Excessive Tool Wear Problems in Gear Hobbing Machine and Potential Solutions

Press Release | January, 2024

Excessive tool wear is a common problem during Gear Hobbing and can be caused by several factors. Here are some of the most common causes:

1. Improper Cutting Parameters: Incorrect cutting parameters like speed, feed rate, and depth of cut can cause excessive tool wear. Running the hob at high speed or using the wrong feed rate can put too much stress on the tool, leading to accelerated wear.

2. Inadequate Lubrication: The use of insufficient or incorrect lubricant can result in excessive friction and heat, leading to quick tool wear. Proper lubrication is necessary to reduce tool wear and ensure the smoothness of the cutting process.

3. Tool Material Selection: Choosing the wrong tool material for a specific gear hobbing application can result in premature wear. Different materials have varying hardness, toughness, and heat resistance properties. Using a tool material that is not suitable for the workpiece material being cut can lead to rapid tool wear.

4. Poor Tool Maintenance: Neglecting the maintenance of the hobbing tool can contribute to excessive wear. Failure to sharpen or replace worn-out cutting edges can cause the hob to lose its cutting effectiveness. Regular inspection, regrinding, and replacement of worn tools are necessary to maintain optimal performance.

5. Workpiece Material Properties: The properties of the workpiece material being cut can also influence tool wear. Hardened or abrasive materials can cause higher tool wear rates compared to softer materials. It is crucial to consider the workpiece material characteristics when selecting the appropriate cutting parameters and tool materials.

6. Inconsistent Gear Hobbing Setup: Improper setup of the Gear Hobbing Machine or misalignment of the workpiece and tool can lead to uneven contact and increased tool wear. Proper alignment, calibration, and setup of the machine and workpiece are crucial to achieve uniform cutting and minimize tool wear.
To minimize excessive tool wear during gear hobbing, it is essential to optimize cutting parameters, use appropriate lubrication, select suitable tool materials, perform regular maintenance, and ensure proper machine setup.

To mitigate these issues, several potential solutions can be considered:

1. High-Quality and Wear-Resistant Hob Cutters: Using high-quality hob cutters made from wear-resistant materials can significantly reduce tool wear and extend tool life.

2. Adequate Lubrication: Ensuring proper lubrication of the cutting process can help reduce friction and heat generation, ultimately reducing tool wear and extending tool life.

3. Controlled Cutting Temperatures: Implementing measures to control cutting temperatures can help prevent thermal cracking and other forms of wear on hob cutters.

4. Optimized Cutting Speeds and Process Strategies: Optimizing cutting speeds and process strategies can help reduce the stress and wear on hob cutters, improving their longevity.

5. Tool Condition Monitoring (TCM): Implementing TCM can provide a methodical approach to tracking tool wear, enabling the early identification of potential issues and optimization of tool life.

By implementing these potential solutions, manufacturers can effectively address excessive tool wear problems in Gear Hobbing Machines, leading to improved tool performance and reduced maintenance costs.

About Zhejiang Toman Intelligent Technology Co., Ltd. (Toman)

Toman is a company that adheres to the strategic vision of to be the leader in the professional field, with the mission of innovation to drive customer value enhancement, and the business philosophy of WISE, ALWAYS KEEP STEP AHEAD. In operation since 2006, the company includes the complete range of gear Hobbing Machine, Gear Cutting machine, gear machining compound machine tools, Gear Shaving Machine, automatic production units, automatic turning production lines, and MES manufacturing execution system, etc. TOMAN today, is recognised as an industry leader for machines in China.

Toman cutting machines:

CNC high precision gear hobbing machine, Gear Chamfering Machine, Gear Shaving machine, gear hobbing machine with integrated chamfering station etc.

-Profitable -Intelligent -Accurate

Our machines are suitable for commercial vehicle gear, passenger vehicle gear, construction machinery gear, especially for the processing of new energy vehicle gear.

For more information about cnc Gear Cutting Machines, please visit our website:

www.zjtoman.com

www.tomanmachines.com

For further information, please contact:

Sharon Gong

Master of Mechanical Engineering

Whatsapp/Wechat: +8613589398142

Mail: sharon@zjtoman.com

gongyx@zjtoman.com

Skype: sharon.gong525