Ring gear blank machining: automated process control for high volume turned parts

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1 Case brief Ring gear blank machining: automated process control for high volume turned parts Fully automated process control 100% part inspection All inspection on one device

2 Overview Manufacturers of ring gear blanks use high speed CNC turning centres, with production involving several operations to create a gear blank ready for the final gear cutting process. Typically a combination of various forms of gauging are used alongside the machine to monitor gear blank quality and allow engineers to correct the process. However producers are now looking to reduce regular costly maintenance and high capital investment, and to improve production cycle times. This case brief examines a typical ring gear blank manufacturing process with actual benefits that Renishaw technology has delivered to manufacturers who must meet demanding expectations for quality and process yield, inspect parts as quickly and as thoroughly as possible. Typical ring gear blank manufacturing process - without the Equator gauge Solid billet Heat treat OP10 Semi-finish OD and ID Hand gauge OD/ID size OP20 Turn front face, groove, finish ID and OD Hand/bench gauges - size and position Temperature stabilisation CMM inspect geometric features Cut and harden gear teeth Assemble into transmission Ring gear blank machining Challenges 1 Combine all the gauging and inspection activities into a single operation The current bench gauges are manual and unable to inspect geometric features. Geometric features are inspected on a CMM in the quality room, which could be better used for QA, and can act as a bottleneck that is not capable of keeping pace with production cycle times. To meet production cycle times, gauging of size, position and geometric features must be carried out on one device in a single operation. 2 Reduce operating costs Current gauges have a high purchase cost and require costly ongoing maintenance. 3 Improve process yield and quality Reduce variation by gauging critical features and keeping part dimensions as close to nominal as possible.

3 Inspection requirements for a ring gear blank # Inspection Tolerance Why is this feature critical to part function? Active tool offsetting action 1 Roundness of bore ± 25 µm (± ) If the bore is not true, offset action will result in vibration when the finished gear is used. 2 Outer diameter ± 15 µm (± ) Incorrect alignment can cause contact with gear casing, resulting in misalignment and rapid wear. 3 Parallelism to front face 50 µm Poor contact with surface on mating bearing can cause inconsistent drive and wear on gear. 4 Flatness 25 µm ( ) Need flat surfaces for consistent gear cutting, so gear meshes perfectly with mating gear. 5 Perpendicularity 50 µm If not aligned correctly the result will be vibration when rotating. 6 Width ± 75 µm (± ) Affects the hobbing process. Too small, surface is reduced. Too large, gear teeth might not be cut. Accurate automated control of roughing and finishing tools can have a beneficial effect on these characteristics. Accurate control of tool replacement - updating offset values to minimise the effects of tool wear on these features.

4 Process considerations Renishaw engineers considered key elements within the ring gear blank manufacturing process using Renishaw s Productive Process Pyramid. This framework is used to identify and control the variations that can occur at key stages of the machining process. For this process, methods to control variation include machine maintenance and calibration, tool breakage detection and shop-floor gauging for inspection and feedback. Informative controls applied after machining is complete Active controls applied during metal cutting Predictive controls applied just before cutting Preventative controls applied in advance Postprocess monitoring In-process control Process setting Process foundation Productive Process Pyramid Manufacturing process - opportunities for improvement Original process Solid billet Heat treat OP10 Semi-finish OD and ID Hand gauge OD/ID size OP20 Turn front face, groove, finish ID and OD Hand/bench gauges - size and position Temperature stabilisation CMM inspect geometric features Cut and harden gear teeth Assemble into transmission Improved process Update tool offsets* Solid billet Heat treat OP10 Semi-finish OD and ID OP20 Turn front face, groove, finish ID and OD Equator gauges 6 critical features in 45 seconds Cut and harden gear teeth Assemble into transmission Broken tool detection Machine maintenance Robot loading between operations * Offset updates can be automatically applied using IPC (intelligent process control) software which uses dimensional data to feedback offset updates to CNC controllers. Updates could alternatively be applied manually based on the inspection data displayed in Process Monitor. Typical results Ring gear blank manufacturers have installed Equator systems to replace hand and bench gauges, fixture gauges and CMM inspection operations, which significantly reduces operator costs. Equator gauges compare production parts against master part inspection data. Remastering removes thermal effects and ensures high repeatability over a wide temperature range. Inspection results are captured in a way that enables easy reporting, analysis and feedback to improve process control.

