For Gear, Spline & Rack Manufacturing

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1 For Gear, Spline & Rack Manufacturing METR

2 Advanced Technologies for Gear, Spline and Rack Manufacturing See it in action The VARDEX Gear Milling Concept Advanced milling tools with multi-flute indexable carbide grade inserts for super fast machining Offering a competitive alternative to the traditional ob system Tailor-made inserts and holders designed per customer application, with the exact required profile shape (evolvent, involute or any other profile) to be transferred to the component Major Applications GEAR SPLINE RACK VARDEX Gear milling tools are suitable for machining both straight and helical teeth covering modules from mm or DP VARDEX Spline milling tools are suitable for machining both involute or straight-sided profiles, covering modules from mm or DP 48/96-4/8 VARDEX Rack milling tools are suitable for covering modules from mm or DP Gear Milling System Advantages Super Fast Machining At least 50% less machining cycle time over other methods Carbide inserts with Semi Partial & Partial designed for single pass machining Long Tool Life Tough sub-micron grade coated inserts with up to 3 cutting edges igh Accuracy & Quality Machining No need for additional machining igh quality surface finish Economical Solution Absolute price/performance advantage over existing technology igh Precision Machining For example: Gears: Up to Class 7 according to DIN 3962 and DIN 3967 or Class 11 according to AGMA Involute Splines: According to DIN 5480 or ANSI B92.1 Straight Side Splines: According to ISO 14 Simplified Machining Easy set-up and use on standard 3.5 axis CNC milling machines 2

3 New Clamping System New stopper technology for guaranteed radial and axial run out s are pre-assembled on the toolholder and remain intact when changing inserts Gear Milling Tool Range End Mill Shell Mill Disc Mill Solid Carbide See page 17 Gear Milling Standard s Gear Milling Tailor-made s DIN 3972 Basic Profile See page 6 Tailor-made inserts for Gear, Spline and Rack See page 7 U Style 3 U Style 3 UT Style 1 Edge 3

4 Gear Milling System Gear Milling Special s 5 1 U 2 T 3 E 4 M GM 8 VBX 9 2/ /4 3-3/8 4-1/2 5-5/8 2 - Style U - U Style 3 - T - Single None Application E - External 5 - Module or DP M - Module DP - Diametrical Pitch 6- Module or DP Value 7 - Gear/ Spline teeth 8 - Product Line 9 - Grade - Special No. M DP GM - Gear Milling VBX / Gear Milling Standard s 5 1 U 2 3 E 4 M N GM 9 VBX /4 3-3/8 4-1/2 5-5/8 2 - Style U - U Style 3 - None Application E - External 5 - Module M - Module 6- Module 7 - Milling Cutter No. 8 - Teeth Range Gear 9 - Product Line - Grade M min 12 max GM - Gear Milling VBX Gear Milling olders (Weldon Shank) GM 1 E W U 9 215/... OR M1- M Product Line 2 - older Type Shank Diameter 5 - Shank Style GM - Gear Milling E - End Mill 5 25, 32 W - Weldon Shank 6- Diameter [mm] 32, Toolholder Overhang () 2-1/4 3-3/8 9 - Style U - U Style - Special older No. / OR - Module Range M Gear Milling olders (Shell Mill and Disc Mill) GM 1 S S 4 D U /... OR M2 1- Product Line 2 - older Type Clamping System 5 - Diameter [mm] GM - Gear Milling S - Shell Mill D - Disc Mill 3-12 S - N - with front stopper Drive ole Diameter [mm] 22, /4 3-3/8 4-1/2 5-5/8 8 - Style U - U Style 9 - T - Single None Special older No. / - Module Range OR M

