Gear Shaving Machine Model Y W423?
YWA4232
Packing List
Max. dia. to be cut: (320 mm
Max. module: 8 mm
Serial No.:
g Erjichang Machine Tool Co., Ltd.
Nanjing 210004, P.R. ChinaPacking bist
PACKING
sor
ane ; Wy,
GEAR SHAVING MACHINE MODEL H¥,232
Max. dia. of workpiece
Max. module
Serial No.
Case No. wn
Case dimensions (ixWxi) 212%190%280
Net weight, approx. 14900
Gros’ weight, approx. 5600
Designation Specification Placed at
nal fa
Gear shaving machine Mosel Tw423 in wooden
Ciiiose) cane
Workpiece positioning Ywu232.91001 fixed on the
seals” nae : totter
workpiece carriage va2s20-91002 rountes on
ss a 320-9 sount
Change gears tn=344=22,25,29, in ace. box
ie 33,37 81,85 48. at leftside
£28253°94201 to of coluse
reaa32-91208
Hoisting stub wwti232-91209 mounted on
Botton
aitto
Spindle filler ring 42520-91209 to
10252091012
thickness: 7.5,
Socket spanner 291213 28ww
70
a
2
%
14
6
”
18
YW 1232
Now
Designation
Double-end open spanner
aitto
Single-end open spanner
ditto
Hex key
Ring nut spanner
Dial indicator
Foundation bolt
Claes tube fuse
Change gear
aiteo
ditto
ditto
stto
aitto
aitto
aitto
aitto
aitto
aitto
ditto
aitto
aitto
aitto
aitto
aitto
aitto
aitto
ditto
Packing List
Specification
orf
17x19 892=7
22x24 89° 1 pee.
40 301-1 1 pee.
44 891-2 1 pees
5,6,8,10 991-7 | pos.
78-85 893-1 1 pee.
#60, 007 4 pees
NeoxW00 J23-8 | 3 pair
250", 24 7 pes.
5x1 .5x20/82021~1
2x1 .5x20/82021=1
3ox1.5x20/N2c21=1
35x1.5x20/N2021=1
Ox1 .5x20/82024~4
act 5x20/892021-1
4Bx1 .5x20/82021=1
521 .5x20/N2021—1
5Px1 .5x20/2021~1
2x1 .5x20/12021-1
65x1.5x20/112021-1
69x1.5x20/112021-1
2x2. 5x 30/1202.
28x2.Sx30/N2021-1 1 pee.
35x2.5x50/N2021~1 1 pee.
38x2.5x30/N2021~1 1 pee.
42x2.5x30/¥2021~1 1 pee.
Bupx2.5x30/92021-1 1 poe.
B52x2.5x30/¥2021-1 1 pos.
B55x2.5x30/N2021~1 2 pos.
Placed ot
in ace, box
at lertesde
of column’
aitto
aitto
aitto
aitto
aitto
ditto
mounted on
‘potter
in ace. box
at lertesae
of column
ditto
ditto
ditto
ditto
aitto|
ditto
ditto
ditto
ditto
ditto
aitto|
aittol
ona/e, ene i
Been bax’
ditto
aivto
vox
ditto
ditto
ditto
one in ace.
Box, one is
zouived on’Biysese Packing use
39. Operation Hanual
Test Vertiticate
facking List
40 Operation Hanual for
programable controller
each oneMachine Tool Co.,
hi, Shuixi
eeOperation Nenual
I, Application and Peatures
Technica! Specifications
IIT. Bransportation and fnstallation
IV, Main Parte and Control protect
4, Main >
2, Control Protection on Machine and Hunc|
Control Eletient
3. Operating Cycle of Machine
1, Mechanically Briving Systen
2), Parallel or Underpass Peed
3)+ Plunge Feed
ectric System
+ lydraulic System
Lubricating and Cooling
+ Sevting-up
4. Mounting of cutter
2. Adjustment of Crossed Axis Angle Setween Cutter and
7-3
75
workpiece |
Mounting of Korkpiece
+ Adjustment of Radial Feed and Micro-feturn of Cutter 7-7
71%
Set-up Length of Morktable ravel
Selection of Cutter Speed
Selection of Worktable Travelling Speed
. Boleetion of Plunge Feet (only for Ywaun32)VIIT, Arrangement of Rolling Be
TX. Ligt of O11 Sealers
&. Let of Eagy
Operation Manus!
