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Case study 1

 

„TOOL LIFE 26M PER ACTIVE HOB TOOTH, 17’000 PARTS PRODUCED PER RESHARPENING"

Application

Car Gear Box Manufacturing

Customer request

Reduction of cost per part maintaining the same cycle time, dry finish hobbing before heat treatment, in DIN quality class 7

Suggested solution by Schnyder

Replacement of PM steel hob with solid carbide nanograin hob.

Component / tool



Component / gear data

31 tooth spur gear, DP12 (M2.1167) – 20° PA, external Ø70.3mm, useful length 17mm, material 16MnCr5 with 630 N/mm2

Hob specification

Shank type gear hob: Ø80 x 273/ 200 – shank Ø32/ SK30 - 19 gashes, Nanograin solid carbide (AAA) / 2 RHS
Coating: Alcrona

Process

First cut: h 4.60mm in climb cutting vc 280 m/min. / fa 1.80 mm/R
Second cut: h 5.125mm conventianal cutting vc 400 m/min. / fa 1.20 mm/R
chip thickness ca. 0.10- 0.13mm

Hobbing machine

Pfauter P210 CNC

Result

# of parts produced per resharpening: 17‘000 pcs (!) 
# of resharpenings: 25
Total cutting length: 151‘000 m 
Chip volume: 6‘300 mm3/piece
Total # of hob teeth: 285
# of active hob teeth: 238
Tool life: 26 m / active hob tooth



 

Achieved gear quality with new hob



Achieved gear quality after 13'000 parts (wear of 0.05mm)


Customer benefit

Tool life of PM steel hob: 2'000 parts per resharpening.
Achieved tool life with Schnyder solid carbide hob: 17'000 parts per resharpening.

Benefit:
 lower cost per part
 longer tool change interval



Case study 2

„TOOL LIFE 26M PER ACTIVE HOB TOOTH, 17’000 PARTS PRODUCED PER RESHARPENING“  

Application

Car Steering System Manufacturing

Customer request

Reduction of cost per part maintaining the same cycle time, dry finish hobbing before heat treatment, in DIN quality class 7

Suggested solution by Schnyder

Solid carbide shank hob type PERFECT CUT®

Component / tool


Component / gear data

9 tooth helical pinion, Mn 2.00 – 25° PA, external Ø24mm, useful length 45mm, material 16MnCr5 with 630 N/mm2

Hob specification

Shank type gear hob: Ø50 x 233/ 153 – shank Ø22 (2x) - 15 gashes, Nanograin solid carbide (AAA) / 1 LHS
Coating: Alcrona

Process

First cut: h 3.16mm; in climb cutting vc 375 m/min. / fa 1.50 mm/R
Second cut: h 3.46mm; conventianal cutting vc 400 m/min. / fa 1.20 mm/R
chip thickness ca. 0.16mm

Hobbing machine

Gleason Pfauter P60 CNC

Result

# of parts produced per resharpening: 44‘000 pcs (!) 
# of resharpenings: 24
Total cutting length: 440‘000 m 
Chip volume: 5'042 mm3/piece
Total # of hob teeth: 349
# of active hob teeth: 296
Tool life: 65 m / active hob tooth

Achieved gear quality with new hob


Achieved gear quality after 44'000 parts (wear of 0.1mm)


Customer benefit

Tool life of standard hob: 12'000 parts per resharpening.
Achieved tool life with Schnyder PERFECuT® hob: 44'000 parts per resharpening.

Benefit:
 lower cost per part
 longer tool change interval