5 GEAR MILLING CATALOG The Vardex Gear Milling Concept _ Page 2 Gear Milling System Page 4 GEAR MILLING INSERTS Gear Milling Standard s _ Page 6 Gear Milling Tailor-made s Page 7 TOOLOLDERS Toolholder - Weldon Shank for 1/4 U Page 8 Toolholder - Weldon Shank for 3/8 U _ Page 8 Toolholder - Shell Mill for 3/8 U Page 9 Toolholder - Shell Mill for 1/2 U Page 11 Toolholder - Shell Mill for 1/2 UT _ Page 12 Toolholder - Shell Mill for 5/8 U Page 13 Toolholder - Shell Mill for 5/8 UT _ Page 15 Gear Milling Toolholder - Disc Mill for 1/4 U Page 16 Gear Milling Toolholder - Disc Mill for 3/8 U Page 16 Solid Carbide Gear Milling Page 17 TECNAL DATA Recommended Grades and Speeds Page 18 Gear Milling Request Form _ Page 19

6 Gear Milling Standard s External Circular Pitch L DIN 3972 Basic Profile U Style - 3 According to Standard DIN 3972 Basic Profile, there are 4 different modules available: 1.0, 1.5, 2.0, 2.5. For each module, there are 8 different types of inserts to select, according to the number of teeth on the gear. Standard s for Gear Applications L mm Module 3/8 U /8 U /2 U /8 U Milling Cutter No. 3UEM N1GM... N UEM N2GM... N UEM N3GM... N UEM N4GM... N UEM N5GM... N UEM N6GM... N UEM N7GM... N UEM1.0135N8GM... N8 135 and up 3UEM N1GM... N UEM N2GM... N UEM N3GM... N UEM N4GM... N UEM N5GM... N UEM N6GM... N UEM N7GM... N UEM1.5135N8GM... N8 135 and up 4UEM N1GM... N UEM N2GM... N UEM N3GM... N UEM N4GM... N UEM N5GM... N UEM N6GM... N UEM N7GM... N UEM2.0135N8GM... N8 135 and up 5UEM N1GM... N UEM N2GM... N UEM N3GM... N UEM N4GM... N UEM N5GM... N UEM N6GM... N UEM N7GM... N UEM2.5135N8GM... N8 135 and up - Range of Teeth on Gear Toolholder Page GME5N 32W U M1-M1.5 GMS6N D U M1-M1.5 GMS7N D U M1-M1.5 GM2N D U M1-M1.5 GME5N 32W U M1-M1.5 GMS6N D U M1-M1.5 GMS7N D U M1-M1.5 GM2N D U M1-M1.5 GMS4S D U M2.0 GMS7N D U M2.0 GMS3S D U M2.5 GMS6N D U M

7 Gear Milling Tailor-made s External Circular Pitch L L Module = Pitch / π DP = 25.4 / Module U Style - 3 UT Style - 1 Edge Based on the required customer application, VARDEX designs and supplies tailor-made inserts to suit a specific Module / DP as well as the exact number of teeth used on the component. Tailor-made s for Gear, Spline and Rack Applications Application Module Diametrical Pitch (DP) Gear L /4 U /8"U 16 3 Toolholder GME5N 25W U 215/... 8 GM2N D U 215/ GME5N 32W U 215/... GMS6N D U 215/... GMS7N D U 215/... GM2N D U 215/... Page Rack /2"U 22 3 GMS4S D U 215/ GMS7N D U 215/ /2"UT 22 1 GMS6S D UT 215/ /8"U 27 3 GMS3S D U 215/ GMS6N D U 215/ /8"UT 27 1 GMS5S D UT 215/ Spline /96; 40/80; 32/64; 24/48 1/4 U /40; 16/32 3/8"U /24; /20 1/2"U 22 3 GME5N 25W U 215/... 8 GM2N D U 215/ GME5N 32W U 215/... GMS6N D U 215/... GMS7N D U 215/... GM2N D U 215/ GMS4S D U 215/ GMS7N D U 215/ /12; 5/; 8/16 1/2"UT 22 1 GMS6S D UT 215/ /16; 6/12 5/8"U 27 3 GMS3S D U 215/ GMS6N D U 215/ /; 4/8 5/8"UT 27 1 GMS5S D UT 215/

