The CNC Gear-Hobbing Machines LC 80 - LC 180.

The CNC Gear-Hobbing Machines LC 80 - LC 180: In 1994 Liebherr set new standards in gear manufacturing with the introduction of high speed cutting (HSC). Impressive increases in performance of up to 300% and the cleanliness of dry hobbing characterize this innovation. For the enhanced series LC 80 – LC 180, Liebherr used the experience and knowledge from more than 950 installed machines. Over 120 million “dry cut” gears have provided a valuable source of technological data.

A1 V1 Z1

X1

2

Z4

B1 C2

...the most successful gear-hobbing machines in its class. Today, dry hobbing has established itself in automotive transmission gear manufacturing with an impressive usage rate of almost 50%. The new LC 80 series offers a machine concept that is distinguished by its remarkable performance. Direct-drive work and hob spindle with high drive power and speeds up to 5500 rpm provide extensive reserve capacity for future developments in cutting tools. The vertical machine concept offers significant advantages for cutting, part loading, and clamping. The efficient removal of chips was one of the key criteria for the design of the machine base and work area. Two chip augers are integrated into the machine bed for fast and safe chip removal. Stainless steel lining of the work area further improves the chip discharge.

The platform strategy: Optimal price and performance. A wide range of machine sizes offers the optimal machine model for each application in automotive gear manufacturing. Through the combination of different building blocks selected from the complete product program, an excellent price/ performance ratio can be achieved. The machines are available with a variety of different material flow and automation systems.

C3

X1 - Radial travel main column V1 - Tangential travel tool Z1 - Axial travel tool B1 - Rotary motion tool C2 - Rotary motion work piece A1 - Swivel motion tool Z4 - Vertical travel tailstock arm C3 - Rotary motion ring loader

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Technology competence and universality. 12 years after the successful introduction of the dry cutting process, more than 120 million dry hobbed gears have been cut with Liebherr machines. Today the technological developments and innovations derived from this experience allow the flexible use of a broad range of applications for generating and single index cutting of gears. With operator oriented and menu guided programming screens, a wide choice of specific lead variations are displayed in user friendly formats. The possibility to interlink cutting programs allows the machining of up to 5 different gears in one operation sequence. The tailstock is utilized for automatic or manual loading and dry or wet cutting of shaft and bore type parts. Workpiece clamping is accomplished either from the table side with high clamping force or with the faster NC tailstock. Liebherr offers automatic workpiece storage systems and loading systems for a complete range of workpiece. This allows machine integration into existing cell or line concepts.

The Hob Head. A maintenance free direct drive AC motor is used for the hob spindle. Drive power up to 26 kW and speeds up to 9000 rpm offer large reserve capacity for future tool developments. For very high torque requirements the hob head is equipped with a reduction gear drive. The tool interface is offered either with a hollow shaft taper (HSK), a collet or a steep taper (ISO).

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Integrated roll deburring and chamfering Roll deburring and chamfering of the gear teeth, with removal of secondary burr, is suitable for bore and shaft parts. The deburring and chamfering operation is parallel to the main cutting time.

Intelligent tool concept. With the optional use of either shank type or bore type cutters, or a combination of both, it is possible to do complex gear cutting operations in one clamping (e.g. cutting of multiple gears on a shaft).

Finish machining with hobbing The “finish hobbing” of planetary gears and sun gears with coated carbide hobs has established itself as a proven method for high volume production. With cutting speeds of more than 600 m/min, surface qualities of Rz < 5 µm are achieved. Compensations for possible geometric distortions during heat treatment are accomplished with tool and cutting cycle modifications.

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Service Perfection. For highest availability. Easily accessible control elements, long maintenance intervals, short repair times: Well thought out equipment design, coupled with an optimal service concept, reduce machine down times for routine maintenance - increasing productivity and lowering life cycle costs. Service friendly ex-works A distinctive feature of Liebherr gear cutting machines is their service friendliness: Quick routine checks and long service intervals result in high machine availability. • For easy access, all components are mounted on the outside of the machine to allow fast routine maintenance and service. • R+M concepts (reliability and maintainability), used for many years by Liebherr for aircraft component manufacturing, is standard-practice throughout all product lines. Major automotive manufacturers have shown appreciation for our efforts with international supplier awards. The Control and Drive Technology The PC based control, in combination with highly dynamic digital drives, guaranty excellent gear quality. The consistent use of standard field busses and highly integrated control modules allow a minimum of wiring. Software With the operator friendly programming menus, a variety of different corrections can be implemented. For this, different software developments are available: • Aligned cutting of multiple gears • Tooth end correction with straight or circular interpolation • Worm wheel hobbing • Stack hobbing with up to 5 separate lead and size corrections • Dip hobbing (radial clearance for a subsequent finishing operation)

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Technical Data.

Max. workpiece diameter Max. nominal module for steel Hob slide travel Table diameter Table speed Centre distance hob/work table

mm mm mm mm rpm min. mm max. mm degree

Hob head swivel angle Hob arbor main bearing Max. shift travel Max. hob diameter Max. hob length Rapid traverse axial Rapid traverse radial Rapid traverse tangential Hob-spindle (Torque) Driving power hob spindle Weight of machine with tailstock column Total connected load

mm mm mm mm/min mm/min mm/min rpm kW appr. kg appr. kVA

LC 80 LC 120 LC 150 LC 180 80 125 150 180 3 3 3 3 250/400 250/400 250/400 250/400 125 145 145 145 800 800 800 800 10 10 10 10 130 160 180 200 +/-45 +/-45 +/-45 +/-45 Cylindrical Shaft, HSK, SK 180 180 180 180 90 90 90 90 210 210 210 210 7,500 7,500 7,500 7,500 7,500 7,500 7,500 7,500 7,500 7,500 7,500 7,500 1.000/1.500/2.000/3.000/4.500/5.500 19 19 19 19 9,500 9,500 10,000 10,000 25-35 25-35 25-35 25-35

5260 4560

H/S

2215

E C 625

2995

C

700 4390

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The locations.

Liebherr-Verzahntechnik GmbH Werk Ettlingen

Liebherr-Utensili S.r.l.

Liebherr-Gear Technology Co.

Liebherr Machine Tools India Pvt. Ltd.

Hertzstrasse 9-15 D-76275 Ettlingen

Via Nazioni Unite 18 I-10093 Collegno TO

1465 Woodland Drive Saline, MI 48176-1259 USA

70/1 Mission Road 4th Floor, Sheesha Tower Bangalore - 560 027, INDIA

 +49 (0)7243 708-0 Fax +49 (0)7243 708-685 E-Mail: [email protected]

 +39 (0)11 4 24 87 11 Fax +39 (0)11 4 55 99 64 E-Mail: [email protected]

 +1 7 34 429 7225 Fax +1 7 34 429 2294 E-Mail: [email protected]

 +91 (80) 2 227 2782 Fax +91 (80) 2 227 6324 E-Mail: [email protected]

Printed in Germany by Wolf 09.05 BK

Liebherr-Verzahntechnik GmbH Kaufbeurer Strasse 141, D-87437 Kempten  +49 (0)831 786-0, Fax +49 (0)831 786-1279 www.liebherr.com, E-Mail: [email protected]

Subject to modifications.