HDSD máy phay lăn răng

Guangxi Xiashi Machinery Equipment
Co., Ltd.
Gear Hobbing Machine
MODEL: XSY3150K

Operation Manual

INDEX


I.

Main usages and working principles

PAGE 02

II.

Main technical parameters

III.

Transportation of the machine tool

IV.

Installation base and installation

V.

Main parts and operation institutions of the machine tool

VI.

Preparation before starting

VII.

Hydraulic and lubrication system of the machine tool

PAGE 02
PAGE 04
PAGE 04
PAGE 05

PAGE 08

VIII. Cooling for hob

PAGE 08

PAGE 09

IX.

Transmission system of machine tool

X.

Electrical system of the machine

XI.

Adjustment of the machine

XII.

Hob shifting

PAGE 12
PAGE 17
PAGE 20
PAGE 28

XIII. Adjustment on institutions

PAGE 28

Attached sheet 1 Sub-gear wheel adjustment table

PAGE 29

I.
Main usages and working principles
This machine tool is for the manufacturing and processing cylindrical gear and worm gear in mass and small patches, and
samples, as we as the spline-shaft on 6 pitches and over 6. Chain wheel as well.
When processing cylindrical gear, up milling and climb cutting can be selected, the whole pitch width can be worked out by
1


axial feed.

Manual operation feeding is for hobbing normal worm gear.
The machine adjustment and processing method when working on spline and chain wheel is same as cylindrical gear.
Knife rest is adjusted by quick motor and manual.
II.
Main technical parameters
1. Processing range
Max work piece diameter

510mm

Max workpiece moulds

8mm

Max additional breadth

250mm

Least pitches on workpiece

Z min / K hob number=6

2. Knife rest
Max vertical distance

300mm

Max rotating angle

240˚

Min rotating angle

6˚

Fast moving speed vertically

0.52mm/min

Manual moving distance vertically

0.754mm

Vertically feeding level

12

Vertically feeding range

0.4-4mm/workbench/circle

3. Workbench
Workbench diameter

510mm

Workbench bore diameter

80mm

Taper of workpiece axis core

MT5

Horizontal hydraulic drive of workbench

50mm

Workbench moving distance on each rotating manually

1mm

Min value of workbench horizontal moving

0.01mm

Max distance from workbench to mini upright sliding
axis part

850mm

Min distance from workbench to mini upright sliding
axis part

380mm

4. Hob main axis
Applied max hob diameter

160mm

Applied max hob length

160mm

Diameter of cutter thread brace

M16

Taper of main axis hole

MS NO.5

Max moving of cutter axis

55mm

Distance from cutter main axis core to workbench
Max
Min

535mm
235mm

Distance between workpiece axis core and hob axis core
Max
Min

330mm
20mm

Rotating speed range of main axis

40-250rpm

Rotating level of main axis

9

5. Weight of motor and machine tool
2


Main motor
Power
Rated speed

5.5kw
1440rpm

Axis (vertical) quick motor
Power
Rated speed

0.75kw
1380rpm

Radial quick motor
Power
Rated speed

0.75kw
1380rpm

Fluid pump motor
Power
Rated speed

1.1kw
910rpm

N.W of the machine

4500kg

Means of machine (L*W*H)

2450*1272*1790 (mm)

6. Other statements
Applied diameter for hob
D=22mm
D=27mm
D=32mm
MS NO.5 Taper=1:5
Sketch of hob core
Diameter of workpiece core
D=30mm

MS NO.5

Sketch of workpiece core

7. Adjustment on the applied clutch
3


Structure sketch without differential mechanism

Structure sketch with differential mechanism

III.
Transportation of the machine tool
Net weight of the machine is around 4500kg, gross weight is 5500kg.
There is no specific jack-up hole on main upright of the machine.
When jacking-up, use the steel sticker with diameter no less than 40mm to cross jack-up hole according to fig 1, pad
wooden board between lifting rope and machine (to prevent damage on machine), then jack up.
When transporting by roller, the machine must be fixed on tight wooden base to transport.
For long-distance transportation, there shall be reliable water-prevent packing. The important transmission mechanisms
including main/vice internal boring of the bevel wheel on machine knife rest, workbench, guide rail, working axis and
external working surface, etc. Level worm gear vice part shall be full-filled with lube, mini upright supporting shall be
placed in the center and tightly clipped, between the workbench pressing plate and guiding rail shall be padded with a
industrial paper with the thickness less than 0.1 mm. The pressing plate shall be tightly pressed.