Relationship of Noving Di Cutter and
Shaving Shoulder Gear
Set-up of Diagonal Shaving 728
Set-up of Undexpase Shaving 2227
Set-up of Plunge Shaving (only for Ywi4232) 7-28
owning Shaving
Tapered Gear Shaving
XI, Appendix T: Electric Blenents List at Ditterent a4
Vo tageantxorear
Operation Manual
I, Application and Features
The gear shaving machine ie used for the gear Finishing.
Except that the clamp of the workpiece and the radial feed
are controlled by the hydraulic, others movenent
machine are driven by the mechanisnss such as: the feed of
the worktable and the radial feed of the cutter head
fare controlled by the free-vacklash pro-joad ball screw
devices the eutter-head and the taileto¢k are equipped with @
high rigidity bearings: the conical rotor braking motors are
used a8 aain drive motor, longitudiel and radial feed
motors; the programable controller ia supplied in the electrical
syste. It is suitable for batch and mass production in tractor,
eutonobileynachine tool and general industries,
The radial feed is carried ou: by the cutter slide. The
operating principle of the machine is baded on thet the gear
ie generated by a dise-type cutter whoee hixis intersects vith
the axis of the workpiece at 2 setting anjple. The main festurce
ure as follows!
1. Hor Model Ywii232, Three aitferent shaving aodes are
provided for the machine, they are paralipl(axial), diagonal.
underpsss( tangential) sheving mode.
‘or Model YWAK2%2, four different| shaving modes are
provided for the machine, except the above mentioned three
shaving modes, the plunge shaving mote tan'be used on the
nachine.
2, The machine is normally arranged to operate on a semi-
auto operating eycle. Only when load a wotkpiece on the carriageration Hanual
Bes, Soci,
DS ast cate sienis: veep Sac
3. when the ¢ “0 ing flopted on the machine,
i ae
‘or the adjustment
faved.
be Stopped at a fixed position, te.
t any Selected position. at aane tine,
‘pass number can
be pre-selected.
6. the clamp of wore find the radia. feed are controlled
2)
oe Fougbing and finishing functien,
| of the worktable gan be sutamaticslly
changed to perfora Wf and Tinishing shaving operetion
during ai operating }
8. The cutter can be micro-returned back before the last
Hing accuracy and to eliminate
jrnagnetically.Morkpiece
Maximum 0.D
Maximum module
Swivelling angle o:
Range of the travel angle of worktable
Range of cutter speed (@ steps)
Benge of vale! fecdlah yaketie (15 af
:
Radial feed
er alin)
cutter I
Max. 00D
Diameter of bore
“Motors
Nain motor
55 to 270 rpm
12 to 300 mm/ni|
8 to 190an/aia|
5 KW, 1880 rpm
Longitudinal feed motor 0.5 KW, 1300/850 rpm
Radial feed motor
Hyarautie motor
0.8 XW, 1380 rpm
0.55 KW,1500. rpmCooling motor
Hagnetic axart
Overall dimeneions i
Length
widen
Hien
Net weight, approx,
a
41500
Pee
1555
9720 a‘be hoisted in a manner ap shown in F:g.2.
erted into the hoisting
mo hoisting
suitable places to
hole located at
stubs are inserted
1¢ bed (accessory
alance as 1ifting.
e that no ateel vires
faces or vulnersble
be used in the
om damage.
the mahtay/igi@eihelgrestealon'n covcrate. coudation,
the depth of which depends on the soil vearing capacity,
but not teas than 400 ms.
The foundation plan is shown as in
is installed on’the adjustable iron wedge:
the level of the machine can be regulated
down the Bolt mute.
Clean all machined surfaces with ker¢
rust-proof 011 and then coat with 1ubri
Be sure to understand ali’ requirement
ial before starting the machine.
