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What is the process of gear cutting in a horizontal milling machine?
HiteshKalita
The basic process of cutting gears on a horizontal milling machine:
- The operator makes sure the machine is off and leaves it off at this point. He also checks the coolant and oil levels and cleans the machine if necessary.
- The milling machine head is removed and the overarm is extended over the bed.
- A milling cutter (selected according to the profile of the gear tooth) is installed on the arbor and centered with spacing sleeves. It is then inserted into the spindle and fastened.
- An arbor support is slid into the overarm and over the arbor, then fastened.
- On the table of the milling machine, a dividing head is placed and fastened to the bed (to the left of the arbor and its chuck facing toward it). The billet (workpiece) to be cut into a gear is gripped in the chuck of the dividing head. The dividing head is locked.
- The operator makes sure no feed levers are engaged and the spindle is in neutral.
- The machine is switched on, started and warmed up.
- After the machine is ready it is stopped and the correct speed and feed for machining the gear is selected.
- Before starting the machine, the table is moved so the workpiece is below the cutter and the workpiece is centered to the cutter along its Y-Axis.
- The machine is started again and the operator touches the workpiece with the rotating cutter then zeroes the Z-Axis dial on the vertical feed crank.
- The table is moved to the left along its X-Axis so the workpiece clears the cutter and the table is lifted a few millimeters for the first cut.
- Coolant is turned on and the X-Axis feed is engaged towards the cutter enabling the cutting of the gear groove.
- When the groove is complete, the table is lowered and moved to the left again to clear the cutter, then lifted to the same amount as the last cut.
- The dividing head is indexed and rotated to the next groove position, locked, and the cutting process is repeated until all the grooves are cut. This process can be repeated several times depending on the depth and size of the gear grooves and only a fraction of a millimeter will be left for finishing.
- The operator will ensure the cutter is still sharp and in good condition before commencing with the finishing cuts.
- A pre-finishing cut is taken and the groove depth and profile is measured. If all is fine, the table is lifted to the final cut depth and the cutting process is repeated until the gear is finished.
- Once the gear is removed from the machine, the sharp edges are removed.
The above method is just a basic explanation of how the operation is achieved. Operating any machine tool without proper training is not recommended and could lead to serious injury!
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