Automotive gears and their opportunities and challenges

The challenges and opportunities related to automotive gear business are discussed. More speeds translate into better fuel economy by allowing the engine to operate at its most efficient load point more of the time. There is also an increasing demand for all-wheel drive, which means more transfer cases with even more gears. Another change in the process itself is the move away from first hobbing a gear, then shaving it and then heat treating it. Hobbing is a multipoint cutting process that rotates both tool and workpiece in precise relations to each other. he push for environmentally friendly factories is adding yet another challenge for machine tool builders eliminating potentially toxic coolants. Star SU partner Samputensili introduced a new dry grinding machine in October, 2015, in response to the pressure to eliminate the mess and bother of coolants while grinding after heat treating. Called the SG160 Sky Grind, it features two spindles, one for skiving hobbing and the other for generating grinding. While engineered chamfers are important for weight, Liebherr has also developed a new gear grinding technology that improves fuel economy and NVH directly. Liebherr developed a generating grinding process that solves the complex machine movements needed to grind asymmetric gears. Perhaps the most exciting new technology for addressing NVH is Noise Excitation Optimization, or NEO, developed in a partnership with the Technical University of Munich. Machines that provide multitasking operations is another niche area of gear and spline cutting. Mazak is currently developing cutting processes for power skived gears and splines of all sizes and types, both OD and ID in either straight and angled teeth patterns.