Flanx – The WFL gearing solutions

Flanx-Spline is suitable for the straight or even helical shaping of external andinternal gears. Conventional slotting tools are used here too, which can also beimplemented with prismatic clamp holders. The graphically supported programmingsimplifies use and achieves the same level of quality as special gear hobbingmachines.
The Flanx-Large Module (Flanx-LM) WFL gearing solution is designed to manufacturelarge, involute Hirth serrations. This highly flexible process using standardtools is compatible with small machines and enables both hard and soft machining.
Gear hobbing is used for straight and helical external gears (cylindrical or crowned).In addition, Flanx-Hob comes with "radius end", "conical" and "variable feed" specialsolutions. Flanx-Hob uses conventional gear hobbing cutters - either solid carbidecutters or with cutting inserts. Flanx-Hob is designed in such a way that it canbe used with any conventional gear hobbing cutter available on the tool market.Graphic support also simplifies programming.
Flanx-Gear Skiving is a hob peeling process for the highly efficient production ofshort external and internal gears with synchronised operation of the main and millingspindles. High cutting speeds allow for quick gearing production. This cycle istherefore an extremely useful application and ensures maximum productivity andefficiency in the MILLTURN. Flanx-Gear Skiving is used in many different industries– particularly in the automotive industry.
The Flanx-Invo cycle is the result of the collaboration with Sandvik Coromant (InvoMilling™ by Sandvik Coromant) and is used to mill the involute forms of toothflanks without an undercut. It is a flexible process that allows short machiningtimes to be achieved from a tool operating at a very high feed rate. WFL achievesthe highest level of machining efficiency here thanks to the application of Crash-Guard and CrashGuard Studio in process integration. This hybrid technology fromWFL and Sandvik Coromant also ensures the levels of quality of a gear hobbingmachine as a minimum.
Flanx-Measure is a complete software solution for scanning and measuring all relevantparameters, such as tooth shape, tooth thickness, pitch or concentric running.Essentially, all features that can be measured on a special measuring machine arenow also directly measured in the MILLTURN. The results are visualised and displayedon the control panel. They can also be printed out as a measuring protocol.The data is also used for feedback to the machine control. This enables tools to beoptimised and refined in order to achieve the desired and required accuracy.

Flanx-Measure under the microscope

From filigree internal gears with high accuracy requirements to large external gears that

require high roughing efficiency. Thanks to the extensive experience and development assets

it has gained over many years, WFL offers the right technological solution for every type

of gear cutting. Are you already making the most of our expertise in gearing solutions to generate

more added value in your company? The critical features when manufacturing gearing are high

quality standards, profile accuracy and machining solutions that offer both reliability and flexibility.

Flanx combines the development of software as well as hardware solutions for integrating

complete gearing solutions into a WFL machine.

The various WFL Flanx hardware solutions
The turning-boring-milling unit has a few additional functions that are essential for milling work. The tool spindle can be released from the spindle bearings and the spindle can be hydraulically clamped so that the bearings are not compromised during machining. This is a major advantage in terms of the durability of the bearings. The machine also features a cooled ball screw on the Z-axis, which prevents localised overheating.
The B-axis is also decisive when it comes to the manufacture of gearing solutions. The machine can index or clamp the B-axis and reaches an extremely high holding force. The MILLTURN therefore provides an extremely stable and efficient way of producing gearing with the B-axis. A further technological feature is the WFL prismatic clamp holder for gear hobbing tools. This prismatic clamp holder is hydraulically clamped to the underside of the turning-boring-milling unit by means of a special interface. This gear hobbing device can be used to securely and precisely clamp hobs with a diameter of 160 mm and a length of 254 mm, i.e. relatively large hobs. The hobs are clamped in the spindle of this device without backlash, which enables a faster changeover if the tool needs to be replaced due to wear.

 

As a pioneer in complete machining, WFL offers the following advantages when it comes to gearing tasks:

  • Comprehensive gearing expertise
  • Flexible and user-friendly gearing software solutions
  • Advanced, reliable and automatically exchangeable tool solutions
  • Closed-loop measurement solutions, including for gearing
  • Greater flexibility thanks to various machining options
  • Reduction in special tools
  • Reduced lead times
  • Better machine utilisation (special machines are often poorly utilised)
  • Higher productivity, minimally manned or unmanned shifts
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