[g-3- The machine
+ through which
and then serew
sone to got rid
jeating oil.
"3 in the operation5 }
7 |
jv
ae — i —__] Le
Pig. The Hoisting Diagram of Machiegran of machine
g
&
a
&Teese i Operation Manual -
peu vosorves holes depth
Power inlet rte Toman” “Eo9
volte
Note: The depth of foundation depents on the soil
bearing capacity.
Fig.3 Foundation plan4232 Operation Manual
IV. Main Parts and Control Protecting Devices
(A), Main parts on machine (refer to see ¥ig.4)
a. Bed
he bed is a solid casting body. ‘he column and the
worktable are mounted at the top of the bed. The longitudial
feedbox ie fixed inside the front chamber |and two square heads
(95,28) for locking the worktable rotating disk ie arranged
above the door. The cooling system ia mounted leftside chasber
and oil distributing plate in righteide chanber; hydraulic
device in the middle part of rightside of the bed; magnetic
owarf separator is fixed at the rear of the bed and the bo:tor
ie divided into two parts aa the hydndulic 031 and coolant
pools.
2. Coluan
The vertical guideways is locased |at front of the
coluan for mounting the cutter slide, on Tight and left sides
there is an electric control panel. Hain drive gearbox , main
notor (4), radial fendbox and radial feed potor(5) are mounted
st the top of colunns the change gears (42) and oft diatriiutor
(#1) aro put Snoide the left chanber; the plecteic terminal
box is set at the rightside ‘chamber and the electric control
device is mounted at the bacRéide of the column.
3, Cutter headstock and slide
Cutter headstock is mounted at th¢ low part of the
slide and connected with the slide by meas of' four boltsOperation Yasual
Te cutter head can be rotated by loosening the four
volts for adjusting the rotating angle of the cutter heads
The slide ie mated with the vertical guideways on the
column and the backlash between them is adjusted ty throurh
2 Jib. The radial feed of the cutter is controlled vy the
trip dogs (29) on the control diek (16). The radial feed can
be altered by adjusting the distance bewtten two dogs. Right
up the handle (30),on the utter head | and turn the square
head 18, the cutter alide cen be moved up and down. As the
handle (30) is put down, the power radial feed and poverly
vertical adjustment of cutter head can be carried out.
Bofore the manual and power adjustments are performed, the nut
(7) must be loosened.
4, worktable
The worktable consiste of table qurface, slide
guideways, ball screw pair, rotating disk |and crown shaving
device, ete. The rotating disk 48 mounted |in the positioning
hole at top of the bed. loosen the locking square (24,35) and
crank the bundle (34), Uherolating disk dan be wmivelled
fron -5° to 90 and the rotating valve ean be read out from
the scale disk (23), which is ased to determine the travel
angle in the diagonal shaving. Two locking equare shafts( 24,35)
are used to control the rotation of the roteting disk. The
movement of the slide of the worktable is |ariven by the ball
screw along” the guideways of the rotating |disk.
fe guideway
surfeces of the worktable slide is inleied with the plastics
and with steel to improve the wearability And vo reduce thew
at232 operation Manual
friction resistance force for avoiding the creep of the work=
table.
Thé worktable ie driven ty the ball screw for eliminating
the backlash and ensuring the stability of the movement of
worktable.
The tooth crowning device is fixed at the lett end of
the’ worktmble- According to the calculated) value from the
crown adjustment calculating formula. The tooth crown value can bel
adjusted by turning the handle 48, The tooth taper value cen be
obtained by turning the equare head 47. Before the tooth crown
and taper attachment is adjusted , the locking bolts must be
Loosened first; after the adjustment has been done, then tighten
in. for the detailed information, see the sections 14 & 15
in Chapter 7.
‘he movenent of the worktsble is driven by a conical rotor
braking motor which is fixed at the leftsige of the bed. The
travelling length of the worktable ie contfolled by the trip
dogs on the lon#itudial feedbox control disk. And the travelling
speed is set-up by the change geara.
