Gear Tools

Liebherr-Verzahnwerkzeuge2

Gear Tool Product Range

Liebherr offers a comprehensive range of gear tools, many years of experience in gear manufacturing and maximum product quality. We are a reliable partner offering innovative development and best tool performance.

Our product range is in demand by customers all over the world. Liebherr offers not only tool calculations, design and manufacture for all customers but also outstanding after-sales services, including sharpening and coating of gear tools and also reconditioning of CBN grinding tools in our in-house electroplating shop.

Tools• Shaping cutters• Indexable insert cutting discs• Wafer cutters• Solid wafer cutters• Shaving cutters• Rack type cutters• Rolling deburring discs• Rolling chamfering discs• Calibration tools• Rolling racks• Rolling dies• Gauges• CBN grinding tools• Customized grinding tools

Services• Sharpening and coating• Reconditioning of CBN

grinding tools• Software• Component and contract

manufacture

Liebherr-Verzahnwerkzeuge 3


Shaping Cutters

We can look back on 50 years of ex-perience in the design, development and manufacturing of gear tools at our plants in Ettlingen and Turin. Through this continuity and ongoing develop-ment, our customers have access to the extensive technical knowledge of our specialists. In particular, this also inclu des developing solutions and special designs for all types of gears that can be manufactured by shaping processes in involute or non-involute profiles.

Shaping cutters are available as disc, hub, shank and internal toothed hub types. PM materials and in special cas-es high-quality hard metals are used.

Shape, designs and coatings are adapted and customised in accord-ance with the gearing requirements.

Various hub, disc and shank type cut-ters are available from our stock for dif-ferent modules and pressure angles. They can be delivered at short notice for standardised reference profiles such as DIN 3972, DIN 5480, DIN 5482 and DIN 8197.

If required, semi-finished disc type shaping cutters are available, from which we can manufacture express shaping cutters for special gearing tasks at very short notice. The express shaping cutters can generally be deliv-ered within 10 business days.

Indexable insert cutting discs are pri-marily suitable for roughing operations. Even with a tool change to a conven-tional cutting wheel for final machining, reduction in the overall gear cutting time is considerable.

Applications• Straight gear cutting• Gear cutting quality ≥ 9• Pre-cutting of gears

Versions• Disc cutting wheel• Bell-type cutting wheel• Shank-type cutting wheel• Module ≥ 4

Certified quality• Very durable• Long service life• 100% quality control

Indexable insert cutting discs


The wafer cutter is a coated one way tool, which represents the optimum tool status – comparable to a spur toothed shaping cutter. The thin, coated wafer disc is clamped in a special wafer holder and mounted on the shaping cutter holder of the shaping machine like a shaping cutter.

Advantages:• Maximum process reliability• Economical in mass production• No changes in the gear profile as a result of wear• Very easy machine adjustment (reduced setup time)• Fully coated tools always in use• Machine adjustment after wafer change not required during one series of workpieces

Wafer Cutters Solid Wafer Cutters

Solid wafer cutters are used when a constant gear work-piece profile is required and thereby reducing the usable tool height. Solid wafer cutters are available for any kind of spur or helical toothed gears with an optimum coating for each application. The solid wafer cutter has the same advantages as the wafer even when used with smaller batch sizes.

In special cases solid wafer cutters can also be manufac-tured with different toothed sectors for up- and / or down-stroke shaping processes.


Shaving Cutters

Shaving cutters are available for all standard gear-shaving processes in hobbed, preground or fully ground quality.

The following types and limit ranges are available:• Module 0.5 to 12.7• Helix angle up to 45°• Max. tool diameter 305 mm• Max. tool width 65 mm• Slotting: straight or spiral, also available with positive

front rake angle.• Root shape: milled or drilled

Grinding diagrams for optimum sharpening of the tools are optionally available.

Rack Type Cutters

Liebherr supplies all kind of rough-cutting and finishing rack type cutters that are required for manufacturing gears on suitable shaping machines.

This includes:• Standard and helical rack type cutters• HKR rack type cutters• Stepped rack type cutters• Single-tooth rack type cutters• Backing plates


Rolling deburring discs are used for creating chamfers on the teeth at both faces of the gear. Rolling deburring discs are available with an additional smoothing disc to minimise waste on the faces of the gear workpieces.

Different chamfering types such as:• parallel• comma-shaped or• parallel with chamfers at the root of the teethare also available with face-bevelled workpieces. The tools are supplied already presetted and can be used for chamfer-ing gears with the same gearing parameters and the same tooth width, if there is no risk of collision with the workpiece contour.

