Machine tools
Complete machining of differential gear housings on one machine
• incl. internal machining
• 2 clamping situations
• Cycle time: 94.2 seconds
The housings are machined simultaneously by two separately operating main spindles on 6 driven and up to 12 stationary tools.
The machine concept:
Complete and complex machining on only one machine bed
Application – suitable for …
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Equipping the plant
The loading conveyor equipped with pallets with a capacity of 20 blanks conveys the workpieces to the machine loading station.
Grippers transfer the workpieces to the clamping device of the first of 2 machining stations.
Processing station OP10
grün eingefärbt = bearbeitete Flächen
colored green = processed areas
Work steps
1 Calottes: roughing
2 Bolt hole: pre-drill and deburr, inside and outside
3 Outside diameter and flat surfaces: roughing
4 Inner diameter: roughing
5 Inner diameter: sizing
6 Outer diameter and flat surface: finish
Processing station OP20
7 Pin bore: centering and reaming
8 Bolt hole: reaming
9 Outside diameter and flat surfaces: roughing
10 Inner diameter: roughing
11 Inner diameter: sizing
12 Outer diameter and flat surfaces: finish
13 Calottes: sizing
Highlights
Differential gear housings place the highest demands on a machine tool:
- Rotary machining of a wide range of internal and external surfaces with high accuracies
- Precise insertion of holes
- Machining of spherical inner surfaces, fits and contours
- Optimum use of the actuating tool: the workpiece is moved to the actuating tools via the main spindles, which can be moved in X, Y and Z, with the tools plunging horizontally radially into the differential gear housing
- The entire machining process, including internal machining of the differential housings, is carried out by just one machine with only 2 clamping situations
Complete processing of the sophisticated housing:
Cycle time 94.2 seconds
100% control and removal
All finished differential gear housings are fed to a measuring machine via a drain station after machining. The results of the 100 % measurement are used by the control system for automatic tool correction.
If the measurement results meet the specifications, the workpieces are removed via an accumulation conveyor in combination with a robot arm.
Equipment |
|
| 2 driven actuating tools | 50 Nm / 20,3 kW / 4500 min-1 |
| 2 driven vertical radial drilling units | 16 Nm / 8,9 kW / 6000 min-1 |
| 2 driven axial drilling units | 3 Nm / 0,82 kW / 3000 min-1 |
2 main spindles |
|
| Torque | 125 Nm |
| Power | 34,2 kW |
| Rotations | 3000 min-1 |
Peripherie |
|
| Loading conveyor with individual pallets for position-oriented insertion into the machine | |
| Blow-off unit | |
| Measuring station for 100% measurement | |
| Unloading cell with industrial robot | |
| Unloading dust belt for finished parts | |
Machine dimension |
|
| Machine tool | 4850 mm x 2870 mm |
| Machine tool incl. periphery | 8000 mm x 4000 mm |