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Construction and production of cemented carbide gear manufacturing tools for high speed cutting processes

Objective



Objectives and content
Despite important technological and economic advantages,
the use of dry high-speed machining with coated cemented
carbide tools has not yet found acceptance in the gearmaking sector. The main reasons are to be found in high
tool costs and as yet unsatisfactory process reliability.
The objectives of the planned project are therefore to
develop a technology for the efficient production of
cemented carbide hobs and to create the necessary
conditions for widespread use of dry high-speed hobbing
in European industry, through the development of
effective cemented carbide tools specially suited for
coolant-free cutting.
In the field of cemented carbide hob manufacture, the
development of a grinding test bed meeting the
requirements for grinding and profiling cemented carbide
hobs with dressable diamond grinding wheels under
laboratory conditions will be of vital importance.
Significant innovations are the dresser unit integrated
in the grinding test bed, with path-controlled dressing
of diamond grinding wheels, using diamond dressing rolls,
and the development of corresponding, efficient,
dressable diamond grinding wheels. The overall
development of an efficient process for the manufacture
of cemented carbide hobs will be completed by new cooling
lubricants and optimisation of the process parameters
both for grinding and dressing.
Another key area of the project is the adaptation of the
gear cutting tool properties to the special requirements
of dry high-speed hobbing. New cemented carbide
substrates and hard thin films will be developed,
together with the coating technology needed to deposit
the films. In this context, the development of effective
de-coating and re-coating methods for cemented carbide
hobs is of great economic importance. Development
activities in this project area are supplemented by the
design of a suitable tool geometry and optimisation of
the process parameters for coolant-free hobbing.
The project adopts a holistic approach, taking global
account of the sub-aspects hob manufacture, cemented
carbide substrate, wear protective coating, tool geometry
and process parameters for coolant-free hobbing, together
with the interactions between them. Successful
completion of the project will therefore mean a
significant advance for coolant-free gear-making, with
important ecological advantages through the elimination
of cooling lubricants and, above all, significant
increases in productivity and competitive advantages for
the European automotive industry and the overall engine
and transmission engineering sector. Results achieved in
the field of cemented carbide hob production will also
create competitive advantages for the manufacturers of
tool grinding machines and gear-making tools.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

SAMPUTENSILI SPA
Address
13,Via Triumvirato 13
40132 Bologna
Italy

Participants (8)

AACHEN UNIVERSITY OF TECHNOLOGY
Germany
Address
53 B,steinbachstraße 53 B
52056 Aachen
Cemecon - Ceramic Metal Coatings GmbH
Germany
Address
21,Talbotstrasse
52068 Aachen
Ernst Winter & Sohn Diamantwerkzeuge GmbH & Co.
Germany
Address
13-17,Norderstedt Schützenwall
22844 Norderstedt
Plansee Tizit Gesellschaft mbH
Austria
Address

6600 Reute
SVA i Tyringe AB
Sweden
Address

282 22 Tyringe
Scania CV ab
Sweden
Address

151 87 Sødertdlje
Volvo Car Components Company Transmission
Sweden
Address

731 29 Køping
Winterthur Technologie AG
Austria
Address
85,St. Magdalener Strasse
9500 Villach