Cutting-Edge Gear Machining Technology Showdown!

The evolution of CNC tool technology has significantly driven the rapid development of machine tools towards CNC, high-speed, efficiency, and composite directions, meeting the demands for high-precision and efficient cutting processes. In recent years, the research and development of CNC gear tools worldwide have progressed alongside the development of efficient CNC machines, relying on advanced design, CNC-specific processing, and precision testing technologies. Superior CNC tool materials, scientifically advanced surface coating techniques, and crucial heat treatment methods for high-speed steel gear tools have played key roles in these advancements. The trends and characteristics of gear tool development in recent years are evident in several aspects.

1. Overall Carbide Gear Hobbing:

  - Utilized for gears with a module less than 2mm, achieving AAA-grade precision and cutting speeds surpassing 250m/min.

  - Carbide indexable hobbing is ideal for gears with a module between 6 and 45mm, mainly used for pre-grinding, with cutting speeds reaching 120-150m/min.

  - Powder metallurgy high-speed steel hobs cover a wider module range, ensuring flexibility. These tools, manufactured with high-performance powder metallurgy high-speed steel, exhibit good toughness, reduced machining difficulty, and enhanced durability and efficiency. Cutting speeds can reach 150-200m/min, with precision at DINAA or GBAA levels.

2. Hard Alloy Transformation in Gear Tools:

  - Traditionally, gear tool materials were primarily high-speed steel (with widespread use of high-performance powder metallurgy high-speed steel). However, the development of hard alloy materials and processing technology has seen an increase in the proportion of carbide tools, exceeding 70% in developed European countries.

  - Various companies like Gleason, Kennametal, Fette, Ingersoll, and Sandvik Coromant have developed carbide indexable gear tools, significantly improving gear processing efficiency and tool lifespan.

  - The introduction of carbide gear hobbing tools, with one or two heads, offering 2 or 4 reversible blade positions, has enhanced cutting speeds (up to 100-150m/min) and efficiency by 1-3 times, especially in dry cutting scenarios.

3. Oversized Tool Specifications:

  - The demand for oversized gear tools has risen with the enlargement of machining equipment and the need for large gears. Tools like the 40-50-inch hobbing cutter are designed for processing 1600-2000mm oversized spiral bevel gears on large gear cutting machines.

  - Large module (m40-m45) hob cutters, used with large gear hobbing machines, find extensive application in industries such as cement, metallurgy, lifting, and shipping.

  - Specialized insert gear tools for large internal gears have evolved from m18 to m25, showcasing the advancement in tool manufacturing technology and improved tool innovation capabilities.

4. Development of Coating Technology and Tool Integration:

  - Coating technology has played a crucial role in the development of modern, high-efficiency cutting tools. Advanced coating technologies, whether chemical (CVD) or physical (PVD), continue to explore new materials, transitioning from single coatings to multi-layer coatings, gradient coatings, nano-coatings, and nano-composite coatings.

  - Advanced coating technologies contribute significantly to tool durability, achieving high-speed, efficient, and dry cutting. These coatings have improved tool wear resistance and lifespan, enabling high-speed cutting of hard materials and challenging workpieces.

  - The close integration of coating technologies with pre-coating and post-coating processes enhances the overall effectiveness of modern cutting tools.

As gear machining progresses towards CNC, high efficiency, high precision, and composite flexibility, tool development follows suit. These advancements, driven by advanced tool design, CNC processing, superior materials, and cutting-edge coating technologies, align with the simultaneous progress in machine tools. Despite the substantial progress, there remains a significant gap between the overall capabilities of domestic high-end gear tools and those from foreign counterparts. It's time for our domestic tool industry to catch up!