8 Toolholder - Weldon Shank for 1/4 U D L3 L1 L1 L Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts L L1 D 1/4 U 3 GME5N 25W U 215/ SN2T K2T 5LST SN5LTR K7T Toolholder - Weldon Shank for 3/8 U D L3 L1 L1 L Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts L L1 D 3/8 U 3 GME5N 32W U 215/ SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 For Standard Gear s Spare Parts L L1 D 3/8 U 3 GME5N 32W U M1-M SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 8

9 Toolholder - Shell Mill for 3/8 U (=42 & 41, =6) d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) older 3/8 U 3 GMS6N D U 215/ SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 M8x1.25x40 For Standard Gear s Spare Parts d (6) older 3/8 U 3 GMS6N D U M1-M SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 M8x1.25x40 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 9

10 Toolholder - Shell Mill for 3/8 U (=48 & 47, =7) d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) 3/8 U 3 GMS7N D U 215/ SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 Mx1.5x40 older For Standard Gear s Spare Parts d (6) 3/8 U 3 GMS7N D U M1-M SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 Mx1.5x40 older * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

11 Toolholder - Shell Mill for 1/2 U (=52 & 51, =4) d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) older 1/2 U 3 GMS4S D U 215/ SN4T K4T Mx1.5x50 For Standard Gear s Spare Parts d (6) older 1/2 U 3 GMS4S D U M SN4T K4T Mx1.5x50 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 11

12 Toolholder - Shell Mill for 1/2 U (=70 & 69, =7) d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) older 1/2 U 3 GMS7N D U 215/ SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8 M12x1.75x40 For Standard Gear s Spare Parts d (6) older 1/2 U 3 GMS7N D U M SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8 M12x1.75x40 Toolholder - Shell Mill for 1/2 UT d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) older 1/2 UT 1 GMS6S D UT 215/ SN4T K4T M12x1.75x40 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 12

13 Toolholder - Shell Mill for 5/8 U (=60, =3) d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) older 5/8 U 3 GMS3S D U 215/ SN5TM K5T Mx1.5x55 For Standard Gear s Spare Parts d (6) older 5/8 U 3 GMS3S D U M SN5TM K5T Mx1.5x55 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 13

14 Toolholder - Shell Mill for 5/8 U (=80, =6) d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) older 5/8 U 3 GMS6N D U 215/ SN5TM K5T 3ST SN3TM K3T M12x1.75x50 For Standard Gear s Spare Parts d (6) older 5/8 U 3 GMS6N D U M SN5TM K5T 3ST SN3TM K3T M12x1.75x50 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 14

15 Toolholder - Shell Mill for 5/8 UT d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) older 5/8 UT 1 GMS5S D UT 215/ SN5TM K5T M12x1.75x40 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 15

16 Gear Milling Toolholder - Disc Mill for 1/4 U d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) 1/4 U 3 GM2N D U 215/ SN2T K2T 5LST SN5LTR K7T Gear Milling Toolholder - Disc Mill for 3/8 U d(6) Image for illustration only. Final and values will be supplied with the toolholder. For Tailor-made Gear, Rack and Spline s Spare Parts d (6) 3/8 U 3 GM2N D U 215/ SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8 For Standard Gear s Spare Parts d (6) 3/8 U 3 GM2N D U M1-M SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8 * is measured from the center of the profile to the end of the toolholder. The value is for reference purposes only. For an exact measurement, please use the Controller pre-settings. 16

17 Solid Carbide Gear Milling External Circular Pitch D Module = Pitch / π DP = 25.4 / Module Solid Carbide Tool Benefits Small Tool Diameter Excellent solution for applications that require cutting close to the shoulder igh RPM and fast feed Solid Carbide Tool Guarantees higher accuracy Multi-flute Tool Enables fast machining Tool Range Diameter Range: mm ( ) Module: For Tailor-made Gear, Rack and Spline s Shank Diameter Gear & Rack Module Range, Max Spline Module Range, Max D mm Module Diametral Pitch (DP) Module Diametral Pitch (DP) DP DP40/ DP DP32/ DP DP24/ DP DP20/ DP DP16/ DP DP12/ DP DP/ DP DP8/16 17