Fig 1

IV.
Installation base and installation
Installation base shall apply the concrete structure according to the size in Fig 2, the base depth shall be decided by
geological condition.
When installing, please apply with gradienter with the accuracy no less than 0.02/1000, measure the level of machine on

the lengthways and crosswise, allowed error as 0.04/1000. And leave enough space for normal works and repairs
according to Fig 2

4


Fig 2 Machine base sketch
V.

Main parts and operation institutions of the machine tool

NO
1
2
3
4
5
6

Name and usage
Axial feed gear case
Pressure gage
Oil filling scutcheon
Upright guide rail lubrication hand vale
Operation buttons area
Axial feed gear sticker

NO
24
25

26
27
28
29

Name and usage
Cover
Knife rest balance oil tank
Lathe bed
Workbench
Shell part of workbench
Move the hand-square forward and reverse
on workbench

7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

23

Move the hand-square up and down on knife rest
Limit switch for working range
Adjustment on cracking piece during the process
Hand-square at the corner of knife rest
Knife rest slide
Hob cage
Spray of cooling liquid
Screw for hob cage
Workpiece core axis
Mini upright moving supporting
Mini upright
Operation stick for three-position valve
Hand valve for lathe bed guide rail
Electric cage
Huge upright
Axial direction feeding change wheel
Plug screw for releasing hydraulic pressure and
lubricating oil

30
31
32
33
34
35
36
37
38

39
40
41
42
43
44
45

Rise and for-back gas-level on workbench
Differential gear rack
Main axis speed change, pitch, differential pitch
Main axis speed change pitch
Main axis speed change stick
Cutter tooth hanger
Limitation crash for knife rest fast processing
Limitation switch for knife rest fast processing
Limitation crash for workbench fast processing
Limitation switch for workbench fast processing
Plug screw for cooling liquid
Slag case room
Plug screw for lubricating oil into worm gear
Plug screw for lubricating oil releasing worm gear
Screw to floor
Power cable

5


Fig

3-1

Machine

appearance

and

operational

6

institution

for

XSXSY3150K


Fig 3-2 Machine appearance and operational institution for XSXSY3150K
7


VI.

Preparation before starting
1. Be aware of the machine structure and operation method.
2. Clean up the machine: clean up everywhere of the machine that with antirust oil , pull off oil-plug 43 (refer to fig 3),
release all lube in worm gear room, and plug back.
3. Start the machine after base fully dry.

4. Recheck the machine of installation level, be sure the error is within 0.04/1000, or re-adjust.
5. Take out the paper pad between workbench and guide rail.
6. Inject corresponding engine oil according to the oil mark (lathe bed hydraulic oil pool and cooling oil pool shall be
inject with much oil), inject lube according to fig 4.
7. After power on, start the pump motor first, adjust the flood valve P, (refer to fig 4), observe the pressure meter P,
adjust the system pressure to 2.5-3.0Mpa, check the dividing worm wheel, lathe bed guiding rail, horizontal plane
adjustment institution of workbench, oil mark of workbench, peak oil pool of big upright, transmission case,
feeding case and all automatic lube nodes, to confirm if oil arrives, if not or the oil volume is not correct, please
adjust the check valve A and B-C-D of the big upright oil distributor. The oil volume adjusting screw for workbench
oil distributor, after all transmission institution well lubed, the knife rest quick motor can be started, when knife
rest fast down, adjust the flood valve P2, adjust the pressure to 1.0-1.5Mpa.
8. The machine must be running with not loading for 2-3 hours before testing cut, the operating range as: main axis
rotate speed 80rpm, vertical cutter volume as 1mm/workbench/circle, workbench rotating speed as 1rpm (gear
wheels shall be equipped by cutting 80), differential change gear as:
9. After starting, please check all parts of the correctness and flexibility when independently running, if good the test
cutting can be started.

