SOLUTIONSGEAR GRINDING€¦ · Single profile gear grinding forms the exact shape of each gear...

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800.835.9999 / weilerabrasives.com

GEAR GRINDING

SOLUTIONSGEAR GRINDING

SOLUTIONSGEAR GRINDING

SOLUTIONSMaximize your machine efficiency with products specifically designed for high performance gear grinding and deburring.

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DRIVING PRODUCTIVITYPeople who take work seriously partner with Weiler. We work collaboratively to help solve our customers’ biggest challenges.

We understand that every production operation is different, so is every production challenge. One solution does not fit all.

Weiler experts can examine your specific production and product challenges and develop customized solutions that optimize your operation.

Together we will maximize productivity enabling your business to be more efficient and ultimately more profitable.

WORLD-CLASS CAPABILITY

• Best-in-class lead-times

• On-site technical support

• CNC finishing

• Newest abrasive and bond technologies

• Extensive R&D capabilities

• Green manufacturing footprint

• Precision tolerances

• Unrivaled safety inspection

• Global distribution network

• Custom wheel shapes

SINGLE PROFILE CONTINUOUS GRINDING BEVEL

Straight or Spiral Bevel Gears

Plunge or Continuous Grinding

Wheel Shapes for Multiple Applications

Small Grinding Zones

Multiple Tooth Grinding

Efficient Machine Throughput

Large Grinding Zones

Single Tooth Grinding

Larger Stock Removal

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HONE DEBURRING PRODUCTSDRESSING TOOLSHOB SHARPENING

Hob Cutter Maintenance

Multiple Machine Offset Variations

Improve Surface Finish

Correct Gear Geometry

Remove Grinding Burrs

Improve Surface Finish

Maintain Workpiece Geometry

Maintain Grinding Wheel Form

Extend Grinding Wheel Life

Provide Consistent Surface Finish

Increasing Competitive Capability Through Process Improvements

Weiler Process Solutions (WPS) is a structured application engineering

program designed to provide Weiler Abrasives customers with engineering

support to identify value-added cost savings opportunities in their respective

processes. WPS is a comprehensive process where our expert application

engineers assess a specific process to identify improvement opportunities

resulting in quantifiable cost savings.

For more information and to schedule a consultation with a WPS expert visit: weilerabrasives.com/wps To discuss specific requirements with a specialist call: 800.835.9999.

WPS BENEFITS INCLUDE:• Reduced cycle times

• Elimination of bottlenecks

• Reduced consumable and tooling cost

• Elimination of rejections and rework

• Reduced energy consumption

• Reduced work in process

• Documented cost saving

• Documented best practices

• Elimination of process variability

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SINGLE PROFILE WHEELSSingle profile gear grinding forms the exact shape of each gear tooth and can be used to grind from solid or used to finish grind after machining. Opposing teeth surfaces are ground simultaneously to maintain continuous geometry of the desired gear tooth shape. Single profile grinding wheels are designed to be used on large contact areas.

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SINGLE PROFILE A - 4N D/J X T/U X H – V

TYPE 27: DEPRESSED CENTER

Grinding Faces

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SINGLE PROFILE B - 5Y17 D X T/U X H – P X F – V

Wheel dimensions are configured based on machine capabilities and the size of the gear tooth being produced. When using a wider faced grinding wheel, single or double recesses can be added to aid in mounting a wider grinding wheel on a shorter arbor shaft.

WHEEL CONFIGURATIONS

PERFORMANCE TIERS

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SINGLE PROFILE C - 7Y3 D/G X T/U X H – P X F/G - V

TIER TECHNOLOGY ATTRIBUTES VALUE

Max Performance V59-MAX Dual high performance ceramic paired with superior V59 bond technology

• Maximum cut rate • Longest wheel life • Superior form holding ability • Large depth of cuts

High Performance V59 Engineered aluminum oxide abrasive paired with high performing V59 bond technology

• High performance at lower price point • Cool cutting • High material removal rate • Reduced dressing

Performance V35 Premium aluminum oxide abrasive paired with advanced V35 bond technology

• Excellent cost performance • Suitable for low to medium removal rates • Excellent surface finish

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Minimum MaximumDiameter (mm) 150 610

Arbor Hole (mm) 20 254Thickness (mm) 20 127V Angle (Deg) Application Specific

Max Operating Speed 80 m/s

SIZES AVAILABLE

CASE STUDY: GAINING EFFICIENCY TO MEET CUSTOMER DEMANDS

Shape Typical Thickness Range (mm)4N <40

5Y17 40-607Y3 >60

Common EquipmentLiebherr

KlingelnbergGleason

KappSamputensili

With this single profile gear grinding application, our Weiler 16 gear grinding

wheel helped increase material removal, reduce dressing, and cut their total

grinding time by almost 50%.

