The mechanical element, which is one of the most important position in the industry, now and in future, is the gear. Due to its versatility and high efficiency, gear drives are used in nearly all areas of the powertrain technology. In addition to the design of gears the production of these is a technological challenge. Therefore, diverse processes and process chains were developed. A major part in the manufacturing process chain is the soft machining of the gear. The choice of the soft machining process depends on the component geometry, the required quality as well as the productivity. In the automotive and commercial vehicle sector, hobbing, shaping and broaching are the dominating processes for soft machining of gears. A highly productive alternative to the methods mentioned before is Scudding® of Profilator. Scudding® combines a high flexibility with a high productivity.

High productivity with scudding

Due to the geometrical boundary conditions, hobbing can only be used with external gears with enough axial tool travel space. For other cases gear shaping is required, but this results in decreasing productivity. Another high productive alternative for machining internal gears is broaching. Due to the process characteristics regarding tool and machine technology, broaching has a low flexibility and it requires comparatively high investment costs. Only Scudding® offers the possibility to produce internal and external and gears with and without interfering contours.

During Scudding®, tool and workpiece mashing together, like a gear pair. External and internal-external combination can be implemented. A significant and decisive difference is the cross-axis angle between the two partners, which ensures a relative movement along the gear flanks. This relative movement of the cutting edge along the flanks ensures the chip removal. The rotational speeds of the workpiece and tool are coupled by the numbers of teeth. Under a defined penetration, a tool tooth rolls through the gap of the component to be generate the involute. To this movement an axial feed fa is added, which ensures that the component is machined to its complete face width. The cutting speed results out of the rotation speeds of tool and workpiece as well as the set cross-axis angle. Today cutting speeds, which are now being implemented with modern machine and tool technology, are up to vc = 250 m/min. Regarding the high spindle speeds high process dynamics occur. To avoid negative effects of the process dynamics on the process, it is necessary to design a Scudding® machine in a tailor-made manner to the process. This is the only way to ensure that vibrations are minimal and a rigid machine structure provides an optimal quality result.

High productivity with scudding

The process runs continuously until the complete face width of the part is machined. Back strokes, such as are necessary in shaping, are not required. To reduce the load on the cutting edges of the tool and increase the tool life, today multi-cutting strategies are dominantly used.

Profilator and Samputensili formed an alliance to offer the market the best tool and machine technology. Together they have many years of experience in SCUDDING® and they successfully supply well-known companies in the gear industry all over the world.