18 Recommended Grades, Speeds Vc [m/min] and Feed f [mm/tooth] Material Group P Steel M Stainless Steel K Cast Iron N(K) Non-Ferrous Metals S(M) eat Resistant Material (K) ardened Material ardness Indexable s Solid Carbide Brinell Vc [m/min] B Feed f Vc [m/min] Feed f Material VBX [mm/tooth] VT [mm/tooth] 1 Unalloyed Steel Low Carbon (C= %) Medium Carbon (C= %) igh Carbon (C= %) Low Alloy Steel Non ardened (alloying elements 5%) ardened ardened igh Alloy Steel Annealed (alloying elements>5%) ardened Cast Steel Low Alloy (alloying elements <5%) igh Alloy (alloying elements >5%) Stainless Steel Non ardened Ferritic ardened Stainless Steel Austenitic Austenitic Super Austenitic Stainless Steel Non ardened Cast Ferritic ardened Stainless Steel Austenitic Cast Austenitic ardened Malleable Ferritic (short chips) Cast Iron Pearlitic (long chips) Grey Cast Iron Low Tensile Strength igh Tensile Strength Nodular Sg Iron Ferritic Pearlitic Aluminium Alloys Non Aging Wrought Aged Cast Aluminium Alloys 37 Cast & Aged Aluminium Alloys Cast Si 13-22% Copper and Brass Copper Alloys Bronze And Non Leaded Copper Annealed (iron based ) igh Temperature Aged (iron based) Alloys Annealed (nickel or cobalt based) Aged (nickel or cobalt based) Pure 99.5 Ti 400Rm Titanium Alloys α+β alloys 50Rm Vardex No Rc Extra ard Steel ardened & Tempered Rc* * Note: Special tools, which are not listed in this catalog, are required for extra hard steel (51-60Rc). Grade Application Sample Indexable VBX VTX TiCN coated carbide grade. Excellent grade for general use. TiAIN coated carbide grade. Excellent grade for general use and hardened materials. Solid Carbide VT TiCN coated carbide grade. Excellent grade for general use. Other grades are available upon request. 18

19 Distributor Name NEUMO Ehrenberg Group ENQUIRY No. Request Form* * Please submit a completed version of this form with each request (a drawing is recommended). For Rack, Straight Spline, Worm or other special forms, a drawing must be supplied with all relevant dimensions! Basic Dimensions 1 Gear / Spline Standard 2 Class of Accuracy 3 Module (M) / Diametrical Pitch (DP) 4 Number of Teeth 5 Pressure Angle 6 elix Angle 7 Direction of elix (R/L) 8 Pitch Diameter (REF) 9 Major Diameter Max: Min: Minor Diameter Max: Min: 11 Form Diameter (For Spline only) 12 Fillet Radius 13 Root Type (For Spline only) Fillet Root One of the following must be supplied: 14a Measurement Over Pins 14b Tangent Length Over (N) Teeth 14c Actual - Tooth Thickness Additional Information Ø: N: Flat Root Max: Max: Max: 15 For Tool Exit Limitation, a detailed component drawing must be supplied! 16 Exit Arc Radius (R) 17 Material ardness (During machining) 18 Material Designation Min: Min: Min: Tool Radius (R) < Exit Arc Pin Diameter R (/2) Tool Radius (R) < Tool Exit Limitation R (/2) Exit Arc Limitation Pressure Angle Flat Root Spline Form Diameter Involute Fillet Radius Major (Outside) Diameter Minor (Root) Diameter Pitch Diameter Measurement Over Pins Fillet Root Spline Involute Tooth Thickness Fillet Radius Form Diameter Fillet Radius Tangent length over (N) teeth

20 For Gear, Spline & Rack Manufacturing VARGUS Ltd METR EE 06/2016 EDITION 06W

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