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Gear mill developed for DMG Mori Featured

A new milling tool for manufacturing cyclo-palloid gears in the 0.5 to 30 module range has been developed by Horn. Based on the Klingelnberg design, the M279 milling system is intended for producing one-offs and small batches of components. A high chip volume can be achieved with a low cutting pressure thanks to the novel cut distribution of the 12-insert tool.

The requirement for the tool was specified by DMG Mori, which wanted a system that would be at least 20% faster than existing solid-carbide solutions. A robust tool with indexable inserts was needed for taking full cuts on milling and turning machines, while also being suitable for simultaneous five-axis milling using DMG Mori’s GearMill software.

Horn’s S279 features four indexable inserts (with a corner radius of 2 mm) that are screwed into place on the tool’s face. These are interspersed with eight tangentially secured 409 inserts. The fact that the rows of edges overlap enables the system to achieve high depths of cut.

Thanks to test runs at DMG Mori’s Pfronten facility in Germany, along with modifications to the cutting data, machining of convex and concave gear-tooth flanks can be achieved with the milling tool in five-axis simultaneous operations. A crown wheel of module 7.6 machined from 17CrNiMo6 was used as a trial workpiece. The Klingelnberg cyclo-palloid gear was produced at a cutting speed of 250 m/min and a feed rate of 650 mm/min, with full cutter engagement, while the tooth flanks were milled at a feed of 2000 mm/min.

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