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6 Axis-CNC Hobbing Machine

KL1000

A Versatile Hobbing Machine suited for Large Sized Gears

Max. Workpiece Diameter
1000mm
Max. Module
12
  • Feature
  • Specifications
  • Catalog

Feature

For details, click on the Icon.

  • 縦型ホブ盤

    Vertical
    Hob Machine

  • 摺動面きさげ加工

    Hand
    Scraped
    Guideways

  • テーブルB/E

    Zero
    Backlash
    Table

  • 自動化

    Auto-mation

  • 機内面取り装置

    In Machine Chamfering Unit

  • ハードホビング

    Hard Hobbing

  • 加工プログラム

    Program

Typical Parts Hobbed

Construction Machine Gear
Marine Gear
Large Reduction Gear

A Highly Rigid Machine Structure

The double-walled machine bed with suitably aligned ribbing has wide guideways supporting the work table saddle. The column resists cutting forces as it is securely fixed to the machine bed creating a dynamical structure. Also, the machine structure is designed to reduce distortions caused by thermal changes. This dynamic rigidity delivers excellent thermal stability, which minimizes the lead variations caused by heat buildup when hobbing large pitch gears with a long cycle time.

Excellent Hobbing Accuracies

The core units of a hobbing machine (work table & work table saddle) have a rigid design allowing superb rotational accuracy during heavy duty hobbing for many years. Moreover, the diameter of the Master Worm gear is 12% larger than its predecessor improving hobbing accuracies. Outstanding manufacturing technologies and superb assembly techniques, accumulated over many years of hobber manufacturing, are incorporated into those core units, which produces excellent hobbing accuracies.

Easy Loading/Unloading of a Large Gear

The tailstock column is easily retracted out of the way by means of a ball screw, which creates clearance for 1,000 mm diameter gears. Additionally, the tailstock arm is hinged, allowing an easy loading/unloading of a large diameter/pitch gears.

Efficient Finish Hobbing is Available.

By using Dual Hobs mounted on a single arbor (HSS hob for roughing and a Cermet Hob for finishing), a highly accurate finished gear can be achieved, eliminating the shaving process.Moreover, the Cermet hob cutter effectively prevents “Built-Up” cutting edge problems (workpiece material welding to the hob’s cutting surface) during the hobbing cycle. Also, a Carbide Skiving hob cutter having a negative rake angle can be used to finish heat treated (hard) parts.

Specifications

  • Specs

    Max. Workpiece Diameter

    1000 mm

    Max. Module

    12

    Max. Axial Feed Travel

    450mm

    Max. Hob Head Swivel

    ±40°

    Max. Hob Size: Diameter x Length

    180×220mm

    Max. Hob Shift Travel

    170mm

    Max. RPM of Hob Spindle

    37~300rpm

    Max. RPM of Work Table

    15rpm

    Weight

    10,500kg

    Floor Space: Length x Width x Height

    3,695 × 1,945 × 2,620 mm

Product Catalog

You can download the PDF data of product catalogs by adding the desired catalog to the list and filling out the form at each download link.

Inquiries about This Product

We are dedicated to a fast response to your request, and will make every attempt to respond in a timely manner. Requests received on Holidays or Weekends will be handled on the next business day in most cases.

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Vertical Hob Machine

Changing Fixtures, Hob Cutters or Workpieces (manual loading) is far simpler and faster than in a horizontal hobber as compared to a vertical hobber. As the workpiece /fixture are positioned vertically, they are very easy to exchange and accurately mount. The Hob Head of a vertical hobber allows great accessibility to the work table/tooling area and peripheral equipment (auto loader, transfer unit etc.) can be added without reducing operability!

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Hand Scraped Guideways

Kashifuji hand scrapes the guideways on all its hobbing machines to create a platform that dampens and absorbs the intermittent cutting forces that are inherent to hobbing process. This feature allows many years of use while still maintaining superb hobbing accuracies.

Generally, machining has limited achievable accuracies due to friction created distortions and/or internal stress relief produced during the machining process. Variations of temperature and humidity during the machine process can also reduce accuracy. Kashifuji utilizes a hand scraped surface finish to assure highly accurate guideways that are not possible by any machining/grinding process.

