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Machining gearboxes

1. Gearbox housing

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

2. Gearbox shaft

From soft to hard – stress-free steel machining

3. Differential housing

Contains the bevel gear set for wheel compensation

         

1. Gearbox housing machining
Silky-smooth gear changes, thanks to high-precision manufacturing

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 the tools from the CERATIZIT Group this means no compromises when it comes to cutting values 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. Gearbox shaft machining
From soft to hard – stress-free steel machining

Machining gearbox shafts requires a combination of factors, including state-of-the-art machines, sound expertise and advanced tools. Only when these come together can the stringent requirements of precision, tensile strength and surface quality be met. On top of this, the complex geometries of the high-strength steels and alloys make stress levels in production soar. Luckily, with tools from CERATIZIT, you can simply ride the wave.

1. ISO­-P indexable insert

Pre-machining with our new ISO­-P steel grade

  • Improved wear detection on the flank
  • Up to 45% longer service life thanks to our new ISO-P
    coating
  • Different grades available for individual
    cutting conditions
  • Three different grades for smooth, universal and
    interrupted cut
To product

2. Turning tool holder

Turning tool holder for our new ISO-­P steel grade

  • Wide range of different grades
  • High cutting speed and therefore very productive
  • Universal application and versatility
  • For maximum process security and reduction of the
    scrap rate
  • Greater stability in the tool holder increases
    process security even in difficult machining situations
  • DirectCooling for optimum tool life
To product

3. CBN HardCut

Finishing the hardened gearbox shaft

  • Quicker cycle time
  • Several machining operations can be carried out with one tool: longitudinal and face turning, roughing and finishing in a single operation
  • Three grades available
    CTBH1000 - straight cut grade
    CTBH2000 - all-purpose grade
    CTBH3000 - grade with interrupted cut
To product

         

3. Differential housing machining
Get ahead of the curve with smart tool solutions

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. Clever tool systems, however, enable high-precision production methods to be used – without much adjustment at all.

Whether you are working with special-purpose machines or machining centres, the CERATIZIT Group 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
To product

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
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