1/4 U 3 GME4S 100W U 32/64-24/ Z Screw Torx Screwdriver SN2T (70036) K2T (70227) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 10

11 Toolholder - Weldon Shank for 3/8 U D L2 L3 L1 L1 L Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s L L1 D Dimensions inch (max) 3/8 U 3 GME3S 125W U Z Screw Torx Screwdriver SN3T (70038) K3T (70228) Spline Toolholders For Standard Spline s EDP Dimensions inch L L1 D 3/8 U 3 GME3S 125W U 20/40-16/ Z Screw Torx Screwdriver SN3T (70038) K3T (70228) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 11

12 Toolholder - Shell Mill for 3/8 U d(6) L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions inch d (6) 3/8 U 3 GMS4S U Z Screw SN3T (70038) Torx Screwdriver K3T (70228) older Screw 3/8-24x1.5 (70264) Spline Toolholders For Standard Spline s EDP Dimensions inch d (6) 3/8 U 3 GMS4S U 20/40-16/ Z Screw SN3T (70038) Torx Screwdriver K3T (70228) older Screw 3/8-24x1.5 (70264) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 12

13 Toolholder - Shell Mill for 1/2 U d(6) L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions mm d (6) 1/2 U 3 GMS4S U215/ Z Screw SN4T (70039) Torx Screwdriver K4T (70241) older Screw 3/8-24x2.0 (70302) Spline Toolholders For Standard Spline s EDP Dimensions inch d (6) 1/2 U 3 GMS4S U12/24-10/ Z Screw SN4T (70039) Torx Screwdriver K4T (70241) older Screw 3/8-24x2.0 (70302) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 13

14 Toolholder - Shell Mill for 1/2 U d(6) L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions inch d (6) 1/2 U 3 GMS5S U Z Screw SN4T (70039) Torx Screwdriver K4T (70241) older Screw 1/2-20x1.5 (70224) Spline Toolholders For Standard Spline s EDP Dimensions inch d (6) 1/2 U 3 GMS5S U 12/24-10/ Z Screw SN4T (70039) Torx Screwdriver K4T (70241) older Screw 1/2-20x1.5 (70224) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 14

15 Toolholder - Shell Mill for 1/2 UT d(6) L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions inch d (6) 1/2 UT 1 GMS6SD UT215/ Z Screw SN4T (70039) Torx Screwdriver K4T (70241) older Screw 1/2x20x1.5 (70224) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 15

16 Toolholder - Shell Mill for 5/8 U d(6) L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions mm d (6) 5/8 U 3 GMS3S U215/ Z Screw SN5TM (70041) Torx Screwdriver K5T (70229) older Screw 3/8-24x2.0 (70302) Spline Toolholders For Standard Spline s EDP Dimensions mm d (6) 5/8 U 3 GMS3S U8/ Z Screw SN5TM (70041) Torx Screwdriver K5T (70229) older Screw 3/8-24x2.0 (70302) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 16

17 Toolholder - Shell Mill for 5/8 U d(6) L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions inch d (6) 5/8 U 3 GMS4S D U Z Screw SN5TM (70041) Torx Screwdriver K5T (70229) older Screw 1/2-20x1.5 (70224) Spline Toolholders For Standard Spline s EDP Dimensions inch d (6) 5/8 U 3 GMS4S U 8/ Z Screw SN5TM (70041) Torx Screwdriver K5T (70229) older Screw 1/2-20x1.5 (70224) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 17

18 Toolholder - Shell Mill for 5/8 UT d(6) L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions inch d (6) 5/8 UT 1 GMS5SD UT215/ Z Screw SN5TM (70041) Torx Screwdriver K5T (70229) older Screw 1/2-20x1.5 (70224) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 18

19 Gear Milling Toolholder - Disc Mill for 1/4 U L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions inch d (6) 1/4 U 3 GM0S D U Z Screw Torx Screwdriver SN2T (70036) K2T (70227) Spline Toolholders For Standard Spline s EDP Dimensions inch d (6) 1/4"U 3 GM0S D U 32/64-24/ Z Screw Torx Screwdriver SN2T (70036) K2T (70227) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 19

20 Gear Milling Toolholder - Disc Mill for 3/8 U L2 Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s (max) Dimensions inch d (6) 3/8 U 3 GMD8S D U Z Screw Torx Screwdriver SN3T (70038) K3T (70228) Spline Toolholders For Standard Spline s EDP Dimensions inch d (6) 3/8 U 3 GMD8S D U 32/64-24/ Z Screw Torx Screwdriver SN3T (70038) K3T (70228) * L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 20