5. Head and tailstock
The head and tailstock are separately fixed on the
surface of the worktable by T-type bolts, Uke quill in t)
tailstock can be axially moved and operated by the hydraulic
For clampingvand unclanping the workpiece.
6. Magnetic svart separator
Magnetic swarf separator consists of the worn-type apsed-
reduce gearbox and magnetic drun. The magnetic drum is equippedBi ease Operation Menuet oa
the permanent magnet blocks. When the cooling liquid flow
‘through the magnetic drum, the svarf in the coolant will be
attached on the rotating drum and collected into the chips
box by the action of the scrapor.
2. Longitudinal feedhox
The longitudial feedbox ie mounted at the front part
of the bed, which is used to ensure the travel and the direction
exchange of the worktable.
Additional, main drive gearbox, radial feedbox are fixed
at top of the culonn.
(2). Functions of control protecting and operating el
ents
The positions of operating, protecting and controling
elements are shown in Fig.4, the function of each element
ie’ given in the Table.
(3). Working eyete
fe semi-automatic operating cycle can be carried out
on the machine, the procedure of the working cycle is shown in
‘hen the machine is in the set-up case, the every action
on the machine say be separately done.xoqpeos
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Operation Manuel
dn-208 some
poageas oq s0uuss ot0ko
Tpeddoge st ston:
(330)
duwyo soetdysom 0s A
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4032
pea
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posenion af yoaTae
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Arprdex eq trys 7e33R9
nubs cite warns start
Tasuenom Se0ad eTqet3I0K
ww
aes -OTSAS _OINeR TONS _T
worseesreedIperation Henual
The opersting and controlling elenents in Pig. are
deseribed 28 fella 2
presgure rela
Grertlow val
Sorepiece
saaial Feedbo
face
rpase travel
Snipa box
charge gears
rutin feed
tak
aoe
sing angle of custer
of crowning device
angle
dual-speca co or brak eateietarelrapid-opeed
yar [radial ings
Dress a
BAS
h mein wotor Feveracs,
ee ee
Tranaveras ator
is stopped
L FeRToRe BIGTo=
Eeture
Taedoor
uncleap work-
iece’
(atop hydraulit_m
el
Fig.5 Semi-auto ope:
cycle frame diagram
Geno)Nester
Byazze Operation Manual
V. Driving System
(2). Heh
ical driving eysten:
For %W4232, please refer to see Fig.6a; for YaA 4232,
see Fig.cb).
4, Main driving:
The cutter spindle is driven by @ conical rotor
braking motor Hotel ZD,31-8,which is fixed at top of colum,
via a flexible Joint, gearbox, spline shaft and several gear
paire. Cutter spindle
be obtained 8 kinds of speeds by
change-the ratio of change geare a and bj and the rotetin
Girection of the cutter is controled by electric motor.
The formula of cutter apeed is given as follows:
Righig 2, M05 40,25) Bt tin A ope
36°B 29° 40 ue 26) 34 B
ble. cue
2oe ea BB wm 45 [a
4g 45 41 37-33 29s | 22
speed
3 70 «90 0 10 175205By aore Operation Manual
2. Longitudine) or tangential (parallel or underpass) feed
The longitudinal (or tangential) of the worktable is
riven by @ dual-speed conical rotor motor mounted at the
side of the ved, via a coupling, gearbox, n bevel gear pair,
‘and the ball corew. The travelling direction of the worktable
and the speed change from the roughing shaving into finishing
shaving are controlled by means of the electric system. The
travelling length of the vorktable is controlled ty means of
the adjustable trip dogs fixed on the contirol disk.
The travelling speed of vorktable is as follows:
v = 10,1 ey My 20,22 yg. | yt yAt an/nin.
30 “a2 “2 B40" 36 seu f "Bt
Ae the maxinun travel of worktable is 90 m=, the swiveled
angle of the travel contro! disk is as follows:
60% 22 x H xt, Wy L - agp?
