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4 Axis-CNC Shaft Groove Grinding Machine

KGV151

Extremely Productive in Grinding CVT Ball Tracks
High Machine Accuracy with Tremendous Grinding Speeds

Max. Workpiece Diameter
150mm
Max. Grinding Wheel Speed
30,000rpm
  • Feature
  • Specifications
  • Catalog

Typical Parts Hobbed

・ CVT Pulley Shafts
・ Splined Shaft Parts

High Speed / High Accuracy

A 30,000 rpm(max) grinding spindle offers a performance advantage over grinding with the use of electroplated CBN grinding wheels or small diameter (dia. D 45~100 mm) Vitrified CBN Grinding Wheels. This allows a shaft part with a tight radius to be easily ground. Large roller bearings utilized in the main spindle allow high rigidity and accuracy. The full closed-loop system on the X-axis (radial direction) creates highly accurate positioning. Additionally, the special guideways used on the Z-axis (axial direction) eliminates waviness which can occur when linear guideways are used.

Auto Part Orientation Device(Special Option)

Fast and stable part orientation is automatically performed by a non-contact type sensor. A contact type sensor (a touch probe) can be also utilized depending on the shapes of the grooves, delivering more accurate part orientation.

Auto Thermal Compensation Device(Special Option)

The grinding wheel position is automatically checked and compensated to reduce variations caused by thermal growth, producing stable machining accuracies from a machine cold start (Y-axis compensation). Also, an in-processing checking/compensation is performed by directly checking the ground grooves (X and Y-axis compensation).

Auto Rotary Dressing Device(Special Option)

A Vitrified CBN grinding wheel can be dressed on board by a profiled diamond dresser. An AE (Acoustic Emission) sensor and closed loop Y and Z-axis allow highly accurate dressing.

Specifications

  • Specs

    Max. Workpiece Diameter

    150mm

    Max. Workpiece Length

    250 mm

    Max. No. of Index

    99

    Max. Grinding Wheel Speed

    30,000rpm

    Max. Index Speed

    25rpm

    Max. Grinding Wheel Diameter & Length

    100mm×50mm

    Weight

    5,000kg

    Floor Space: Length X Width X Height

    2,710 X 2,245 X 2,200 mm

Product Catalog

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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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