Preowned gear shaping machines 39

Gear Shaping Machines: A Comprehensive Guide

Gear shaping machines are pivotal in the metalworking industry, specifically designed to cut and form gears with high precision. Utilizing a reciprocating cutting tool known as a shaper cutter, these machines progressively remove material from the workpiece to create gear teeth. Gear shaping is particularly effective for internal gears, external gears, and complex profiles that are challenging to produce using other methods. Industries such as automotive, aerospace, heavy machinery, and robotics rely heavily on these machines for their gear production needs.

Variations of Gear Shaping Machines

Gear shaping machines are available in several configurations, each suited to different gear production requirements:

Horizontal Gear Shaping Machines

These machines have a horizontal spindle orientation, making them suitable for producing various gear types, including spur, helical, and spline gears.

Vertical Gear Shaping Machines

With a vertical spindle orientation, these machines are ideal for larger and heavier workpieces, such as large-diameter gears and gear rings. They offer better stability and ease of handling for such components.

CNC Gear Shaping Machines

Equipped with computer numerical control (CNC) systems, these machines provide high precision, automation, and flexibility. CNC gear shapers can produce complex gear geometries and are suitable for high-precision applications.

Universal Gear Shaping Machines

These versatile machines can handle both horizontal and vertical gear shaping tasks, providing maximum flexibility for various gear types and sizes.

Essential Features and Specifications

When choosing a gear shaping machine, consider the following key features and specifications:

CNC Control System

Modern gear shaping machines often feature CNC controls for enhanced precision and automation, allowing for complex gear profiles and high repeatability.

Workpiece Capacity

The maximum diameter, height, and weight of the workpiece the machine can handle are crucial for ensuring the machine can accommodate the intended gear sizes.

Stroke Length

The maximum length of the reciprocating motion of the shaper cutter. Longer strokes are necessary for larger gears.

Cutting Speed and Feed Rates

Adjustable speeds and feeds allow for optimal cutting conditions for different materials and gear types.

Tooling System

The type and quality of the shaper cutters and their quick-change capabilities can significantly impact productivity.

Machine Rigidity and Construction

The structural stability and build quality of the machine affect the precision and stability during the shaping process.

Advantages of Gear Shaping Machines

Investing in high-quality gear shaping machines offers numerous benefits:

• Precision and Accuracy: Ensures gears meet exact specifications, which is critical for high-performance applications.
• Flexibility: Capable of producing a wide range of gear types, including internal gears, which are difficult to produce with other methods.
• Cost-Effectiveness: Generally more economical for producing smaller batches of gears compared to other gear cutting methods like gear hobbing.
• Versatility: Can handle various gear sizes and profiles, making them suitable for diverse industrial applications.
• Enhanced Surface Finish: Provides high-quality surface finishes, reducing the need for additional finishing processes.

Considerations for Selecting a Gear Shaping Machine

To select the right gear shaping machine for your needs, consider these factors:

Production Volume

Determine the volume of gears to be produced to choose a machine with suitable capacity and efficiency.

Gear Types and Sizes

Ensure the machine can handle the specific types and sizes of gears you need to produce.

Precision Requirements

Match the machine’s precision capabilities with your quality standards.

Budget

Balance the initial investment with long-term operational costs, including maintenance and consumables.

Service and Support

Consider the availability of technical support and maintenance services for the machine.

Training

Assess the need for operator training to effectively use the machine’s advanced features.

Leading Brands and Pricing

Several reputable brands manufacture gear shaping machines known for their reliability and performance:

• Gleason: A leading manufacturer of gear shaping machines, Gleason offers a range of models for different applications. Prices typically range from $200,000 to over $1 million, depending on the model and specifications.
• Liebherr: Known for high-precision gear shaping machines, Liebherr provides solutions for various industrial applications. Pricing generally ranges from $250,000 to $1.5 million.
• Mitsubishi Heavy Industries (MHI): MHI produces robust and reliable gear shaping machines suitable for various gear types and sizes. Prices for MHI machines typically range from $300,000 to $1.2 million.
• Starrag-Heckert: Specializes in advanced gear shaping machines with high precision and automation capabilities. Pricing generally falls between $350,000 and $1.4 million.
• Lorenz: Renowned for their high-quality gear shaping machines, Lorenz offers a range of models suitable for different production needs. Prices typically range from $250,000 to over $1.3 million.

Conclusion

Gear shaping machines are indispensable tools for producing high-precision gears required in various industrial applications. With different types such as horizontal, vertical, CNC, and universal gear shaping machines, selecting the right model depends on specific production needs and gear types. Key factors to consider include CNC control systems, workpiece capacity, stroke length, cutting speed, tooling system, and machine rigidity. Leading brands like Gleason, Liebherr, Mitsubishi Heavy Industries, Starrag-Heckert, and Lorenz offer a range of high-quality gear shaping machines to suit different applications and budgets. By carefully evaluating production volume, gear types, precision requirements, and budget, businesses can ensure they invest in the right gear shaping machine to enhance their manufacturing capabilities and ensure consistent, high-quality gear production.