Product category:
Machining centres - all types
News Release from: Ixion Auerbach | Subject: Machining centre for transmission shafts
Edited by the Manufacturingtalk Editorial
Team on 06 September 2007
Machining centre completely machines
gear shafts
Machining centre completely machines utility vehicle gear shafts - including main shaft, countershaft and input shaft - up to 140mm diameter by 770mm long faster than expected.
Ixion recently delivered a machining center for gearshafts to a well-known utility vehicle manufacturer The system, realized according to customer specifications, is based on Ixion standard components; it performs the following
This article was originally published on Manufacturingtalk on 4 Sep 2007 at 8.00am (UK)
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* Machines core holes, cross-holes and deep-boreholes up to 53xD.
* Generates or cuts internal threads.
* Deburrs the parts.
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* The conversion to different shafts takes at most an hour.
The machining centre has maximum shaft and bore length capacity up to 770 mm and the largest part diameter is 140mm.
When the machine was commissioned, the cycle time per complete machining task was 25% under the time required.
At the time of machine acceptance, the output was 16 pieces.
By optimizing the running process, the cycle times will certainly be able to be shortened.
Ixion bettered the required set-up time of 15 min per machining unit as delivered 'ex works'.
Thus, in close agreement with the customers, the realized solution outperforms all expectations from the very beginning, which says something about the qualities of the used Ixion standard components.
The system was ordered for the piece-cost-effective complete production of utility vehicle transmission parts, such as the main shaft, countershaft and input shaft.
The automatic system drills core holes, cross-holes and deep holes up to 53xD, deburrs and can cut or generate threads.
The only limits are workpiece and borehole lengths of maximum 770mm as well as part diameters of up to 140mm.
In the case of the acceptance part, for example, boreholes were made with 540mm depth and 10mm diameter, and the cross-holes were drilled according to their location.
The machine has a built-in 3D Renishaw probe for the obligatory measurement of the shape and position of the workpieces.
Besides the required, reproducible machining precision in the hundredths of millimetres range, the materials used for the highly-stressed shaft parts were a challenge.
The materials are tough and the chips are usually long.
Still, the Ixion drilling centre can process-safely cut or shape threads up to depths of 130mm.
The usual 20 to 25% reserves can be exploited with no problem.
Linked via a six-axis NC-controlled cycle belt, the overall system consists of five working spindles and 19 NC axes.
The system is controlled by a Siemens 840 D.
The complete application software, consisting of a PLC for the basic sequences in addition to an NC program, was developed at Ixion.
There is also an interface for TPM (total production management).
Via Transline 2000, essential planning data, such as operation readiness, maintenance or set-up times of the drilling centre are directly available.
Because the electric-related project planning, software and mechanical engineering, as well as the realization come from one source, the user also has the advantage of clear responsibilities.
Ixion has designed the deep-drilling center according to the special requirements of the customer.
Although the machine is actually one of a kind, proven components from the in-house product range are used throughout.
The gearshaft machining center, then, is based on the successful Ixion deep-drilling machine of type 'TLW' and integrates other proven Ixion systems, such as the front-face drilling and thread-cutting unit 'SBE', as well as the cross-drilling and deburring station 'QBE/ENT'.
As they say at Ixion, the modular machine design may be extended completely according to the needs and order situation of the customer or can be reconfigured for other workpieces.
Ixion managing director, Dr Frank M.
Scholz, therefore does not see the application area of the drilling centre: "Fundamentally limited to truck transmissions.
The system pays for itself everywhere where rotation-symmetric series parts and also part families can be completely machined (piece-cost-effective) with high reproducibility precision".
* Ixion Auerbach at EMO 2007, Hannover, Germany, September 17-22, Hall 13, Stand D86/D96.
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