VII.
Hydraulic and lubrication system of the machine tool
Please refer to fig 4
1. Hydraulic system
The pressure oil of the hydraulic system for this machine is feed by Y90L-6B5 motor, with YB1-10 vane pump. The working
pressure as 2.5-3.0Mpa, pressure shall be adjusted by flood valve P1 in Y-10B, between the oil pump and center flood valve
it’s XU-40*50 filter, working oil as the pure 30# engine oil.
After starting the hydraulic motor, no matter if the machine works, solenoid valve YV1 (23D-10B) are free, pressure oil
enters the knife rest balance oil tank via solenoid valve. Only when the knife rest decreases fast, solenoid valve YV1 is on
power, the pressure oil would not enter knife rest balance oil tank, by then knife rest oil tank is in absorbing condition,
backing pressure is adjusted by center flood valve P2 (pressure as 1.0-1.5Mpa)
The mini upright supporting is controlled by hydraulic 3-positions valve, when the sticker is in horizontal position, the
supporting stops and tights. When rotated up for 45°, supporting raises, when rotated down for 45°, supporting declines.

The workbench is equipped with in-out oil tank with the work-rang of 50mm. When the solenoid valve YV2 is free, the
pressure oil enters the back tank of workbench via solenoid valve YV2, the workbench would be driven forward for 50mm.
When solenoid valve YV2 is on power, pressure oil enter the front tank of workbench, the workbench would be driven
backward for 50mm.
2. Lubrication system Please refer to fig 4 and 5
The lubricate oil of machine is feed by Y-B10 flood valve P1 in hydraulic system, with the pressure around 0.05-0.15Mpa
(adjusted by check valve A), the oil is exported to workbench and big-upright distributor, to lubricate the workbench worm
gear, circle guiding rail, horizontal moving operational institution, lathe bed and big-upright guiding rail, upright and slide,
transmission cage, feeding cage.
Lathe bed and big-upright guiding rail is manual intermittent lubrication (refer to fig 5). lubricating when pressing the valve
sticker, and stopping when sticker released. Knife gear and pitch gear is lubricated by oil pool, other lubrication points
please refer to fig 5.
8


Please remain the clean of machine hydraulic oil, a new machine - all hydraulic oil shall be replaced after working for 600
hours, then replace once per 6 months.
VIII.
Cooling for hob
Please refer to fig 5
Cooling oil is feed by AOB-50 cooling pump, crossing oil-conveying pipe to knife rest, size of cooling oil is adjusted by
bibcock ahead of the spray, there exists a switch on operational button board to control the cooling pump. When not using
the workpiece core axis, please cover the workbench hole by cover (91-2011), to avoid any mixing.

分分分 Oil distributor
分分分分分分分 workbench in-out oil tank
分分分分 Balance oil tank
分分分分分分 supporting tight oil tank
分分分分分分 Workbench oil distributor 分分分分分分 supporting raise-decline oil tank
分分分分分分 Line gap filter

分分分
Vane pump
分分分 Flood valve
分分分分分分分 Two three-way solenoid valve
分分分 Motor
分 4 XSY3150K 分分分分分分分分分 Fig 4 XSY3150K lathe bed hydraulic and lubrication system

9


10


11


分分分分分分分 分分 2-3 分 lubricate the lathe bed guiding rail, 2 or 3 times per use
分分分分分分分分分分分分 Lubricate the pitch worm gear, vice oil vol adjustment
分分分分分分分分分分分 lubricate the hand-control institution, oil vol adjustment
分分分分分分分分
feed the gear case and lubricate the oil pool
分分分分分分分分分分分分分分分分 lubricate the workbench circle guiding rail and cone oil vol adjustment
分分分分分分 workbench oil distributor
分分分分
inject oil per use
分分分分分
replace oil per 3 months
分分分分分
replace oil per 6 months
分分分分分分分分分分 knife rest helical gear vice lubricate oil pool

分分分分 cooling down oil pool
分分分分分分分分分分分分 2-3 分 start the lubricate big-upright guiding rail, 2-3 time per use
分分分分分分分分分 transmit the lubricate oil pool on gear case
分分分分分 C/D big-upright distributor C/D
分分分分分 B big-upright distributor B
分分分分分分分分 gear with curved teeth lubrication oil pool
分分分分分分分 Hydraulic and lubricating oil pool
分分分 check valve
分分分分分 Center pressure flood valve
分分分分分 pressure cone
分分分 pressure meter
分分 Y3150 K 分分分分分 Fig 5 XSY3150K Hydraulic and lubricating
分分分分分分分 Three-position three-way solenoid valve
分分分分分分分 Three-position four-way solenoid valve