22°20 31 56
The Travelling Speed of Worktable (mz/ain)
a2 62 24 2 =
ay We 30 |
2025
125
80
in Table, ¥ the travelling speed of worktable in the shaving,
¥ the travelling speed of wprktable in the free-
pass.Batese
3. Radial feed motion
Bot Katiat food mot for Hoter Yu4232
he wadial feed motion is driven ty @ conical rotor
-notor fixed at top of the coluan. The radial feed can be
‘controlled ty seane of the adjustable trip dogs. Tho cutter
fed up oF down by |turning the equare
head at the end of the control disk.
Hedial feed of cutter is calculated Aeconding to the
formula,
Voagiar * 1380 *
Me scale valye for one round of radial feed scale disk
Bio en ine *
axUetze - 0.65
i" * a * 50 4
e oe
3.2 Radial feed sotion for 1 wa4232 |(piunge-cut shaving)
3 The radial feed motic 8 driven by alconical rotor
sotor fixed at top of the coltum. The radjel feed can be
controlied by manna of the adjuatable trip doge. Te cute
sige can be sanuelliy car Fr dots Bhnbeaing the
squats heui at the ai af ie
|
41380 x 1x28 x 4 x6 = 3,75 n/ain.
ue 35° 50°
control dis
x B= 0,616 x &Way
W nase
Te seale value for one round of radial
feed
enle diskRe
+ - yp Ae
va_ | oi
ener ey ia ee sien as
Pee eae i 4 Ay pare re ped yet (£2
:
bpd 1, fb
: +t
eRe ee oo — a
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pA Ae0 rel Ace yp set »
ie mead
Ley aze pacer ‘Ox
L al : a te 4 ae yaa Ou
b 424 4
ji zg sy el 20.
4 #2 — $4 2 —4- ae eee a id
ee + caaiaalt Na |
2 pee yp nee hee A2o_, Ried 1t ye her Yo
pte p oon
ras Hee(1D) Hectric system
4, Designation and function of sete:
| the control panel are described as foll
8A1, manval/semi-autonatic eo ae ewiten.
SAD, mumber of free-pasa selector
SAB, clanb/conventional shaving aodp selector switct.
GAe, worktable positioning atop seipctor axiteh-
ee es aa
switens i
ie
Ske, tailatock advance/withdray selector switch.
Sk?, cutter side moving up oF down selector avitch
Sho, vorntanie en/ett selector 9
S49, cooling pusp on/off selector a
S70, Roughing /finishing shaving 8
For 1440232
19, plunge/paralielin, dingoned
underpass shoving
selector switch
SA11, cooling pump on/off selector avitch
ie
2, Proceduse of seni-nute operating
For parallel, aiagonéal and tangential shavings:
Agoume that the worktable has debn stopped at the
aoe Se) a
apanist the linit eiteh S410.
Press down the pushbutton “SI __ the hydraulic
notor M1 will be started. 7
Put the workpiece on the carsiage ___ close the
guard door ___ the centre in the tailetock will automaticallyOperation Manust
‘Advance and hold the vorkpiece ___ pres
actuate,
the right in the cutting speed ___
started ___ cutter is sterted in c.ow.
‘tovand the ripht in lov spead ——= workts
nut twice (or 4 tines) fra0 pansen, bere
“As perforsed, the cutter head will automatically withdraw
‘and loosen the workpiece __ take out the| workpiece __ ‘tte
eutting cycle of a vorkpiece is finished,
Plunge shaving:
Assume that when the machine is started, cutter is exectly
jorktable are
centered with workpiece ant the trip dogs 0
ie i
ut the workpiece on the oe
door6
Sorew on the sliding block
paint
Cam roller wine 7 point
Fig.? Lubricating points
arrangenent of machineOperation Manual
sutton "SB5" cutter, cooling pusp and magnetic
fare started; cutter head rapidly approach toward
cutter head continuously radial infeed in a
{ th11 redial feed hes been finiehed ___ etay for
cutter reversely rotates ____ stay for seconds
cutter head is micrereturned 0.0% ma et this
utter head will stay for seconds kgsin for doing
- shaving ___ cutter head will sutonatically return
fe original position in the rapid speed __ cutter,
stop working ___ open guard door
and magnetic separator 7
ida <|
contre in the teilatock will eeatiy witharay
minautomtic
long in the set-up
Gadd da pet in
heir function.
