background
Voith Turbo, based in Heidenheim, Germany, hopes that HELLER will help it develop alternative solutions for processing larger size bevel gears. The goal is to increase flexibility, reduce lead times, reduce costs, and reduce reliance on a single supplier. The two companies joined forces to directly promote a patent application, which was announced in June 2010 after successful acceptance in December 2008.
As a partner, Sandvik Coromant is responsible for developing the most suitable tool solutions and processing strategies. After the successful implementation of the first commercial project, HELLER decided to choose Sandvik Coromant as the exclusive tool supplier to help it commercialize the concept.
solution
uP-Gear technology is a solution developed for HELLER's five-axis machining center. By embedding advanced digital calculation programs in the machine control system, it is possible to machine spiral bevel gear parts of various sizes very accurately and efficiently. The solution developed by Sandvik Coromant consists of a series of milling cutters for tooth profile formation.
machine tool
HELLER Machining Center FP2000/FP4000 Series and MCH 280-C/350-C/450-C Series (45° “C†type machining head for 5-axis simultaneous machining with special motion) is designed for high-performance cutting operations. Research and development. This type of machine ensures the maximum economic efficiency of gear milling.
Virtual uP-Gear
“Virtual HELLER†allows users to identify and simulate all the processes required for process planning, programming and optimization on a standard computer to ensure the safety of the uP-Gear process. The HELLER machine can be seen as a versatile precision 3D motion model. Combined with the operator interface, the user can find a near real-time machine environment on the computer.
uP-Gear's area of ​​concern
The uP-Gear process is used to achieve maximum profit when processing medium to large gears in small to medium volume production. These parts are widely used in various industrial applications.
Exclusive agreement
HELLER has agreed with development partner Voith that it does not support the direct or indirect production of gear parts for the railway sector. In particular, but not exclusively, the following companies:
a) Flender AG, a subsidiary of Siemens AG,
Place of production: D-09322 Penig (railway gear)
b) Watteeuw, a subsidiary of BMT-Group, website: ,
Production place: B-8022 Oostkamp, ​​BMT in CZ-61900 Brno (railway gear)
c) ZF Friedrichshafen AG, website:
Place of production: multiple locations, only relevant to the gears of the railway sector d) Gmeinder Getriebe- und Maschinenfabrik GmbH,
Production place: D-748212 Mosbac and D-13509 Berlin
Customer benefits
Customers can get many improvements compared to the special machine tools used (Klingelnberg, Gleason) and vertical milling on five-axis machines:
- High flexibility - Increase production efficiency (relative vertical milling process)
- lower investment costs (relative to dedicated machine tools)
- Lower tool cost (relative to dedicated machine tools)
measuring
Customers can measure parts on existing measuring machines such as CMM machines and feed the correction data directly to the machine control panel.
More in-depth development steps
The goal is to process the entire part up to the finished stage. Current development efforts focus on semi-finishing and finishing. A complete solution is expected to be launched in mid-2011.
In addition, the soft cutting process will be further optimized and is expected to significantly reduce processing time.
The all-round cooperation between the business process HELLER and Sandvik Coromant is constantly deepening. The two sides have set up a joint steering committee to hold regular meetings to jointly plan the technology and keep up to ensure that the technology is commercially successful.
Voith Turbo, based in Heidenheim, Germany, hopes that HELLER will help it develop alternative solutions for processing larger size bevel gears. The goal is to increase flexibility, reduce lead times, reduce costs, and reduce reliance on a single supplier. The two companies joined forces to directly promote a patent application, which was announced in June 2010 after successful acceptance in December 2008.
As a partner, Sandvik Coromant is responsible for developing the most suitable tool solutions and processing strategies. After the successful implementation of the first commercial project, HELLER decided to choose Sandvik Coromant as the exclusive tool supplier to help it commercialize the concept.
solution
uP-Gear technology is a solution developed for HELLER's five-axis machining center. By embedding advanced digital calculation programs in the machine control system, it is possible to machine spiral bevel gear parts of various sizes very accurately and efficiently. The solution developed by Sandvik Coromant consists of a series of milling cutters for tooth profile formation.
machine tool
HELLER Machining Center FP2000/FP4000 Series and MCH 280-C/350-C/450-C Series (45° “C†type machining head for 5-axis simultaneous machining with special motion) is designed for high-performance cutting operations. Research and development. This type of machine ensures the maximum economic efficiency of gear milling.
Virtual uP-Gear
“Virtual HELLER†allows users to identify and simulate all the processes required for process planning, programming and optimization on a standard computer to ensure the safety of the uP-Gear process. The HELLER machine can be seen as a versatile precision 3D motion model. Combined with the operator interface, the user can find a near real-time machine environment on the computer.
uP-Gear's area of ​​concern
The uP-Gear process is used to achieve maximum profit when processing medium to large gears in small to medium volume production. These parts are widely used in various industrial applications.
Exclusive agreement
HELLER has agreed with development partner Voith that it does not support the direct or indirect production of gear parts for the railway sector. In particular, but not exclusively, the following companies:
a) Flender AG, a subsidiary of Siemens AG,
Place of production: D-09322 Penig (railway gear)
b) Watteeuw, a subsidiary of BMT-Group, website: ,
Production place: B-8022 Oostkamp, ​​BMT in CZ-61900 Brno (railway gear)
c) ZF Friedrichshafen AG, website:
Place of production: multiple locations, only relevant to the gears of the railway sector d) Gmeinder Getriebe- und Maschinenfabrik GmbH,
Production place: D-748212 Mosbac and D-13509 Berlin
Customer benefits
Customers can get many improvements compared to the special machine tools used (Klingelnberg, Gleason) and vertical milling on five-axis machines:
- High flexibility - Increase production efficiency (relative vertical milling process)
- lower investment costs (relative to dedicated machine tools)
- Lower tool cost (relative to dedicated machine tools)
measuring
Customers can measure parts on existing measuring machines such as CMM machines and feed the correction data directly to the machine control panel.
More in-depth development steps
The goal is to process the entire part up to the finished stage. Current development efforts focus on semi-finishing and finishing. A complete solution is expected to be launched in mid-2011.
In addition, the soft cutting process will be further optimized and is expected to significantly reduce processing time.
The all-round cooperation between the business process HELLER and Sandvik Coromant is constantly deepening. The two sides have set up a joint steering committee to hold regular meetings to jointly plan the technology and keep up to ensure that the technology is commercially successful.
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