12


IX.
Transmission system of machine tool
Please refer to Fig 6
1. Main movement of machine tool
Main movement of machine tool is driven by Y132S-4B3 motor which equipped on lathe bed. The power of main motor is
5.5kw, rotate speed is 1440rpm, transmitted into transmission case via level A - triangle tape A1448 in a lower speed, and
obtained the level 9 (sheet 1) rotate speed by change gear and gears altering (fig 3), the main axis rotating path is
controlled by the direction change switch on control board, please refer to fig 8.
Sheet 1. Main axis rotating speed
分分 change gear 分分 rotating speed 分分分分 hand-sticker position

2. Dividing movement of machine

When applying the number of thread as K of hob and roll cutting number as Z of the gear, each circle of hob would drive
the workbench of workpiece as K/Z circles, adjustment of dividing movement is performed by gear wheels (please refer to
fig 3).
Adjustment formula of gear wheel as below: a*c/b*d=24/Z*k * f/e
When 6<= z/k<=20, e=48, f=24, then a*c/b*d=12K/Z -------------formula (1)
When 21<=Z/K<=142, e=36, f=36, then a*c/b*d=24K/Z -------------formula (2)
When 143<=Z/K, e=24, f=48, then a*c/b*d=48K/Z -------------formula (3)

the following are english for Fig6
分分分分分 Main motor
分分分分分分 Axial quick motor
分分分分分分 Radial quick motor
分分 feed
分 6 XSY3150K 分分分分 Fig 6 XSY3150K transmission system


3. Feed movement of machine


(1) . Radial feed: radial feed stands for that workbench moves along with the lathe bed horizontally. It contains
maneuvering and manual of the 2 feeding modes. Maneuvering is divided into motor and hydraulic pressure of
the 2 driven methods, including which hydraulic pressure driven distance as 50mm on forward and backward.
Each rotating on hand-square 29 (refer to fig 3), the radial movement of workbench is 2mm, on calibration loop
each gear as 0.01mm.
(2) Axial feed: it stands for the feed movement that knife rest moves along with the big-upright guiding rail. Axial feed
of this machine is maneuvering, can shift by 4 - on one change gear and one pushing gear speed changing box, to
obtain level 12 of the feeding power (refer to fig 3). To hang one pair of gearing wheel can obtain 3 types of
feeding vol by shifting. When processing gear by right-hand hob, please refer to the following sheet (2) for
installation of feeding gear wheel. When processing gear by left-hand hob, the installation location of down and
back milling is opposite against sheet 2.

Sheet 2 Adjustment on axial feed volume

Down milling

Up milling

Gear adjustment when using
left-hand hob to feed

a1/b1
26/52

32/46

46/32

52/26

1

0.4

0.56

1.16

1.6

2

0.63

0.87

1.8

3.5

3

1

1.41

2.9

4

position of
hand sticker

*Attention please: Axis X-IV and axis X V, the gear cannot be paired.
(3) Position of gear change hand lever (please refer to fig 7)

Fig 7 Gear change hand lever

4. Differential movement of machine (please refer to fig 3)
This machine contains cylindrical gear differential movement backup institution.
When differential movement is not necessary, equip axis IX with a 3-jaw clutch M1 (91-2010M).

When differential movement is necessary, equip axis IX with a 3-jaw clutch M2 (91-2009M).
The differential chain adjustment as below:
(1) When processing axial feed to work on helical gear, when hob vertically move for 1 workpiece rotating distance L2,
the backup movement from differential institution for workbench is +/- 1 circle.
Rotating distance of workpiece:
Including which: β= Gear helical angle
m = Gear molding
Z = Gear ratio
Calculation formula of differential gearing wheel as:
-------------------------------Formula (4)
Including which K= hob head number, +/- shall be decided via sheet 3
Sheet 3 confirmation on +/- for formula 4
Cutter

Left hand rotating

Right hand rotating

Left hand rotating

+

-

Right hand rotating

-

+

Workpiece

*Remarks: when the calculating result is +, no use of idler, on - the idler is necessary.
(2) . When choosing axial feeding method to process the spur gear that the number of gear is over 100 or as the
integer multiples, it can’t be adjusted by gear wheels only, it also requires support from differential institution.
By then the prime gear of the number can be transformed to: Z’=Z+α
Including which: Z’ can be the gear number adjusted from gearing wheel.
, α is a algebraic value, can be +/-, IαI <1
Firstly adjust the pitch gear according to a/b*c/d=24k/Z’, or a/b*c/d=48k/Z’
The calculate the differential gear wheel according to the following formula:
-----------------------------------formula 5
When calculating please bring +/- of α with it, the +/- ahead of formula shall be decided according to sheet 4, i shall be
selected according to sheet 5.
Sheet 4 confirmation on +/- for formula 5
Down milling

