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Radial dentation shaper cutter :
Radial dentation shaper cutter is a method that has only radial cutting but no
axial cutting. It is highly effective with respect to machining efficiency,
precision, bit endurance, economy, etc. It can realize the machining of
multiple gear that cannot be done by axial dentation shaper cutter. In
1700K1-141 radial dentation shaping experimentation, while axial shaping needs
2.1 minutes per piece, radial shaping needs only 34 seconds; while axial
shaping reaches grade seven and a half in precision, radial shaping can reach
grade six; this process experimentation successfully marked the advancement in
process of the Gearbox Company.
Radial shaping cutting bit :
In radial shaping cutting process, radial shaping cutting bit contributes
critically in improving efficiency, precision, and endurance; the breadth of
the bit is larger than the working breadth of the part. In whetting the bit,
the dentation and its direction are modified, therefore the workbench does not
move repeatedly to feed but only feed radially along the main shaft, thus
greatly enhancing the machining efficiency. The reduction of the dentation
error direction error, accumulated error, and dentation ring radial jump error
is guaranteed by this high-precision bit. The comb-shaped cutting edge of the
bit is arranged in such a manner that along the circular direction the cutting
edge is arrayed orderly in a spiral way, the front part of the cutting edge is
perpendicular to the bit's dentation face, resulting in a better cutting
outcome. The residue on the work piece's dentation face is gradually offset by
the spirally arranged cutting edges, with each cutting edge's workload evenly
distributed. Therefore the friction is evenly distributed as well, resulting in
a longer durance.
After each whetting, the axial shaper cutter bit can machine 1000-2000
workpieces; the radial shaper cutter bit can machine 8000-10000 workpieces; an
axial shaper cutter bit's endurance is 6000-7200 workpieces; however the radial
shaper cutter bit's life is 48300-60000 workpieces.
The promotion of the application of radial shaper cutter bit will bring new
drive to the Gearbox Company.
Roller bit deep cold treatment:
The deep cold treatment after quenching of the gear roller bit help change
further the metal phase structure of the material; after quenching and
tempering, 6-8% of the residual Austenite will be transformed into tempering
martensite , meanwhile large quantity of tiny carbite (less than 0.2μm in
diameter) will result in dispersion manner; its existence greatly improves the
bit's friction resistance and life. After deep cold treatment, the roller bit's
life is extended by 60-100%, and after re-whetting its life is extended by
60-70%. This process especially is suitable to precision machining bits, such
as reamers, broaches, tap, and shaper cutter bit. Besides, the cost of deep
cold treatment is only 30% of a new one. Gearbox Company is striving to improve
the life of its machining bits and to cut bit consumption.
General-purpose loading cart:
There are numerous types of onsite loading carts. Every part has a categorical
cart with extremely low commonality. In loading and unloading parts, collision
often occurs, thus greatly affecting the product quality and becoming a bottle
neck for improving product quality. Gearbox Company looks at this problem as
one of the priority jobs and endeavors to improve continuously in designing and
manufacturing such carts. The carts' features include: a common usage among all
parts and adjustable hinging shaft distance according to the size of parts;
avoidance of collision among parts; trimness and neatness on the site,
usefulness in civilized production and improvement on product quality.
Compound material airproof paper gasket :
In airproof sealing of the lid and backgear lid of the gearbox, ordinary
asbestos-based paper gasket is used; because of the inferior process structure
of the lids, after assembling, fuel leakage often appears, thus greatly
infringe the product quality and corporate image.
The common practice now is adopting injecting, heated mould pressing, and
pressing shaping process in making compound material airproof paper gasket,
which, compared with ordinary asbestos paper gasket, has better process
structure, sealing result, and ease in dissembling. In grinding experiment, its
endurance was found to be better than ordinary asbestos ones, fully satisfying
the requirements of the products.
With respect to pricing, compared with ordinary asbestos gasket, it requires no
more investment; while the sealing results can be greatly improved in terms of
quality, and the leakage problem is eliminated.
Therefore, we have been using it since DF5S450 series, gradually extending the
usage to DF6S600 and DF5S900 series toward a total coverage.
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