Gear Honing:Characteristics & Specific applications Matchless Machines & Technology

What do we want in a Gear?Where-ever Gears are used, the characteristics

required are: Noise-less transmission at high speedsOptimization of powerWear resistance

Why Gear Honing?The process of Gear Honing is ideally

suited for obtaining these characteristics.

By improving the surface finish and the quality of the Geometry of the Gear tooth, we can achieve interference free Gear performance with full contact between the two rolling surfaces.

This gives extremely smooth rolling of the Gear and thereby noiseless operation, excellent power transmission and low wear.

What is Gear Honing?Gear honing is a hard finishing process similar to

hard shaving. The flanks of an external teeth gear and an

internal teeth honing ring are in rolling contact with a specified radial pressure at a low cutting speed.

The driven work-piece and tool spindles are crossed at a defined angle.

The superposition of the in-feed movements gives a resulting gliding movement running diagonally from tip to root of the tooth flank.

This produces a micro-cutting process with short cutting point engagement.

Advantages of Gear Honing

Favorable surface texture reduces the noise emission in the transmission

Induced residual stresses in tooth flanks increase the bearing capacity

Low cutting speed prevents structure damages (burning)

New machines and tool systems achieve high stock removal rates and direct honing of hardened gears

Quick process and short floor to floor times are ideal for the quantity production

No limitations of gear size; from a small pinion to the final drive gear, all can be honed to perfection!

Gear manufacturing as it once was

Green machining Gear forming (forging, sintering, …)

Green shaving

Heat treatement / Cleaning

Grinding Hard shaving

Gear honing

Finished gear

Gear manufacturing today

Green machining Gear forming (forging, sintering, …)

Green shaving

Heat treatement / Cleaning

Grinding Hard shavingDirect-Honing

TM

Gear honing

Finished gear

Fäss

ler

Gea

r H

onin

g

Workpiece- spindle

Workpiece

Honing ringTool-spindle

Pic: Fässler HMX 400

Kinematics of Gear Honing:

Cutting veloc.

Axial veloc.

Radial veloc.

Surface structure

Distinguishing marks of gear honing

Pitch dia.PCD

Cutting velocities 1 … 10 m/s

Fässler Technologies

Fässler Gear Honing Hard Broaching Dressing Technology Tool design and manufacturing

Tech

nolo

gies

Fässler HMX-400: 9-Axis

X In feed-AxisZ1 Oscillation-AxisA Cross angle adjusting-AxisB1 Swivel-AxisZ2 Headstock-AxisB2 Headstock rotation-AxisC1 Honing stone direct drive rotation-Axis C2 Work piece 1 direct drive rotation-Axis C3 Work piece 2 direct drive rotation-Axis

HM

X-40

0

Comparison of Honed vs Ground GearsThe reason of the noiseless behavior of

honed gears is the surface structure. The ground surface in the transverse

plane of the gear looks like a saw. This causes vibrations and the gear is

loud. A honed surface in the transversal cut of

the gear looks smoother than the ground gear.

The vibrations are less.

The Honing Process allows you to achieve:

Excellent surface finish and extreme small roughness values

Noiseless surface structure Extreme good wear behavior due to the induction of high

compressive residual stresses (1000 ... 1600 N/mm2). No thermal stresses; no changes of the material

microstructure; no grinding burn! No bias from the process Excellent profile and lead qualities (DIN 6 ... 2). Quite good correction of pitch errors and run out (DIN 6 ...

2). High process capability because of direct drive

technology Low tooling costs because long tool life of ceramic

bonded honing stones High stock removal possible Very economic finishing process - especially in mass

production

HONING :TIME; COSTING AND ECONOMICS

Cost comparison between various hard gear finishing processes

GreenShaving

DirectHoning™

CombiHoning

ProfileGrinding

GenerationGrinding

0%

50%

100%

150%

200%

250%

300%

350%

400%

cost [%]

Labour costTooling costMachine cost

Workpiece data:mn = 2z = 35alpha = 15°beta = 33°b = 15 mm

da = 91mm

Cost comparison between various hard gear finishing processesThe preceding chart compares the

manufacturing costs for a specific part for the different manufacturing methods.

This benchmarking was made from a well known gear box manufacturer.

The chart indicates that the cost of the green shaving are lowest.

The manufacturing cost for single direct honing is about 1.5 times higher, the costs for combi honing about 2.2 times higher.

Comparison between various hard gear finishing processes

Comparison between various hard gear finishing processes

Comparison between various hard gear finishing processes

Comparison between various hard gear finishing processes

Honing : the superior hard finishing process….

REASONABLE PRICE; INSTALLATION & COMMISSIONING SERVICES IN INR PAYMENT LOCALLY.

FREE SERVICE DURING WARRANTY AVAILABLE LOCALLY

POST WARRANTY AFTER SALES SERVICE AVAILABLE LOCALLY IN INR OR WITH INR PAYABLE AMC.

TECHNICALLY MOST ADVANCED DESIGN - TWIN SPINDLE - FASTEST CYCLE TIME 2-SPINDLE AND 2-HONING STONE CARRIER.

POSSIBILTY OF HONING 2 DIFFERENT GEARS. FAST SETUP CHANGE LOWEST RE-DRESSING FREQUENCY HIGHEST TOOL LIFE LOWEST TOOL COSTS

SPECIAL FEATURES & ADVANTAGESOF FASSLER - HMX

In Conclusion….We are confident of our process and our

Machine!We have 3 machines successfully

installed at Bajaj for Honing gears of their premium 2 wheelers, and one to be installed shortly.

IF YOU ARE STILL GRINDING YOUR GEARS, YOU CAN GIVE US YOUR GEAR DRAWINGS.

WE WILL CARRY OUT HONING TRIALS AND DO A COMPARATIVE CASE STUDY FOR YOUR REFERENCE.

THANK YOU!