CHALLENGE: This customer was looking to improve the overall efficiency of their grinding operations to overcome issues they were having meeting customer order deadlines. They consistently had a backlog at their grinding machines causing them to miss customer order deadlines and were at risk of losing key customers.

SOLUTION: The Weiler Industrial Grinding Team designed a wheel utilizing a custom blend of high-performance ceramic grain to increase metal removal rate and improve form retention. This grain combination paired with Weiler’s proprietary vitrified bond technology resulted in a grinding wheel that alleviated this customer's grinding backlog.

RESULT: Weiler’s custom gear grinding wheel allowed this customer to increase overall grinding efficiency and meet their customers’ demands. The Weiler team utilized the WPS process to realize the following improvements:

Material Removal Rate

43%Increase

Form Retention

51%Reduction in Dressing

Cycle Time

44%Reduction

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CONTINUOUS PROFILE WHEELSContinuous generation gear grinding forms the desired gear profile into the workpiece while the gear is rotating. Continuous profile grinding allows for faster cycle times and can be used for both small and large contact areas depending on gear size. Hybrid generative wheels can also be produced to eliminate wheel changes or machine-to-machine workpiece changes to conduct the task of roughing and finishing simultaneously.

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CONTINUOUS PROFILE A - A – 1Z D X T X H

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M=MODUL

CONTINUOUS PROFILE B - 1ZB D X T X H – M/V

Continuous generative wheels can be supplied with or without a profile. Unprofiled wheels allow flexibility to the consumer when multiple gear profiles are being produced. Profiled wheels are available with up to 7 starts and can have modules of 0.5-12 profiled with tight tolerances in a ready-to-use state for consumers with high production volumes.


PERFORMANCE TIERS




High Performance V59 Engineered aluminum oxide abrasive paired with high performing V59 bond technology

• High performance at lower price point• Cool cutting • High material removal rate • Reduced dressing



*B = # of Starts

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Cycle Time Decreased

27%Decrease

Form Retention

51%Reduction in Dressing

Reduction in Passes per Part

44%Decrease

SIZES AVAILABLE


Arbor Hole (mm) 50 150Thickness (mm) 100 250

Pressure V Angle (Deg) Application SpecificStarts 1 7

Module 0.5 12Max Operating Speed 80 m/s

Common EquipmentLiebherr

KlingelnbergGleason

ReishauerKapp

CASE STUDY: DECREASE CYCLE TIME TO MEET PRODUCTION DEMANDS

This gear grinding application increased the output by 28%

eliminating the bottleneck to meet production demands.

CHALLENGE: A spike in demand for helical gears resulted in a significant bottleneck in the customer's continuous gear grinding operation.

SOLUTION: The Weiler Industrial Grinding Team designed a wheel utilizing our new high porosity vitrified bond system that increased cutting efficiency and form retention. The higher metal removal rates and reduced need for dressing increased the output of this customer’s machine by 28%, eliminating the bottleneck and allowing them to meet production demands.

RESULT: eiler’s gear grinding wheel allowed this customer to decrease cycle time by reducing the number of passes per part and increasing the number of parts run between dressing the wheel. The Weiler team utilized the WPS process and realized the following improvements:

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BEVEL GEAR GRINDINGBevel gears can be ground in both static and continuous operations. Static operations are primarily used for straight bevel grinding where the profile is plunge ground into a stationary workpiece. Spiral bevel grinding uses a continuous operation in which the grinding wheel and the workpiece rotate in unison to generate the desired profile along the angled plane of the gear.

PERFORMANCE TIERS


Max Performance V59 High performance ceramic paired with superior V59 bond technology


High Performance V35 Engineered aluminum oxide abrasive paired with V35 bond technology

• Higher performance at lower price point• Cool cutting • Medium material removal rate • Reduced dressing over V57


• Excellent cost performance • Suitable for low material removal rates • Excellent surface finish

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UV1

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BEVEL PROFILE A - 6PZ D X T/T1 X H – W E V

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BEVEL PROFILE B - 2Z D X T – W

Bevel grinding wheel shapes are machine setup specific. Factory profiles for ready to use products can be applied using tight tolerance CNC finishing processes. Unprofiled wheels are also available for the consumer to profile in-machine. Wheel mounting variations include standard arbor hole, nut inserted back, and glued to steel plate.