) and SA9 (For
45 before the seni-auto
hould be put at the
fhe remi-anto
y chapter " Set-up"Operation Manual
3. Others
(A), Put the selector switch "Semi-auto/Manusl" at the
position "Manual" and the tailstock selector switch at the
Position "Advance", then separately turn the correspondent
selector switch, the cutter, worktable, cutter head, cooling
Pump end magnetic wart separator will be) started
The advance and withdraw of the tailstock|/can be
controlled.
(2), The electric system ie provided
protections, such as:
G
Hydraulic produce-less protection
workpiece clamping protection) (SP1); cutter head
vertical movement overtravel protection (S93); vorktable
Feciprocation overtravel protection (Sg); radial feed
overtravel protection (839); workpiece holding protection(S42);
the machine can be started only wnen the guard door is closed
(8Q1); interlock protection between :
smidauto” ana "nanu
The machine cannot be started
sn arranging the change gears
(SQ17 & 6015); underpass shaving overtravel protection (S4i4,
Sqt2 ); overlond and short-circuit protection for all motors
fend grounding protection for all wotors ail) ie electric
elements.
(3) During the semi-auto operating cycle, pre
the
Pushbutton "Cycle stop", the aachine will stop by the way
Gineluding the radial feed control disk will return bs
the original position). When the button "Uycle start” is
again, the semi-auto operating cycle can be re:
varted.
‘The functions of every Iimit switch is listed in the
the electric element.Wvose ogra al taal
Ay Notice
(2). Me voltage of AC cur:
wnt for all notors and the prinery
Winding of the control transformer is rated at 380V/220¥,for
contactors and relaics at 220V/100¥, for working lamp at 2tV,for
indicating lamp at 6.3 V; for cycle indicating lamp and the
electronagnetic valves at 10 24v.
(2). Te machine fs equipped with a terminal tox for pover
supply. The power-supply lin:
and ground |yire must appropriatfy
connected to the terminal in the box according to the current
technical safety regulations. The running direction of xotor
i ghould be in keeping with the sign marked on its housing.
if necessary, the power lines should be re-connected.
(3). Before starting the machine, an electriccian should
be appointed to clear up carefully all electric equipments,
end check for the connections, dap or damage during the
transportation.
(). Blectric equipment is mounted in‘d niche at back of
the column. During the operation, do not allow to open the
cover. The nain switen QF1 should be turned off when the
operator noes away or when the machine is stopped working.
(5). The overtravel safety switch ensures that the hydraulic
motor should be topped as soon as the motions of the macine
ie overtravelled.
(6). For ¥W4332 and Ywi4232, there is a local difference
in the electric ayetem, for example: switch SAQ in Model
Ysa232 represents the On and Off of the cooling pump, but
switch SA9 in Model YWA4232 represents th¢ shaving mode
selection, 30 please the operator carefully read the operation
manual.(Ds Te indicating lamps on PCs
reference only,
normal caee,
s00n 88 the cover is opened
for service technician
he power wil
be cut off asBsowe pert en Hoan
(112) Hydrautic syste
4. Hydraulic eyaten for Model Tei252 (see Fig.™4a)
Me hydraulic syaten is used for the clamp of the
workpiece, the protection of the clanping and the auto~
matic lubrication of aachine.
The hydraulic oil is supplied by 4 gear punp 1 model
BBG y the preecure of the hydraulic 4:2
2 controlled
by @n overflow valve 3 Model Y-108 end ig adjusted within
a range of 1.5 to 2 MPa. he traveling speed of the clasping
cylinder is controlled by ® fixed throttle and has been
adjusted before the machine delivery. The pressure protection
of the clamping cylinder ie controlled ty a pressure relay 5
motel DP-40B, vhen the clamping pressure of the cylinder is
less than 1 to 1.2 MPa , it will sent out the signal to
stop the michine. The lubricating oi1 is|controtled by
safety valve & and the range of the lubricating oil pressure
is tron 0.3 to 0.5 MPa. The flow of the jubricating oi1 at
every Iubricating point is separately controlled yy four
throttle valves in the dietributer.