Up milling

+

-

*Remarks: when the calculating result is +, no use of idler, on - the idler is necessary.
Sheet 5 confirmation on selecting I number
walk

26/52

a1/b1

32/46

46/32

52/26

reduced value
Hand sticker position

S Axis

I walk

S Axis

I walk

S Axis

I walk

S Axis

I walk

1

0.4

5/18

0.56

16/23*5/9

1.16

23/16*5/9

1.6

10/9

2

0.63

13/30

0.87

16/23*13/15 1.8

23/16*13/15 2.5

26/15

3

1.00

7/10

1.41

16/23*7/5

23/16*7/5

14/5

2.9

4

(3) . When choosing axial feeding method to process the helical gear that the number of gear is over 100 or as the
integer multiples, differential movement calculation shall follow the following formula:
------------------formula (6)


Including which: +/- in part 1 shall be decided by sheet 3, the +/- in part 2 shall be decided by sheet 4, i walk value is decided
by sheet 5, when calculating please bring the +/- of α with, the mean of +/- in formula is same as formula 4 and 5. When
the calculating result is +, no use of idler, on - the idler is necessary.
V.
Electrical system of the machine
Power supply volt of this machine is three phase 380V +/- 10%, operational circuit volt as 220V, lamp circuit as 24V,
indicator volt as 6.3V. The electric devices are mainly concentrated in electric case, by the side of big-upright there
contains operation station, function of controlling button switch and indicator please refer to fig 8.

Fig 8 Controlling Button Board of the Machine
1.Switch for lamps 2.Forward and backward rotating button for main axis 3.Power indicator
4. Hydraulic indicator light 5.Lubrication normal indicator 6.Fast exist button on workbench
7. Switch for cooling pump 8. Inching switch for main axis 9. Starting button for main axis
10. Stopping button for main axis 11. Fast raising button for main axis 12. Fast declining button for main axis
13. Starting button for hydraulic 14. Speed button for workbench 15. Hydraulic stopping button
16. Scram button 17. Forward and backward button for oil tank
This machine contains 5 motors for different usages to satisfy the demands of machine craft, their works are mostly
divided into the following parts.
1. Starting the main axis
Switch the switch for sum power QF, machine is powered on, red indicator HL 1 is on, the machine is
ready to work. Press button SB 2 thus the hydraulic motor M 1 is on, green indicator HL 2 is on, when lube
is normally supplying, SP 1 pressure relay is connected, green indicator HL 3 is on, then press the main
axis starting button SB6 to start the main axis.
2. Machine speed
Only when the hand sticker (fig 7) is in speed position, the SQ 2 in close condition, the axial quick motor
M3 and radial quick motor M4 can be on, to start the quick radial motor the button SA 3 must be closed,
thus solenoid valve YV2 would lose electric, piston of oil tank is at the front to reach the goal of
interlocking. When the workbench press the stopping switch SQ 5, radial quick motor M4 stops, by then
it requires to use hand to shank workbench reversal to let the crash piece off SQ 5, then the radial fast
backward could be started, or the same. There exists interlocking point between radial quick and axial
quick, each time only one of the motor could be turned on to ensure the safety. When the knife rest


3.

4.
5.

declining fast, solenoid valve YV1 is powered on for work.