Economical use of tools is guaranteed with the option of reversing the rolling deburring discs.

When the wear limit of the rolling deburring discs is reached, the discs can be reversed and set up again in a very short time to re-use the tool.

Rolling Deburring Discs Rolling Chamfering Discs

Flexible rolling chamfering discs are used with the same workpiece gearing parameters and different tooth widths. They can be supplied in sets or with holders for a specific tooth width.

As with the rolling deburring discs, the chamfers on the teeth at both faces of the gears can be parallel, comma-shaped or parallel with chamfers at the root of the teeth.

The rolling chamfering discs can be designed for wet or dry machining. An additional coating extends the already long tool life even further.


Calibration Tools

Calibration tools are specially designed for calibration of synchro sleeves for the automotive industry. High accuracy in matching the individual tool discs to form a block tool ena-bles calibration of the synchro sleeves by broaching within very fine tolerances.

The calibration tools are supplied preset as block tools and can be used for synchro sleeves with the same tooth geom-etry. The use of special powder-metallurgical steels guaran-tees maximum tool life.

Rolling Racks

Rolling racks are manufactured for special customer re-quirements and are generally used for the manufacture of splines.

Rolling racks are available up to the following maximum values:• module 1,6• length 1500 mm• width 350 mm• height 90 mm


Rolling dies are generally used for manufacturing conical spline, such as for synchro sleeves with broached internal spline. They can be used as single rolling die, single rolling die in a dual model and as set of two rolling dies. Rolling dies can have one or multiple flanks depending on the requirements. The rolling dies are available with hobbed or ground teeth de-pending on the required gear quality.

Subject to special manufacturing guidelines, our rolling dies have the longest possible tool life.

Rolling Dies Gauges

Gauges are manufactured up to quality 3 as per DIN 3962 and are supplied with an inspection certificate.

The following gauge types are available:• Master gears• Plug gauge• Ring gauge

Plug and ring gauges can be supplied as Go and No Go gauges.


CBN Grinding Tools

CBN grinding tools are available as grinding worms and as profile discs with a galvanic CBN coating. The coating is customised for the specific machining requirements. The tools are primarily used for grinding involute gears with the highest possible quality requirements in mass production.

The following grinding worms are available:• Set of rough and finishing grinding worm• Monofinishing worm• Combination worm with profile grinding disc

The following profile grinding discs are available:• Roughing profile grinding discs• Finishing profile grinding discs

Maximum processing reliability in gear grinding is guaran-teed by highest precision during the tool manufacturing pro-cessed by our tool specialists.

Customised Grinding Tools

Profile grinding discs for:• Spline shaft profiles

Slot and surface grinding discs for:• Fixing and indexing slots• External cylindrical grinding

Cup-discs for sharpening of:• The stepped cutting face on helical shaping cutters• The conical cutting face on straight shaping cutters• Hobs


Liebherr after-sales service offers sharpening and coating of gear tools. Our satisfied customers are pleased to take advantage of this well-established service.

Trust the experience of the gear tools manufacturer also for sharpening and coating of your tools.

Sharpening and Coating of Gear Tools

Reconditioning CBN Grinding Tools

Highly qualified specialists will recondition your grinding tools in our in-house electroplating shop.

After incoming goods inspection, in case of new gear ge-ometry requirements the tool body is ground. This takes a very short time at very economical prices. Total quality con-trol at all process steps ensures a consistantly high quality of the tools.

ISO 9001:2008Our high quality requirements induced us to implement the international standards for quality management systems into our tool department as long ago as the 1990s. The benefits of this can be seen in the high degree of customer satisfac-tion and are highlighted by the success of our products in the market. Therefore, it is our goal to improve our quality management system continuously.


Gear-Cutting Software

WinKolliThe WinKolli program is used to check the suitability of the shaping cutters for specific gear applications. The features of WinKolli include:• Integrated database of the Liebherr catalogue of shaping

cutters• Free database for customer-specific gear workpieces

and shaping cutters (for maintenance by customer)• Pairing calculations of gear workpiece and shaping cutter

• Visualisation of gear workpiece and shaping cutter when engaged

• Rolling the shaping cutter with selectable immersion depth and feeds• Calculation of the actual profile offset for shaping cutter

and gear workpiece, optionally with the roll dimension, tooth width or tooth thickness

• Logical test routines for checking input errors• User-friendly Windows interface


XMThe XM program calculates all values of the standard tooth thickness procedures, independently of the initial size. The number of teeth of the base tangent length and the ball di-ameter for the over balls dimension can be selected as de-sired. Therefore it is possible to adapt the requested tooth thickness to the available measurement devices.

