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It is usually machined on off-the-shelf cutting tools on standard multi-function machines. The goal is to produce highly flexible spur and helical gears in small to medium batches. 
Includes involute and non-involute profiles. The exact number of cuts depends on the gear size and the size of the tool used. 
When machining the cogging of the outer spur gear, the groove should first be milled along the axis of the workpiece. For subsequent cutting,
The gears need to be rotated slightly to coordinate with the tool's simultaneous radial plunge milling. The result is an involute curve shape by turning and milling. 
Figure 4A/4B
The InvoMilling method can be used to mill spur and helical gears using the dedicated milling cutter CoroMill 161 and CoroMill 162 (covering the modulus range 2-12).
By cutting the X-axis and the B-axis or the Y-axis and the B-axis, the cutting tool can be machined along the involute path. Therefore, the tooth profile change should be consistent with the tool path (not the tool shape).
The method of milling gears is both advanced and simple, and it requires a high degree of flexibility while achieving high productivity. Invomilling is the latest technology to change the situation when both high efficiency and versatility of production are required in gear manufacturing.
It depends on how a gear manufacturing company positions itself: “Many of the gears we process are manufactured according to the specific requirements of our customers. Customers can request to machine only one gear with specific requirements, or a batch of gears. A set of drive solutions. We most often deal with small batch production, ie processing 1-100 parts, but there are also orders for producing thousands of gears throughout the year. According to industry regulations, some products (especially involved in cars) All parts of the gearbox need to be delivered on time. We are a professional manufacturer of helical gears and spur gears, providing gear products for various industries."
So far, our main goal has been to provide customized, unique gear manufacturing tools for a wide range of industrial applications. With reverse engineering capabilities, it is possible to accurately determine how an worn, unknown gear is designed and then quickly manufacture it. Flexibility is part of our business philosophy.
However, versatility in production has always been difficult to combine with high productivity. The necessary flexibility means that every time you need to machine different gears, you need to use new tools, and each time you need to program the gear machine according to the new gear.
A new way to gain flexibility in gear machining is based on the innovative milling method of multi-axis turning-milling machines: the InvoMilling machining method. This is a series of processes developed by Sandvik Coromant and is being used in cooperation with companies such as Mori Seiki. Mori Seiki needed a way to replace the specialized, relatively slow, flexible gear manufacturing process that is currently the main application on the market. This innovative multi-axis solution is based on an advanced, yet simple-to-use cutting strategy. The strategy is to work directly on standard multi-function machines with off-the-shelf cutting tools that machine spur and helical gears instead of hobbing.
The new InvoMilling multi-axis machining method is a flexible production method for spur gears and helical gears by using standard disc milling cutters and standard special face milling cutters. By cutting the X-axis and the B-axis or the Y-axis and the B-axis, the cutting tool can be machined along the involute path.
InvoMilling is an innovation in the field of gear processing. This multi-axis solution consists of a complex and simple cutting strategy.
The InvoMilling method combines slot milling and turning and milling operations. The same tool can be used to machine gears with any helix angle.
Therefore, the tooth profile change should be consistent with the tool path (not the tool shape). Therefore, for this purpose, the car-milling machine is the ideal machine.
New methods are available on the DMG Mori Seiki NT machine. This multi-axis milling center is capable of simultaneous milling and turning. The flexible B-axis has a rotation range of ±120°. Thanks to the direct drive motor, high speed and high precision are achieved, and the indexing capacity is 0.0001°. It has been proven to significantly reduce machining time, especially at the same time. When machining a complex part with a shaft. Hobbing is a process performed on a machine tool and related to some other types of parts related to the gearbox. However, hobbing is not the best solution when producing many different types and small batches of gears.
Today, if a shop is or is planning to invest in CNC machines, InvoMilling software is a convenient option. Car-milling machines can be used to machine gears directly. We offer gear machining kits for a wide range of moduli, each with three tools for several modules. With these kits, it is easy to produce a wide range of gears, resulting in great flexibility to meet particularly stringent quality standards.
The InvoMilling method combines slot milling and turning and milling operations. The same tool can be used to machine gears with any helix angle, including involute and non-involute profiles. The exact number of cuts depends on the gear size and the size of the tool used. The InvoMilling method can take advantage of the high precision of modern machine control and CNC machine tools, as well as the precision of the cutting tool, so that it can process the precision gears and semi-finished gears required for fine grinding. Applying the newly developed insert material also allows for higher cutting parameters for optimum efficiency.
In this way, it is also possible to chamfer the outer diameter of the tooth teeth and to machine different lobes, tooth profiles and radii at the root. The cutting cross-section of each cutting action is small, and there is no such side pressure, so that the vibration tendency can be minimized.
For example, when machining the cogging of the outer spur gear, the groove should first be milled along the axial direction of the workpiece. For subsequent cutting, the gears need to be rotated slightly to coordinate with the tool's simultaneous radial plunge milling. The result is an involute curve shape by turning and milling. For larger moduli, more cuts may be required. For wider gears, the tool is offset in the axial direction and the cutting step is repeated.
Since each InvoMilling tool covers several modulo dimensions, the InvoMilling method reduces machining costs in small to medium volume production. For example, modulo 2-4 can be machined using the same tool, modulus 2-12 Three tools are available. To date, the maximum gear modulus milled by the InvoMilling method is 18 and the diameter is 800 mm, which has obvious advantages in terms of gear delivery shortening the delivery time and reducing the cost.
Modern indexable insert technology has made the new method a success. With the InvoMilling method, the quality of the gear teeth can reach DIN 3962 level 6 or above. In addition, on machines with sufficient rigidity, the correct application of the tool can achieve a better surface roughness than Rz 3 microns. The InvoMilling method, which uses precise tool paths and precision tools, produces competitively high quality gears. With this method, various gear grinding allowances can be generated. The low cutting force of this method allows for higher cutting parameters for cutting while ensuring the precise tooth profile required for small tolerances. These advantages are combined with the flexibility of this gear processing method, which is a factor in the success of the manufacturing methods involved.
The standard carbide inserts used in the milling tool are easily rotated one position outside the machine and are easily stored in the knife box. The InvoMilling cycle time of a gear with a machining modulus of 4-10 and a number of teeth of less than 30 can be compared to a single hobbing using high speed steel. Since many processes can be incorporated into multitasking, the gears can be machined in a single machine setup, resulting in shorter lead times and product replacement times, giving you the advantage of temporarily inserting products during the production process, facilitating a single piece. Flexible production of small and medium batch gears.
Therefore, even if the cycle time for manufacturing the gear itself is longer than the time for using the hobbing, the overall manufacturing time is shortened. Finally, since there is no need to wait for the time to manufacture a special tool, production can be started with only a new setup. With the introduction of InvoMilling, Sandvik Coromant has upgraded its technology to produce high-quality gears using standard-purpose machines, significantly reducing machining costs, increasing flexibility and significantly reducing lead times.