Electric protection
(1). This machine contains the function that when opening the door, power would be cut and
interlocking, with the automatically air circuit breaker DZ 15-40 as the switch for sum power supply, as
well as the over-load and short circuit protection of this machine.
(2). Over-load and short circuit protection of hydraulic motor, main axis motor, cooling pump motor is
apart realized by breaker QF1, QF2, QF3.
(3). FU1 is the short circuit protection for axial quick motor M 3 and radial quick motor M4, FU2, FU3 is for
protection on transformer short circuit. FU4, FU5 is for indicators and lamps.
The machine controlling button board and back side of big-upright has inching button SB 4, SB5 for the
convenience of adjusting machine and change gear.
Please refer to fig 9, fig 10, fig 11 for electrical schematic diagram, electrical interconnection diagram
and electrical installation diagram.

ii.
分分分分 controlling board
分分分 controlling cage 分分分 adapter junction box
分分分分分分分 short circuit protection for power cable
Fig 11 XSY3150K electrical installation diagram

Sheet 6 detailed list for electrical equipment

electric NO
M1
M2
M3
M4
M5
KM1
KM2
KM3

KM4
KM5
KM

Model and Specification
Y90L-6B5 1.1KW
Y132L-4 5.5KW
YB02-4B5 0.75KW
YB02-4B5 0.75KW
AOB-50
0.12KW
3TB4017-OA 220V
3TB4017-OA 220V
3TB4017-OA 220V
3TB4017-OA 220V
3TB4017-OA 220V
3TB4017-OA 220V

Name and usage
hydraulic motor
main axis motor
axial fast motor
radial fast motor
cooling pump
hydraulic starting contactor
CW contactor
CCW contactor
axial raise contactor
axial decline contactor
radial forward contactor

Qty
1
1
1
1
1
1
1
1
1
1
1

Supplier
分
分
分
分
分
分
分
分
分
分
分

Remark
分
分

分
分
分
分
分
分
分
分
分


KM7
KM8
KA
QF
QF1
QF2
QF3
FU1

3TB4017-OA
3TB4017-OA
3TH8031
DZ15-40
DZ108-20
DZ108-20
DZ108-20
RT18
10A

FU2

RT18

FU3
FU4
FU5
SB0
SB1
SB2
SB3
SB4
SB5
SB6
SB7
SB8
SB9
SB10
SA1
SA2
SA3
SA4
TC
EL
HL1
HL2
HL3
SQ1
SQ2
SQ3

SQ4
SQ5

220V
220V
220V
40A
3.2-5A
10-16A
0.4-0.63A

1
1
1
1
1
1
1
3

分
分
分
分
分
分
分
分

分

分
分
分
分
分
分
分

2

分

分

RT18
2A
RT18
2A
RT18
2A
LAY3-11ZS
LAY3-11
LAY3-11
LAY3-11

radial backward contactor
cooling start contactor
middle relay
breaker(sum power supply)
short circuit breaker for hydraulic motor

short circuit breaker for main axis motor
short circuit breaker for cooling motor
short circuit protection fuse for fast motor
single-use short circuit protection fuse
transformer
short circuit protection fuse for operating loop
short circuit protection fuse for working lamp
short circuit protection fuse for indicator
scram button
hydraulic pressure stopping button
hydraulic pressure starting button
main axis stopping button

1
1
1
1
1
1
1

分
分
分
分
分
分
分

分

分
分
分
分
分
分

LAY3-11

main axis inching button

2

分

分

LAY3-11
LAY3-11
LAY3-11
LAY3-11
LAY3-11
LAY3-11X/2
LAY3-11X/2
LAY3-11X/2
LAY3-11X/2
jbk5-160
380,220,24,6.3
JC-11
AD56-22

AD56-22
AD56-22
X2-N
LW6-11ZL
X2-N
X2-N
X2-N

main axis starting button
axial raise button
axial decline button
radial forward button
radial backward button
rotating switch for main axia
switch for cooling pump
rotating button for oil tank vol
switch for lamp

1
1
1
1
1
1
1
1
1

分
分

分
分
分
分
分
分
分

分
分
分
分
分
分
分
分
分

transformer controller

1

分

分

lamp
power indicator
hydraulic indicator light
lubrication indicator light

switch for stopping main axis
fast processing switch
axis raise limit distance switch
axis decline limit distance switch
radial moving limit distance switch

1
1
1
1
1
1
1
1
1

分
分
分
分
分
分
分
分
分

分
分
分
分

分
分
分
分
分

2A

XI Adjustment of the machine
To make it clear, all stated by real case.
1 Adjustment on machine when processing straight spur gear
<case 1>: straight spur gear: number of pitch Z=46, modulus M=3, pitch breadth B=40mm
Hob: diameter D=70mm, number of head K=1, W=4˚,
Cutting standard by right hand: cutting speed Vcut=35mm/min, full depth of cutting pitch H=6.75mm
Cutting process as twice, first cutting h1=5mm, second cutting h2=1.75mm