Tooth analysisThis program can be used to detect collisions between the shaping cutter and gear workpiece before previously the machining process and to prevent collisions by varying the tooth parameters.


Component and Contract Manufacture

As a service-based company in the field of drive technology, Liebherr-Verzahntechnik GmbH sup-plies complete components as well as a wide range of gears by contract manufacture.

Our practical solutions to problems are the basis for a long-term partnership. You can rely on the knowledge and experience of our competent team.

We manufacture using state-of-the-art CNC machines. Our delivery times are very short as a result of our in-house production depth and flexibility. Quality, on-time delivery and customer satisfaction are essential to our philosophy.

Liebherr-Verzahntechnik GmbH is ISO 9001:2008-certified.

Liebherr-Verzahntechnik GmbHWerk Ettlingen Verzahnwerkzeuge Hertzstraße 9-15, D-76275 Ettlingen +49 (0)7243 708-0, Fax +49 (0)7243 708-685www.liebherr.com, E-Mail: [email protected]

Liebherr-Verzahntechnik GmbHVerzahntechnik und AutomationssystemeKaufbeurer Straße 141D-87437 Kempten +49 (0)831 786-0Fax +49 (0)831 [email protected]

Liebherr-Utensili S.r.l.VerzahnwerkzeugeVia Nazioni Unite 1810093 Collegno TO, Italia +39 (0)114 248711Fax +39 (0)114 [email protected]

Liebherr-Gear Technology Inc.VerzahntechnikLiebherr Automation Systems Co.Automationssysteme1465 Woodland DriveSaline, MI 48176-1259, USA +1 7344 297225Fax +1 7344 [email protected]

Liebherr-Machine Tools India Pvt. LtdVerzahntechnik353/354, 4th Main, 9th Cross, 4th PhasePeenya Industrial AreaBangalore - 560 058, India +91 (0)80 41 273033Fax +91 (0)80 41 [email protected]

Machine Tools andAutomation Systems from Liebherr

Liebherr employs roughly 1200 staff in the area of machine tools and automation technology and has production facili-ties in Kempten and Ettlingen (Germany), Collegno (Italy), Saline (Michigan, USA) and Bangalore (India). They are sup-ported by expert and reliable marketing and service special-ists at a large number of locations worldwide.

High Quality Gear Cutting ToolsLiebherr manufactures high quality, precision tools for the soft and hard machining of gears and all Liebherr gear cut-ting machines are fitted with Liebherr tools. The range also includes Lorenz shaping tools and products customised for specific customer applications.

Automation Systems for a BroadRange of ApplicationsLiebherr has a wide range of products for linear robots, pallet-handling systems, conveying systems and robot in-tegration for projects in all areas of production and can provide above-average availability of systems.

www.liebherr.com

System Solutions in the Areaof Machine ToolsIncluded in the production programme are gear hobbing machines, gear shaping machines and generating- and profile grinding-machines, all noted for their high degree of stability and availability. Particular importance is attached to the energy efficiency of the machines. Gear cutting machines from Liebherr are supplied to re-nowned manufacturers of gears and gearboxes and large-scale slewing rings worldwide. They are in demand primarily from the automotive and construction machinery industries and also increasingly from the wind power industry for the manufacture of gears for wind turbines.

With over sixty years of industrial experience, Liebherr is one of the world's leading manufacturers of CNC gear cutting machines, gear cutting tools and automation systems. The company's innovative products are the result of pioneering ideas, highly qualified staff and state-of-the-art manufactur-ing systems at each of their locations. They are character-ised by economy, ease of use, quality and reliability in com-bination with a high degree of flexibility.

Prin

ted

in G

erm

any

by E

berl

BK

L

VT

Gea

r Too

ls_0

.5-1

2.16

_en

Sub

ject

to te

chni

cal m

odifi

catio

ns.

Liebherr-Verzahntechnik GmbHWerk Ettlingen Verzahnwerkzeuge Hertzstraße 9-15, D-76275 Ettlingen +49 (0)7243 708-0, Fax +49 (0)7243 708-685www.liebherr.com, E-Mail: [email protected]

Gear Tools - IP-Produkter

Documents

Transcript of Gear Tools - IP-Produkter