21 Solid Carbide Gear Milling External Circular Pitch D Module = Pitch / π DP = 25.4 / Module Image for illustration only. Final and values for tailor made toolholders will be supplied with the toolholder. Solid Carbide Tool Benefits Small Tool Diameter Excellent solution for applications that require cutting close to the shoulder igh RPM and fast feed Solid Carbide Tool Guarantees higher accuracy Multi-flute Tool Enables fast machining Tool Range Diameter Range:.23"-.75 ( mm) Module: DP: For Tailor-made Gear, Rack and Spline s Shank Diameter Gear & Rack Module Range, Max Spline Module Range, Max Inch mm Module Diametral Pitch (DP) Module Diametral Pitch (DP) 1/ DP DP40/80 5/ DP DP32/64 3/ DP DP24/48 1/ DP DP20/40 5/ DP DP16/32 5/ DP DP12/24 3/ DP DP10/20 3/ DP DP8/16 21

22 Recommended Grades, Speeds Vc [ft/min] and Feed f [inch/tooth] Material Group P Steel M Stainless Steel K Cast Iron N(K) Non-Ferrous Metals S(M) eat Resistant Material (K) ardened Material Vardex No. 1 Material ardness Brinell B Vc [ft/min] VBX/ VTX Grade Application Sample Feed f [inch/tooth] Low carbon (C= %) Unalloyed steel Medium carbon (C= %) igh Carbon (C= %) Non hardened Low alloy steel (alloying elements 5%) ardened ardened igh alloy steel Annealed (alloying elements>5%) ardened Low alloy (alloying elements <5%) Cast steel 10 igh alloy (alloying elements >5%) Stainless steel Non hardened Ferritic ardened Stainless steel Austenitic Austenitic Super Austenitic Stainless steel Non hardened Cast Ferritic ardened Stainless steel Austenitic Cast austenitic ardened Ferritic (short chips) Malleable Cast iron 29 Pearlitic (long chips) Low tensile strength Grey cast iron 31 igh tensile strength Ferritic Nodular SG iron 33 Pearlitic Aluminium alloys Non aging Wrought Aged Cast Aluminium alloys 37 Cast & aged Aluminium alloys Cast Si 13-22% Copper and Brass Copper alloys Bronze and non leaded copper Annealed (Iron based ) Aged (Iron based) igh temperature alloys 21 Annealed (Nickel or Cobalt based) Aged (Nickel or Cobalt based) Pure 99.5 Ti 400Rm Titanium alloys 24 α+β alloys 1050Rm Rc Extra hard steel ardened & tempered Rc* * Note: Special tools, which are not listed in this catalog, are required for extra hard steel (51-55Rc). Indexable VBX VTX TiCN coated carbide grade. Excellent grade for general use. TiAIN coated carbide grade. Excellent grade for general use and hardened materials. Solid Carbide VT TiCN coated carbide grade. Excellent grade for general use. Other grades are available upon request. 22

23 Distributor Name NEUMO Ehrenberg Group ENQUIRY No. Request Form* * Please submit a completed version of this form with each request (a drawing is recommended). For Rack, Straight Spline, Worm or other special forms, a drawing must be supplied with all relevant dimensions! Basic Dimensions 1 Gear / Spline Standard 2 Class of Accuracy 3 Module (M) / Diametral Pitch (DP) 4 Number of Teeth 5 Pressure Angle 6 elix Angle 7 Direction of elix (R/L) 8 Pitch Diameter (REF) 9 Major Diameter 10 Minor Diameter 11 Form Diameter (For Spline only) 12 Fillet Radius Additional Information 15 For Tool Exit Limitation, a detailed component drawing must be supplied! 16 Exit Arc Radius (R) 17 Material ardness (During machining) 18 Material Designation Max: Max: 13 Root Type (For Spline only) One of the following must be supplied: 14a Measurement Over Pins 14b Tangent Length Over (N) Teeth 14c Actual - Tooth Thickness Min: Min: Fillet Root Ø: N: Flat Root Max: Max: Max: Pressure Angle Min: Min: Min: Tool Radius (R) < Exit Arc Pin Diameter R (/2) Tool Radius (R) < Tool Exit Limitation R (/2) Exit Arc Limitation Flat Root Spline Form Diameter Involute Fillet Radius Major (Outside) Diameter Minor (Root) Diameter Pitch Diameter Measurement Over Pins Fillet Root Spline Involute Tooth Thickness Fillet Radius Form Diameter Fillet Radius Tangent length over (N) teeth

24 For Gear, Spline & Rack Manufacturing Vargus USA 1149 Barberry Drive Janesville, WI U.S.A Tel: Fax: INC EA 05/2017 EDITION 04