Hand Scraping is a finish processing method that makes the guideways extremely accurate with an ideal flatness and straightness by manually removing metal in extremely small amount (1~3 micro meters) by the use of a hand tool called a "Scraper". This hand tool has a carbide tipped single edge blade with a blunt angle. This tool is used to relieve the surface tension (create numerous, evenly distributed small, shallow dips or reliefs) in the guideway surfaces. Scraping produces a very flat surface, and the "shallow divots" retain oil which creates smooth sliding surfaces while reducing wear.

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Hand scraping is a labor intensive process. The guideway surfaces are painted with a “dye” then rubbed with a reference straight edge, the dye collects on the highspots. The highspots are then removed by “hand scrapping”. This process (applying dye, rubbing & scrapping) is continually repeated until approximately 30% of the guideway surface is “relieved” producing ~70% bearing surface. This process produces an extreme flatness.

Hand scraping is referred to as a "Master's Skill". Kashifuji's skilled craftsmen are able to make accurate micro-meter scraping marks compensating for variations caused by material or temperatures changes. The "scraping pattern" produced, is often referred to as an "art form", and is unique to each craftsman. It takes many years of tedious, difficult work to acquire the experience & skill to become an accomplished Kashifuji "Scraper".

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Zero Backlash Table(Work Table Backlash Eliminator)

Kashiufji designed and developed a hydraulically controlled split worm Work Table Backlash Eliminator.

This device creates a Zero Backlash condition for the work table under all cutting conditions. The backlash eliminator suppresses work table vibrations assuring smooth and highly accurate work table rotation. The rotational accuracy of the work table will not degrade with use, as the device is self-adjusting (maintenance-free).

The backlash eliminator allows consistency in hobbing accuracies especially when hobbing large pitch gears, hobbing with a carbide skiving hob cutter and opposite hand hobbing (lead angle of a hob cutter is opposite of the helix angle of the part).

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Automation

Numerous styles and types of auto loaders, conveyors or part stockers are available for automatic part transfer. All loader design are labor saving and increase efficiency.

Basic 2-Arm Auto Loader(KN80, KN152)

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Basic Ring Loader
(KE201/251、KA220/400)

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Transfer Example for Flat Gears

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Transfer Example for Flat Gears

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Transfer Example for Shaft Gears

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Transfer Example for Shaft Gears

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In-machine chamfering unit (optional specifications)

<Stock removal process using a chamfering cutter>
The use of an auto part loader device enables chamfering and deburring during the hobbing process. By effectively using the open space of the machine and by making the chamfering tool axis and the deburring tool axis independent, it is easy to change / adjust the tooling from the machine front operation side. In addition, the combination of hobbing, chamfering and deburring reduces the line length and cycle time.

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By installing a chamfering device underneath the hob head, it is possible to chamfer the part in the tooling area after hobbing and deburr the part in the open space. Additionally, the secondary burrs caused by deburring can be removed by re-hobbing. The removal of secondary burrs prevents the tooth flanks from getting damaged due to the hardened secondary burrs in the finishing processes such as gear grinding or honing, contributing to improved tool life. The combination of hobbing, chamfering and deburring reduces the line length. Also, it is possible to process a shaft gear.

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<Milling Method by tracing using a carbide rotarty end mill>
The use of an auto part loader device enables chamfering during the hobbing process. Using the machine open space effectively, the rotating carbide end mills lightly touch the rotating part allowing chamfering for both top and bottom ends of the part. Chamfering is possible using the same rotarty end mill even if the part type is chgangred.

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Hard Hobbing

Hard Hobbing is a finish hobbing process for hardened gears.

There are two kinds of Hard Hobbing processes that use carbide hobs. One is "Finish Hobbing" in which hardened gears are "finished" after the initial tooth cutting. The other is "Hardened Solid Gear Hobbing" where hardened solid gear blanks are finished hobbed.

Kashifuji has developed an Auto Part Orientation Device utilizing a special non-contact sensor that quickly and accurately orientates gear teeth to the hob tool.

Finish Hobbing

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Hardened Solid Gear Hobbing

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Auto Part Orientation Device

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Programming

Programs are created by only inputting part gear data, hob data and cutting conditions. After the completion of the programs, hobbing will be automatically performed by selecting the part number.
Optional crowning, relieving and/or taper hobbing cycles are easily performed. Simple and easy-to-operate hobbing programs are available for a wide variety of production situations, from mass production to special prototype hobbing.

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