First Large VTC with Integrated Gear Cutting

First Large VTC with Integrated Gear Cutting

MAGs single-machine solution reduces setups, part transfers, processing time, and space requirements

multi-axis VTC 2500H
MAG's new multi-axis VTC 2500H combines gear hobbing and milling capabilities with the VTC's turning, milling, drilling, threading and contouring capabilities. Its ability to execute rough turning of the outside diameter and gear cutting on the inside diameter in one set up results in higher quality gears, according to the developer, and it eliminates a need for separate gear cutting capability.
gear-cutting specialist Modul
The first technology advancement for large VTCs resulting from MAG’s recent acquisition of gear-cutting specialist Modul introduces integrated gear cutting capability for workpieces up to 2,700-mm diameter.

Machine tool builder MAG is introducing a vertical machine center that it calls “the first technology advancement for VTCs” that follows its acquisition of Hurth Modul GmbH at the end of 2010. The VTC 2500H for workpieces up to 2700 mm diameter is a new multi-axis machine that combines gear hobbing and milling capabilities with the VTC's range of turning, milling, drilling, threading and contouring capabilities. It’s able to turn blanks and subsequently cut gear teeth from one setup, and its ability to execute rough turning of the outside diameter and gear cutting on the inside diameter in one set up results in higher quality gears, according to the developer.

The combination of functions also eliminates a separate gear cutting machine and reduces labor, part transfers, setups, work-in-process, and plant footprint/overhead, MAG stated.

Its gear-producing capabilities include hobbing, form milling (of external and internal gears), turn-milling of gear teeth with carbide end mills, and chamfering/deburring. The new system is recommended for manufacturing turbine components for wind and power generation machinery, mining equipment, marine drives, and other heavy machine designs.

MAG detailed that the hobbing module on the VTC 2500H is fully integrated to allow turning, milling and hobbing or form milling of internally and externally geared slewing rings. Two different heads are available with 36 or 46 kW of power. They can hob modules up to 24.0 mm or form-mill teeth up to module 28.0 mm on parts with a maximum face width of 600 mm.

Importantly, MAG noted that the functions of the new machine’s gear manufacturing software is fully integrated into the turning center’s control with one common HMI. This means that programming gear cutting operations is simplified, and intuitive according to the developer, with features like a workshop-oriented dialog for input of all geometric and technical parameters for the workpiece and hob.

The machine builder emphasized that along with gear cutting its VTCs perform standard and hard turning, as well as live-spindle machining, contouring and part probing operations on multiple sides and the full diameter of a part. They use standard modular tooling, such as KM 80 and Coromant Capto® solutions, and are outfitted with automatic tool changers; green design with minimal hydraulics; minimal or flat-floor foundation requirements for many models; and chip management and removal that minimizes operator intervention. A full machine enclosure meets CE specifications and ensures a dry floor environment.

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