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Gearbox

Houses all the individual parts such as bearings, synchroniser rings and gears

Contains the bevel gear set for wheel compensation

1. Machining gearbox housing

Six manual gears and up to nine in automatic transmissions are a common feature today. The gearbox is protected and supported by a housing consisting mainly of cast aluminium alloy, which is no small feat to manufacture. Ever tighter geometric and positional tolerances call for extreme care when designing the tool. Only the right machining concept can fulfil these stringent requirements. Tools with a long overhang often have to carry out several machining operations simultaneously, and in a manner that is process-secure. 
At the same time, minimum quantity lubrication is often used instead of traditional wet lubrication for environmental and financial reasons – with our tools this means no compromises when it comes to cutting data and cycle times.

1. Multi-purpose tool

Reaming and counterboring the selector fork group with minimum quantity lubrication

  • Reaming, counterboring and chamfering with a single tool saves on tools and reduces cycle times
  • Maximum performance despite long overhang length, thanks to dynamic balancing
  • Diameter can be precisely set via micrometre-precise fine adjustment

2. PCD multi-purpose tool

Reaming and fine boring the selector unit bore with minimum quantity lubrication

  • A combination of brazed PCD reamers and steel base body with indexable inserts that can be adjusted with micrometre-precision
  • Demanding machining due to high standards for geometric and positional tolerances
  • Maximum performance despite long overhang length, thanks to dynamic balancing

3. Boring bar

High-precision forward and reverse machining of the output shaft bore with minimum quantity lubrication

  • Diameter can be precisely set via micrometre-precise fine adjustment
  • VCGW insert for fine boring and axial groove
  • Maximum performance despite long overhang length, thanks to dynamic balancing
  • Forward and reverse machining to keep concentricity errors to an absolute minimum

2. Machining differential housing

The differential plays a key role in a car's driving stability. On corners, it compensates for the difference in speed between the inner and outer wheels. Machining the inner contour of a differential is an extremely difficult task. Sophisticated tool systems, however, enable high-precision production methods to be used – with very little adjustment. 
Whether you are working with special-purpose machines or machining centres, we will help you corner the market with the aid of our perfect tool solutions.

1. U-axis with snap-on tool

Internal turning of the spherical countersinks

  • Tools with fixed insert seats for machining centres
  • High-precision insert seats thanks to special production methods, i.e. no adjustment required after the indexable insert has been changed
  • Quick and process-secure
  • Tool cross-section optimised by FEM analysis for reliable machining
  • Reverse internal turning of the entire contour with one U-axis tool

2. Ball turning tool

Internal turning of the spherical countersinks with a mechanically actuated special-purpose tool

  • Tools with fixed insert seats for special-purpose machines
  • High-precision insert seats thanks to special production methods
  • No adjustment required after the indexable insert has been changed
  • Quick and process-secure
  • Rotary slide is driven by drawbar

3. Ball countersink

Sphere production through bilateral countersinking

  • Tools with fixed insert seats for special-purpose machines
  • High-precision insert seats thanks to special production methods
  • No adjustment required after the indexable insert has been changed
  • Quick and process-secure
  • Ideal for large quantities