2, Hydraulic system for model YHAt237 (see Fig.14b)
For thie model machine, # radial feed cylinder is
added on the basis of the hydraulic system of the model
Yait252, which is controlled by # Z-position-4-way electre-
magnetic valve and the traveling speed if controlled ty
@ fixed throttle 9.
‘Me machinery 041 No.20 ia chosen|for the hydraulic
For new machine, should replace 11 oii afterOperation Manuel
the macine has put into operation for every 3 monthe,
after one year, replace oil at a half year inteveral, then
replacing the oil , should clean the oil pool and of filter
by using silk and foam plastics and others naterials without
fibre, cannot use the spur cotton ani cottpn towel as well
as other arterials with fibre,ete.4232 ion Nenue a
yun Operation Manuel = 35
me. tae Pree
Radial feed
gentecl-aiy
(=)
sae
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Far
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Nea othe!
seaislae0?Ty
Wer
nab Operation Manual 57
padisl feed
contro! disk
ett?1 ga32
real232
Operation Manual
—_____——
sam?
power switch signal Lemp
power
‘tromagnetic
ive power’
contzal power
Prerautif power]
indicator Lamp]
Fig.?
tric cireuit diagram (page 1)(Fron - 40rnR> a
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‘finiehea.
feed has been
‘The shaved gear shouts be checked after the trial shaving
is ended. If necessary, loosen the mn
14 turn the controlUperation tanual
n tighten the nut without any need
The finger 6 for indicating
conveniently reading out the reading.
(trol disk ean be more
ed by through this finger, and it is easy
¥ig.24a Hadial feed adjusting device sketcnOperation anual
For nachine Model YaAa252:
‘There is a only difference as the plunge shaving mode
cen be adopted on the machine comparaing with the Hote
wwu232; for others shaving nodes, the adjustment on the
machine Model Ywis232 are same with that on Model Yw4232.
During the plunge shaving, the radial| feed keeps infeeding
without the reciprocation of the worktabip, as a result,
the eycling time way be reduced and this putting mode is
f shaving method with high producing effetienty.
When the plunge ehaving is to be adopted, the arrangenent
of trip dogs on the control disk is shown as in #ig.21b.
function of the trip dogs are: the trip dog a is used to
control the rate of the plunge-cut trol the rapid speed to
the low speed; the trop dog H is used to géntrol the plunge-cut
amount and the electric signal for changing the rotating
@irection of cutter; the trip dog ™ is used to control the
ampunt of the micro-return and to send ijt the eignala of free
pass; the trip dog K is used to control tHe end position of
withdraw of cutter slide for giving an enough space to Load
and unload the workpiece. 2 |
For example: Hadial feod is given 024% ma, the nicro-return
Of cutter is 0.02mm during the free-pass, the settting
Procedure of radial feed ie decribed as follows when the
Plunge shave mode is adopted on the machine:
1, loosen the nut to unengage the contol disk 3 from
the square shart 4,
2. owiteh on the delector switch 6” side, up/down" te
approach the cutter to the workpiece; switth off the switch 6Fig.2tb Radiel feed adjusting device sketch
in plunge-cut’ shaving
unitl the cutter
going to mesh with the workpiece. Tnen
stand the handle 1 of cluteh up to the eluten.
urn the squire hand 4 to get a free-backlash mesh between
5. Setting-up the trip do:
+ Hix the trip dog a at the
disk end then tighten the nut 2 when
the Limit switch 5.
2). Fix the trip dog # at the of 0.74 am,
3). #ix the trip dog 4 at the position of 0.1% - 0,02
0.12 wm ( i.e. the micro-return anount is 0,02 mn).
4) Turn the aquare head 4 in c.cw Yo move up the cutter1 no32 Operation Hanus!
W239 eration Menusl
slide till a space between the cutter and the workpiece is
obtained ( the space is about 0.2 to 0.3 nm); and then set
the trip do K to press down the linit auiteh 5, where is
the terminal positon of the withdraw of the cutter slide
when the shaving cycle is finished. After the above adjustuents
hhave been done, put dovn the handle 1 to }nrage the cluten.