BEVEL PROFILE C - 2ZB1L – D X T/U – W V/V1

* Mounted to Custom Backing Plate

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SIZES AVAILABLE

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TK

EF

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CUP PROFILE A - 11 D/J X T X H – W E K




Common EquipmentKlingelnberg

Gleason

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EF

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CUP PROFILE B - 6 D X T X H – W E

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HOB PROFILE A - 3K4 D/J X T/U X H – P X F – V

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HOB PROFILE B - 3K5 D/J X T/U X H – P X F – V

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HOB PROFILE C - 3 D/J X T/U X H – V

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HOB PROFILE D - 3K7 D/J/J1 X T/U/N X H – V

Hobbing is a milling process that is used to machine gears instead of grinding from solid. Hob cutters need proper maintenance to maintain life, cut quality, and cutting effectiveness.

HOB SHARPENING WHEELS

PERFORMANCE TIERSTIER TECHNOLOGY ATTRIBUTES VALUE

Max Performance V59 Single high performance ceramic paired with superior V59 bond technology

• Maximum cut rate • Longest wheel life• Superior form holding ability • Large depth of cuts

High Performance V35 Engineered aluminum oxide abrasive paired with V35 bond technology

• High performance at lower price point• Cool cutting • Medium to high material removal rate • Reduced dressing over V57 technology


• Cost performance • Low to medium removal rates• Excellent surface finish

Hob sharpening grinding wheels are offered in several sizes and shapes to fit the machine offset requirements of both CNC and Manual Hob sharpeners.


SIZES AVAILABLEMinimum Maximum

Diameter (mm) 100 400Arbor Hole (mm) 25 125Thickness (mm) 10 75


Common EquipmentKlingelnberg

Kapp

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STRAIGHT DRESSING PROFILE DRESSING STEP DRESSING HAND-HELD STICK

Wheel dressing usually performed with a single point or cluster tool where movement is required along the

face profile of the grinding wheel

Wheel face dressing that achieves a desired special form. Dressing rolls are the tool of choice.

Form dressing usually conducted on face angled wheels with a single profile super abrasive

dressing wheel.

Commonly used on manual grinding machines to cleanup the face of a grinding wheel.

Abrasive Hone Wheels are used to improve surface finish and to modify or correct the gear tooth geometry. Typically finer grit abrasive wheels are used in the honing process.

HONE WHEELS

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HONE PROFILE - 1 D X T X H


PERFORMANCE TIERSTIER TECHNOLOGY ATTRIBUTES VALUE



High Performance V59Single high performance ceramic paired

with engineered aluminum oxide abrasive bonded with high performing V59 bond technology

• High performance at lower price point• Cool cutting • High material removal rate • Reduced dressing

Performance V35/V57 Premium aluminum oxide abrasive paired with either V35 or V57 bond technology


SIZES AVAILABLE

DRESSING TOOLSDressing tools are a critical aspect of the grinding process to maintain the form of the abrasive wheel while also ensuring a consistent RA finish is being applied to the workpiece. Dressing or truing a grinding wheel periodically throughout the life of an abrasive wheel helps remove any material loading that could hinder performance.




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All grinding and shaping operations produce some type of burr or leave a sharp edge. On power components such as gears, these undesirable by-products are especially troublesome. Removing burrs and sharp edges improves the quality, performance, and reliability of the finished part.

DEBURRING PRODUCTS

800.835.9999 / weilerabrasives.comWC2038 / 10195BP / ©2019 Weiler Abrasives Group. All Rights Reserved.

WEILER ABRASIVES GROUPWeiler Global HQOne Weiler Drive Cresco, PA 18326 USA Weiler de MéxicoQuerétaro, México

Weiler do Brasil São Paulo, Brazil

Weiler EMEA HQMaribor, Slovenia Zrece, Slovenia Loce, Slovenia Oplotnica, Slovenia

Bindlach, Germany

For the full offering of Weiler gear deburring products, please refer to our Gear Deburring with Brushes Brochure. For more information and to schedule a consultation with a WPS expert visit: weilerabrasives.com/wps To discuss specific requirements with a specialist call: 800.835.9999.

WHY ARE BRUSHES IDEAL TOOLS FOR DEBURRING GEARS?

• Brushes do not alter part geometry• Brushes remove burrs, round sharp edges, and improve surface finish• Brushes are ideal for automation

CASE STUDY: DEBURR PUMP GEARPROBLEM: Pumps are extremely susceptible to failure due to burrs. Due to the tight fit between components, all edges must be deburred and radiused to ensure proper function. Proper deburring of rotating pump gears is especially important. SOLUTION: A dedicated machine running 14" Nylox® wheel brushes at 900 RPM was a low-cost solution for deburring these gears. By using dedicated equipment, cycle time was minimized and an acceptable edge condition was achieved.

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SOLUTIONSGEAR GRINDING€¦ · Single profile gear grinding forms the exact shape of each gear...

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