BLEND OF KISSsoft AND 5-AXIS MACHINE FOR MACHINING OF

SPIRAL BEVEL GEARS

PRESENTED BY

Shailesh V SGeneral Manager – ManufacturingSAN ENGINEERING AND LOCOMOTIVE Co. LTD.,BANGALORE

Engineered & built to last

TOPICS COVEREDTOPICS COVERED

ABOUT SAN ENGG AND LOCO Co. LTD.ABOUT SAN ENGG AND LOCO Co. LTD.

ABOUT SAN ENGG AND LOCO Co. LTD.ABOUT SAN ENGG AND LOCO Co. LTD.

KEY ELEMENTS OF LOCOMOTIVEKEY ELEMENTS OF LOCOMOTIVE

Following is the list of few key elements required for locomotive assembly

• POWER PACK SYSTEM

• TRANSMISSION

• FINAL DRIVE GEAR BOX • WHEEL - AXLE & HORN GUIDE ASSEMBLY • MAIN FRAME

• BOGIE Engineered & built to last

POWER PACK SYSTEM

The power generated in the diesel engine is transmitted to transmission through Flexible coupling & cardan shaft & from transmission to the final drives through cardan shaft. Final drives which are mounted directly on axle will drive the bevel gear mounted on axle which in turn drives the wheel fitted on axle end.Accessories like Engine cooling fan, alternator, engine mounted compressor, lubricating pump, water pump & fuel pump will take the drive directly from engine through belt drive or gear drive.

Engineered & built to last

KEY ELEMENTS OF LOCOMOTIVEKEY ELEMENTS OF LOCOMOTIVE

GENERAL ARRANGEMENT OF LOCOMOTIVE

(VIEW SHOWN WITH VULKAN COUPLING)

31014170

0231014170

NTS

07.05.10

POWERPACKARRANGEMENT

FUEL TANK

RAIL LEVEL

REV

1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE. 5) * INDICATES NO SEPARATE DRAWINGS.

4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.3) WORK TO COARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS WITHOUT TOLERANCE.2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.

DRG. NO.

COMPANY LTD.SAN ENGG. AND LOCOMOTIVE

DATE

SCALE

APPD.

CHKD.

TRCD.

DRN.

BANGALORE - 560 048

D

C

B

A

654321

654321

D

C

B

A

ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL.

DRG. NO.

Engineered & built to last

FINAL DRIVE WHEEL AND AXLE ASSEMBLY

Engineered & built to last

• Teeth generation on bevel gear and pinion was done at dedicated bevel gear generator at our Mysore plant.

• Bevel gear and pinions generated by this process requires to be manufactured in pairs .

• Each pair is checked for contact pattern in soft condition.

• Finally this pair has to be lapped before taking for final assembly.

Engineered & built to last

PROCESS OF BEVEL GENERATION

GEAR CUTTING MACHINE AT SAN-MYSORE

Engineered & built to last

VIDEO OF GEAR CUTTING ON BEVEL GENERATOR MACHINE

Engineered & built to last

Video Mysore

LIMITATIONS OF BEVEL GENERATOR

• Maintaining each bevel pair identification till completion of all processes is a tedious procedure.

• No interchangeability possible during assembly.

• Replacement of spares during overhauling of final drives is difficult as both gear and pinion needs replacement even if any one is damaged.

• Extra operation of soft checking & lapping required to ensure contact pattern between gear and pinion.

Engineered & built to last

NEED FOR 5 AXIS MACHINE

FLOW CHART OF GEAR CUTTING PROCESS

KISS soft parasolid model of gear

Model imported to Siemens NX 10

Block creation indicating raw material

Operation split to rough, semi finish and finish

Tool selection

Program generation through iterations

Post processing of programs

Cut one tooth & program prove out

NOT OK

Cut balance teeth

Program transfer & dry run on machine

Check for dimensional and geometric accuracies

OK

Engineered & built to last

Check for job collision and tooth profile

• Parasolid model of bevel gear and pinion generated using KISSsoft is imported through SIEMENS NX10 programming software.

• Blocks are created around the model indicating the material which is to be machined.

• Cutting process is split into roughing , semi finshing & final finishing of flange,hub & blend.

• Tools are selected based on minimum spacing betweentooth .

Engineered & built to last

PROCESS OF PROGRAM GENERATIONPROCESS OF PROGRAM GENERATION

PROCESS OF PROGRAM GENERATION

PROCESS OF PROGRAM GENERATION

GEAR CUTTING VIDEO

Engineered & built to last

Video Variaxis

PINION CUTTING VIDEO

Engineered & built to last

Video Integrex

ADVANTAGES OF 5 AXIS MACHINING

Other components machined on 5 axis machines

HOUSING COVER Engineered & built to last

Other components machined on 5 axis machines

OUTPUT FLANGE PINION SHAFT

Engineered & built to last

Other components machined on 5 axis machines

SECONDARY CONTROL PUMP HOUSING Engineered & built to last

Other components machined on 5 axis machines

PUMP IMPELLEREngineered & built to last

Other components machined on 5 axis machines

PRIMARY SHAFT Engineered & built to last

Other components machined on 5 axis machines

TURBINE WHEEL FLANGE Engineered & built to last

Other components machined on 5 axis machines

GUIDE WHEEL FLANGE Engineered & built to last

Other components machined on 5 axis machines

PUMP IMPELLER Engineered & built to last

Other components machined on 5 axis machines

OUTPUT FLANGEEngineered & built to last

LIMITATIONS OF 5 AXIS MACHINES

• Machining of gears with modules lesser than 6 mm is difficult as tool procurement is difficult .

• Need for extra modelling and CAM programming software for gear teeth machining.

Engineered & built to last

Thank you