Precision tools & clamping technology

Field tests have clearly shown that the mathematical mastery of the process and the coordination thereof to tool and machine is the key to success. This was proven during customer trials. - Two to five times faster than gear shaping - One to two quality grades better than gear shaping - Excellent single indexing quality at the workpiece - Tool life similar to gear shaping - Available tool designs: conical and cylindrical - Process-optimized tool design - Tools available in PM-HSS and carbide (also with indexable inserts) - Dry skiving possible - Pressure angle and lead modification possible

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

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. Various chamfer versions such as: - Parallel, - Comma-shaped or - Parallel with chamfers at the root of the teeth are also available with face-bevelled workpieces. The tools are supplied already presetted and can be used for chamfering 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.

Shaving cutters are available for all standard gear-shaving processes in hobbed, preground or fully ground quality. Grinding diagrams for optimum sharpening of the tools are optionally available. The following designs and limit ranges can be realized: - Module 0.5 to 12.7 - Bevel angle up to 45 - Max. Tool diameter 305 mm - Max. Tool width 65 mm - Grooving: straight or spiral, also available with positive rake angle - Foot shape: milled or drilled

We can look back on 50 years of experience in the design, development and manufacturing of gear tools at our plants in Ettlingen and Turin. Through this continuity and ongoing development, our customers have access to the extensive technical knowledge of our specialists. In particular, this also includes 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 cases high quality hard metals are used. Shape, designs and coatings are adapted and customised in accordance with the gearing requirements. Various hub, disc and shank type cutters are available from our stock for different 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 delivered within 10 business days.

Solid wafer cutters are used when a constant gear workpiece 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 manufactured with different toothed sectors for up- and/or downstroke shaping processes.

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

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 depending on the required gear quality. Subject to special manufacturing guidelines, our rolling dies have the longest possible tool life.

Rolling racks are manufactured for special customer requirements and are generally used for the manufacture of splines. Rolling racks are available up to the following maximum values: - Module 1,6 - Length 1.500 mm - Width 350 mm - Height 90 mm

CBN grinding tools are available as grinding worms and as profile discs with a galvanized CBN plating. Whereby the plating is customised for the specific machining requirements. The tools are utilised for the grinding of mainly involute gear profiles with the highest quality requirements, specifically in batch production. The highest safety during the gear tooth grinding process is guaranteed by the greatest possible precision in the gear tool manufacture through our tool specialists. Liebherr offers all customers an excellent after-sales service. Liebherr re-plates the CBN grinding tools in its in-house electroplating facility. The following CBN grinding worms are available: •Roughing and finishing worm •Mono-finishing worm •Combination worm with profile disc

CBN grinding tools are available as grinding worms and as profile discs with a galvanized CBN plating. Whereby the plating is customised for the specific machining requirements. The tools are utilised for the grinding of mainly involute gear profiles with the highest quality requirements, specifically in batch production. The highest safety during the gear tooth grinding process is guaranteed by the greatest possible precision in the gear tool manufacture through our tool specialists. Liebherr offers all customers an excellent after-sales service. Liebherr re-plates the CBN grinding tools in its in-house electroplating facility. Aside from involute gear profiles and spline shaft profiles, CBN profile grinding discs are also used for external and internal gear teeth. Liebherr supplies the following CBN profile grinding discs: •Roughing profile grinding discs •Finishing profile grinding discs •Special applications on request

CBN grinding tools are available as grinding worms and as profile discs with a galvanized CBN plating. Whereby the plating is customised for the specific machining requirements. The tools are utilised for the grinding of mainly involute gear profiles with the highest quality requirements, specifically in batch production. The highest safety during the gear tooth grinding process is guaranteed by the greatest possible precision in the gear tool manufacture through our tool specialists. Liebherr offers all customers an excellent after-sales service. Liebherr re-plates the CBN grinding tools in its in-house electroplating facility. The special versions of our CBN grinding tools include: •Groove and surface grinding wheels (for fixing and positioning grooves and external cylindrical grinding) •Cup discs (for sharpening cutting wheels with stepped or chisel edges as well as hob cutters)