Radial feed: first cutting S1=2.9mm/workbench rotating
Second cutting S2=1.16mm/workbench rotating
Applied with up milling.
(1) Installation of workpiece
The correctness on installation of workpiece would directly influence the accuracy of processing gear, so the
workpiece shall be tightly installed and correctly, to make sure that during the process of processing there is no any
loose. As for some workpieces with small diameter, can be directly installed on the workpiece core axis of this machine
(core axis diameter as D=30h6), and also choose the supporting on mini up-right to support the core axis side. When
process the workpieces with huge diameter, place the workpiece onto the corresponding forck.
(2) Installation of hob
The correctness on installation of hob would directly influence the accuracy of gear. When installing please clean the
hob inner hole, spacer ring, hob core axis, main axis boring and keep it clean, to avoid any deflect when installing, or
damage, to lose the accuracy of the machine.

Installing angle of hob is the included angle between hob core line and horizontal plane.
When processing straight spur gear, installing angle of hob is same as helical angle of hob.
The correct installation on hob please refer to fig 12
The installation angle of hob on this machine is adjusted according to rotating hob cage, can be adjusted according to
the calibration loop, vice ruler of sliding board.
The hob shall be installed according to fig 12 in this case
Remark: in fig 12, the hob installation angle is same as hob helical angle W.

Installation of hob when cutting straight spur gear
A. Right-hand hob

B. Left-hand hob

(3). Selecting and adjusting on main axis rotating speed
Cutting speed: Vcut=
Including which: D= diameter of hob (mm)
Nknife= rotating speed of main axis
After selecting cutting speed V cut according to the processed gear of the material hardness, modulus, accuracy, degree of
finish, the following formula can be applied to calculate the rotating speed of main axis
When the calculating result does not fit the level 9 rotating speed of this machine, shall select the level 1 main axis rotating
speed which closest to calculating result.
The main axis rotating speed can be reached by calculating, as well as checking via fig 13.


The selected main axis rotating speed shall be no more than ruled allowed max rotating speed in sheet 7.

Cutting speed (m/min)
Fig 13 Cutting speed calculating sketch
Sheet 7 Allowed max rotating speed of main axis under all process conditions

Hob with 1 head
Allowed max
Teeth
rotating
qty
speed
6
50
7~8
63
9~11
80
12~13 100
14~17 125
18~22 160
23~27 200
no less 250

Hob with 2 heads
Allowed max
Teeth
rotating
qty
speed
12~13 50
14~17 63
18~22 80
23~27 100
28~35 125
36~44 160

45~54 200
no less 250

than

than

Hob with 3 heads
Allowed max
Teeth
rotating
qty
speed
18-20
50
21~26 63
27~35 80
36~41 100
42~53 125
54~68 160
69~83 200
no less 250
than
84

Hob with 4 heads
Allowed max
Teeth
rotating
qty

speed
24-27
50
28~35
63
36~44
80
45~55
100
56~71
125
72~88
160
89~111
200
no less
250
than
112


28

55

Before the machine work for 600 hours, the allowed max rotating speed on main axis shall be 1 level lower than the lowest
value in sheet 7
This case is according to cutting speed Vcut=35mm/min, hob diameter D=70mm
Found in fig 13 the main rotating speed is n=160rpm, this rotating speed is lower than the allowed max rotating speed in
sheet 7, available.

(4). Calculation and adjustment on pitch gearing wheel
Calculation on gear wheel please refer to formula 1, 2, 3
If the hob is with single head, can select directly from attached list (I) (when over 250 pitches please calculate apart)
Allowed min processing gear of this machine please refer to sheet 8, however before the machine working for 600 hours,
the allowed min processing gear in sheet 8 is not allowed to process, the allowed min gear number shall be 1.5 multiples
of values in sheet 8.
Sheet 8 Min number of teeth that allowed to process
Number of hob head

1

2

3

4

Min number of teeth that allowed to process

6

12

18

24

Supplement of gear wheels as fig 14, when applying with right-hand hob, no use of idler, left-hand hob requires.
Rotating direction of hob

Right-hand hob

Left-hand hob

Supplement of gear wheels

Hanging with four gears as a, b, c, d A

Hanging with four gears as a, b, c, d C

Hanging with two gears as a, d

Hanging with two gears as a, d
D

B

Rotating direction of workbench

Fig 14 Supplement of gear wheels on processing straight spur gear
In fig 14, against Z36, gear A and B is idler.
This case shall install three-jaw clutch M1 (91-2010M) on axis IX
The process number of teeth is Z=46, bigger than the min processing number of teeth in sheet 8, so the gear wheels can
be found in attached list I as:
a=60, c=24, b=30, d=92
As it’s applied with right-hand hob, so the gear wheel shall be supplied according to fig 14 A.


