Super hard helical gear shape processing | Copper graphite and shape electric discharge machining
A twisted tooth shape is formed on super hard alloy G7. By using copper graphite electrodes in stages, we perform shape electrical discharge machining that corresponds to rotation and feed.
At Hanshin Seiko, we accept orders for helical gear (hassuba gear) shapes in carbide and complex tooth shapes for electrical discharge machining (EDM). The case presented involves machining a twisted tooth shape in carbide G7. Copper graphite was used for the electrode, and electrodes with side reduction allowances of 0.3mm, 0.15mm, and 0.07mm were selected according to the machining stage. The rotation of the electrode and the axial feed were coordinated along the twisted shape, managing the relationship between machining depth and tooth shape position. During finishing, care was taken to avoid interference with the tooth surface during oscillation and retraction movements, and the process was designed considering electrode wear and the discharge of machining debris. Even after electrode replacement, the reference for the center position and rotation direction is aligned to maintain the positional relationship with the tooth shape from the previous process. Along with drawings and 3D data, please provide information on material, hardness, number of teeth, module, twist angle, machining depth, required precision, surface roughness, quantity, and desired delivery date. We will guide you on the machining methods, including electrode fabrication.
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basic information
【Processing Conditions of the Case Study】 Workpiece Material: Carbide G7 Processing Content: Twisted tooth profile of helical gear Processing Method: Sinker EDM (Electrical Discharge Machining) Electrode Material: Copper Graphite Electrode Reduction Amount (One Side): 0.3mm / 0.15mm / 0.07mm Processing Accuracy during Rough Machining: ±0.025mm Surface Roughness during Rough Machining: Rz10μm / Ra1.4μm *The electrode reduction amount refers to the amount by which the electrode is made smaller, and it differs from the product's dimensional tolerance. The accuracy and surface roughness are values during rough machining for this case study. The requirements for final finishing and the feasibility of meeting them will be confirmed by reviewing the drawings, materials, and shapes.
Price information
This is an individual estimate for each drawing. We will confirm the details of the carbide material type, tooth shape, number of teeth, module, twist angle, machining depth, required precision, surface roughness, quantity, and electrode production to provide the estimate.
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Applications/Examples of results
【Processing Achievements】 Using copper graphite electrodes on cemented carbide G7, we formed a twisted tooth shape for helical gears. This is an example where three stages of electrode reduction allowances were set, and electrodes were selected according to the processing stage. 【Processing Services Available】 - Machining of helical gear shapes in cemented carbide - Formation of twisted tooth shapes that extend deep - Machining of complex shapes by combining electrode rotation and feed - Tooth groove machining that requires consideration for electrode wear and discharge of machining chips - Shape cutting electrical discharge machining, including the production of dedicated electrodes *This is a contract processing service based on drawings, not the sale of standard gears.*
Company information
Hansei Seiko Co., Ltd. is a precision metal processing company founded in 1948, based in Kobe City, Hyogo Prefecture. We offer integrated processing services centered around wire cut electrical discharge machining, shape electrical discharge machining, and fine hole electrical discharge machining, as well as machining, polishing, finishing, and measurement. We welcome inquiries for precision parts, mold components, jigs, test pieces, and more, whether for single items, prototypes, or small lots. In addition to processing hardened steel, carbide, and stainless steel, we also handle contour machining of thick parts, key grooves, fine slits, and complex shapes. We confirm material, shape, required precision, and application, and consider processing conditions and processes. This reduces the burden of arranging multiple processing locations and supports part manufacturing. Based on the principle of "making according to the drawings," we conduct inspections and measurements in-house to confirm the finish before shipping. Based in Kobe and Hyogo, we accept processing inquiries and quotation requests from across the country. If you have parts you are struggling to process or drawings for which you would like to consider methods and processes, please feel free to consult with us. https://www.hansei.co.jp/
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