Shift shaft machining plant
Complete machining of shift shafts in one plant in three operations
- Motor spindles
- Low-vibration machining
- Compact design
- Cycle time 90 seconds
- Long tool life
Perfectly matched: Machining selector and shift rods
Complete machining: 21 operations in three set-ups.
The welded frame construction of the machine bed in flatbed design supports the machining assemblies and absorbs the generated process forces. Ribbing of the bed provides the necessary rigidity for low-vibration machining.
Along the length of the bed, in three sections, the X-axis guides are mounted with horizontal motor spindles. Intermediate guides, arranged orthogonally to the X-axis, operate as the Z-axis.
Glass scales are used as the absolute length measuring system for the X-axes. The alternating arrangement of the X-axes with overlapping travel paths enable the spindles to transfer workpieces in a secure axial and radial position. Opposite the spindles are the fixed tool carriers. The clamped workpiece is machined on the stationary tools via the spindle axes (X, Z and C). There are 7 driven tools for each task.
Openings arranged centrally between the tool carrier and the X-axes guide the falling chips onto the chip conveyor belt for discharge from the machining area. The cooling lubricant is also fed back through these openings to the coolant system with its belt filter and pumps.
The control shaft is made of short bars, 32 mm diameter, 1500 mm length, in three set-ups. There is no residual piece in the machining process.
Dimensions
Shaft length ≤ 300 mm
Shaft diameter ≤ 60 mm
Bar length ≤ 1500 mm
Highlights
High machining precision
Exact manufacturing quality
Low-vibration processes
Long tool life
Maximum process safety
Experience the machining centre for gearshift shafts in action
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Loading axle for bar
OP10: 8-fold tool carrier, four of them driven
Pneumatic gripper (left) and through-feed collet spindle OP10 with bar (right)
Loading and machining station OP10
The step conveyor lifts the short bar from the parts bunker with a filling quantity of 500 kg into the loading device with its NC axis. This pushes the bar through the opened through-chuck onto a stop for the first unclamping length.
At the turning bars, grooving plates, drills and driven milling cutters opposite the spindle, the longitudinal and face turning, the setting of face holes and the trochoidal milling of the T-slot are carried out.
Via the pneumatic gripper on the tool side and the movement of the opened collet, the bar is positioned in the further unclamping length. Longitudinal turning and finishing follow. With the help of the collet chuck of the motor spindle of OP20, the bar is pulled out of the spindle OP10 to the component length and then cut off in the clamped state.
OP20: 8-fold tool carrier, one of which is driven
Machining station OP20
In this clamping length, the spindle OP20 performs the operations of face drilling, roughing, finishing, facing, recessing and groove milling on the 8 fixed tools – one of which is driven. The transfer to the collet chuck of the motor spindle OP30 follows.
A firm grip: the collets
OP30: Milling spindle with turning tool, hob and disc cutter (in the background); travelling collet chuck to support the shaft (left)
Machining station OP30
The indexing shaft for hobbing is supported by the opposing free-running collet with Z-slide. The milling spindle with tool bearings on both sides drives the hob and disc cutter and has an X, a Y and a Z axis. The Y-axis is also used for shifting the hob. In addition, the external bearing pedestal carries the turning tool, which produces the required radial references before the hobbing process. After the gear hobbing process, the side milling cutter removes the missing tooth. The finished workpiece is taken over by the gripper of the final loading axis from the OP30 spindle and discharged.
Post-treatment
The downstream robot cell dries the indexing shafts in the discharge station, deburrs them with brushes and places them on pallets. Defective indexing shafts caused by faults in the machining process are discharged by the final loading assembly into an NOK container.
Equipment
- 3 work spindles, 24.5 kW, 65 Nm, 8,000 min-1
- Travel per work spindle
X: 1700 mm
Z: 240 mm - 2 chucks with stop, 1 chuck for bar
- 5 fixed, driven tools 6,000 min-1: 2 x HSK 50, 5.8 kW, 10 Nm
2 x HSK 63, 8.9 kW, 16 Nm
1 x HSK 63, 5.8 kW, 10 Nm - 1 hobbing spindle, HSK 50, tool bearing on both sides 4,500 min-1, 14.6 KW, 35 Nm,
- Traverse path of milling spindle
X: 70 mm
Y: 240 mm
Z: 140 mm - 12 fixed tools, Capto C4
- Machine control Sinumerik 840 D SL
- Central lubrication
- Cooling lubricant system with compact belt filter and immersion cooler
- Chip conveyor
- Exhaust air unit
- Hydraulic system
- Step conveyor with blank bunker
- Industrial robot removal side
Options
- Visualisation Tool management
- User interfaces
- Tool breakage monitoring
- Motor spindle with rotary feed-through for tools with internal cooling lubricant supply
Machine dimension
Machine tool incl. periphery:
8000 mm x 9700 mm x 2800 mm