5 Typical results 1 Combined single operation Equator gauges are meeting all the gauging requirements, within the target time. The Equator gauge is measuring 6 critical features in 45 seconds, including the position and geometric form features. Previously manual gauges were used to gather single point data only and multiple stations were needed as well as CMMs for inspection of geometric features. # Inspection Tolerance 1 Bore of roundness ± 25 µm (± ) 2 Outer diameter ± 15 µm (± ) 3 Parallelism to front face 50 µm 4 Flatness 25 µm ( ) 5 Perpendicularity 50 µm 6 Width ±75 µm (± ) Gauge R&R* Range 2.1% 0.7 µm (27 µin) 8.2% 1.2 µm (47 µin) 3.8% 1.8 µm (71 µin) 3.0% 0.9 µm (35 µin) 0.4% 0.2 µm (8 µin) 0.8% 0.8 µm (31 µin) * Type 1 Gauge Repeatability and Reproducibility based on 20 parts 2 Operating costs reduced The Equator gauge s high speed scanning reduces measurement cycle time and means every feature can be inspected in one-hit, so that every part is fully gauged. Automated loading and unloading further reduces operating costs, aiding and improving the efficiency of the manufacturing process. Costs have been reduced by removing the need to take parts to the CMM in the quality room, which could involve lengthy queuing times. Simple selection of different part inspection programmes on Equator reduced change over times. 3 Improved process yield and quality The Equator gauge is providing fully automated offset compensation. Equator gauging data on critical features is being constantly monitored. When any tool offset updates are required they are sent to the turning centre control, adjusting the machining of subsequent parts to bring the features back towards the nominal value. Example of Process Monitor screen showing drift due to tool wear, corrected by IPC

6 Renishaw plc New Mills, Wotton-under-Edge Gloucestershire, GL12 8JR United Kingdom T +44 (0) F +44 (0) E uk@renishaw.com About Renishaw Renishaw is an established world leader in engineering technologies, with a strong history of innovation in product development and manufacturing. Since its formation in 1973, the company has supplied leading-edge products that increase process productivity, improve product quality and deliver cost-effective automation solutions. A worldwide network of subsidiary companies and distributors provides exceptional service and support for its customers. Products include: Additive manufacturing and vacuum casting technologies for design, prototyping, and production applications Dental CAD/CAM scanning systems and supply of dental structures Encoder systems for high-accuracy linear, angle and rotary position feedback Fixturing for CMMs (co-ordinate measuring machines) and gauging systems Gauging systems for comparative measurement of machined parts High-speed laser measurement and surveying systems for use in extreme environments Laser and ballbar systems for performance measurement and calibration of machines Medical devices for neurosurgical applications Probe systems and software for job set-up, tool setting and inspection on CNC machine tools Raman spectroscopy systems for non-destructive material analysis Sensor systems and software for measurement on CMMs Styli for CMM and machine tool probe applications For worldwide contact details, visit RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE THE CONTENT OF THIS DOCUMENT IS CORRECT AT THE DATE OF PUBLICATION BUT MAKES NO WARRANTIES OR REPRESENTATIONS REGARDING THE CONTENT. RENISHAW EXCLUDES LIABILITY, HOWSOEVER ARISING, FOR ANY INACCURACIES IN THIS DOCUMENT Renishaw plc. All rights reserved. Renishaw reserves the right to change specifications without notice. RENISHAW and the probe symbol used in the RENISHAW logo are registered trade marks of Renishaw plc in the United Kingdom and other countries. apply innovation and names and designations of other Renishaw products and technologies are trade marks of Renishaw plc or its subsidiaries. All other brand names and product names used in this document are trade names, trade marks or registered trade marks of their respective owners. *H * Part no.: H A Issued:

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