(5). Adjustment on axial feeding vol
It can be adjusted according to sheet 2 based on the selected feed

S1=2.9mm / workbench per circle
S2=1.16mm / workbench per circle
Consulted from sheet 2 that gear wheel: a1=46, b1=32, installed apart on axis X IV and X VI.
(6) . Adjustment on knife rest distance of the crash piece position
When selecting down or up milling, the final position of knife distance shall beyond the cutting wheel as a suitable
distance.
On down milling, the knife rest processing distance shall apply the lower one crash piece (refer to fig 3)
On up milling, the knife rest processing distance shall apply the upper one crash piece (refer to fig 3)
(7) . Adjustment on fashioning
Adjustment on fashioning after rough machining includes the following aspects:
A. Adjustment on hob main axis rotating speed: same as adjustment on fashioning. 2 times cutting speeding in this
case are the same, so there is no need to adjust.
B. Adjustment on axial cutting vol: just need to change the position of shifting hand-stickier according to sheet 2. in
this case the hand-sticker position shall be moved to position 1.
C. Adjustment on cutting depth: on the position of rough machining, the manual workbench is approaching hob till full
gear.
D. Stop: when cutting is finished the machine shall automatically off, by then the axial shift-sticker shall be pulled to
“fast” position, apart move back the knife rest and workbench to original position.
2 Adjustment on machine when processing cylindric spiral gear
We would express by case as well
<case 2>: cylindric spiral gear: number of teeth Z=63, normal module Mn=3, helical angle β =20°
Rotating direction: right-hand
Applied hob: diameter D=70, number of head K=1, W=4°, rotating direction as right-hand rotation.
Cutting range: cutting speed Vcut=35mm/min, cutting depth H = 6.75mm
First hobing H1=5mm
Second hobing H2=1.75mm
Lengthways feed: First hobing S1 = 1.8, second hobing S2 =1.16, by up milling
(1) . Installation of machine: same as machining straight spur gear.
(2) . Installation of hob: installation and attention matters on hob is same as straight spur gear, Installation angle of hob
shall be decided by helical angle of workpiece and hob, and if it’s same as rotating direction. When the hob rotating

direction is same as workpiece, the installation angle is the difference between them. On the contrary, shall be the
summation (please refer to fig 15).
Installation angle of this case as: β - W=20°-4°=16°
Install by fig 15 (A)
Workpiece rotating direction
Hob rotating direction

Right

Left

Right

A

C


Left

B

D

Fig 15 Correct installation of cutting cylindric spiral gear
(3) Selecting and adjusting on main axis rotating speed is same as machining straight spur gear.
(4) Calculating and adjusting on gear wheels
Calculating and adjusting on gear wheels is same as machining straight spur gear.
When processing cylindric spiral gear, shall install three-jaw clutch M 2 (91-2009M) on axis IX. Due to the usage of
differential device, rotating direction of axis IX is changed, then gear wheel shall be supplied according to fig 16.

In fig against Z36, gear is idler.
In this case: install three-jaw clutch M2 (91-2009M) on axis IX
Process number of teeth Z = 63, bigger than the min processing number of teeth listed in sheet 8, can be processed.
The consulted gear wheel from attached list I shall be supplied according to fig 16 A.
Rotating direction of hob

Left-hand rotating

Right-hand rotating

Supplement of gear wheel

Rotating direction of workbench

Fig 16 Supplement of gear wheel when machining helical gear
(5) Adjustment on axial fee: same as machining straight spur gear.
(6) Calculating and adjusting on differential gear wheel: calculation on differential gear wheel when processing helical
gear please refer to formula 4, the +/- shall be decided by sheet 3.

Differential gear wheel shall be supplied according to fig 17.
In this case:
is supplied according to fig 17 A
When cutting helical gear, adjustment on other institutions of the machine is same as on cutting straight spur gear.