Turn on the selector switch for choosing the plunge-cut
node, up to now, the adjustment for the plunge-cut shaving,
has been ended.
Should check the shaved gear after the trial ‘shaving.
If necessay, loosen the nut 2 and turn the cintrol disk by
fan angle, and then tighten the nut arain. lt is not needed
to reset-up the trip dogs once more.
The scale indicating finger 6 is provided £:
the nore exact reading. The rotating value of the radial
feed control disk can be more exactly controlled by througa
thie finger and it is easy vo detersine tHe amount of the
radial feed. :
Cautions x
Because that the micro-return trip don M ie only adjuated
and fixed at between 0.22 and 0.38 an in the slat of the
graduated disk, if the position at where the trip dog H is
fixed is less thano.22mm, the position of the trip dog @
should be correapondently noved backwards, others trip dogs
are also moved backwards, but the relativg sizes anong thea
are not changed, it must enoure that the trip dog H chould
be falled into this slot for the plunging |shaving.w
wal!
3%
Operation slanual
(5). Setting-up of the! travel 1
th of the worktsble (sae
‘The travel length of the worktable is set by two trip
4ogs 2 and 4 on the control disk 1 (see Vig.22). The scale
value corresponding to these trip dogs is the travel length
of the worktable. After tho adjustment, the worktable should
be separately driva to check for the ongtging condition
between the cutter and workpiece
‘: both pnd positions of
the travel of the table.
is important that the nut 5 for fixing the control
disk must be tightened and does not allowed to loosen duris
is
service period of the machine. Only when the table assenbled
grove in dismentled or the limit ovitch 3 is taken out and
be refixed, the nut 5 may be loosened. when the control dick
is re-adjusted, the center line of worktable should be aligned
ith the rotating axis of cutter head, ang the red graduated
should ain at the conter of contact of the trip switch,
thus, it can ensure thet the moveuent of the worktable
synnetrizes the rotating axis of cutter head.
Tt must be noticed that two trip dogs mist be located at
both sides of contact of the trip avitch and the working dose
Bust face the contact. Never allow to use the non-working
surface of trip dogs to touch ami prese the contact of the
‘trip switch, if this case hapnened, it would cause the
ball-serew of worktable is firmly gripped and danage it.Operation Manual
wt the rotating apeed of cutter spindle (mpm)
ee the perpheral speed of cutter (a/ain.)
na the piteh diameter of eutter (nm)
The change pears cin be selected acconting to the
8 after the speed of cutter waa determined
Table 8 Change gears of shaving cul
OF
x
nen the gear with a fewer teeth and a larger module is to
shaved, having a lower machinability, it ie reconnemded
to adopt @ proper Jubricating liquid for improve the surface
finish of the teeth of gear.
Accorting to tiie rotating speed of cutter, the rotating
speed of the workpiece ean be calculated. Ip normal, the
rotating speed of the workpiece does not excled than 800 rpa.bss
wuat?32 Operation Manual
7-15
(6). Selection of cutter speed
Cutter speed relates to the size, material, required
surface finish of gear to be shaved, crossed axi¢ angle snd
Giameter of cutter, etc. These should ve comprehensively
considered as the cutter speed is going to be aelected. ‘he
Tecommended cutter peripheral speed are shown in “able 6.
The cutter perpheral speed should multiple ty the revision
factor kV according to the material hardiese of gear to
be shaved.
Table 6 Recommended cutter peripheral speed
Groaned [Recommended cutter peripheral spec aa helix angle of
axis workpiece is n/aine
angle (9) [oe ao? vo 16% aml sgeoe saa?
|] 0 10? | vas 440 130_| 425 420
45° 730 425 420 [415_| 470 705
20° 115 110 105 |100 | 90 80
Table 7 Speed revision factor KV i
Materiel Structure steel Mloy szeel
Hardness 1B 170 96 | 217 |) 205 229
Revision tector | 1.15 | 1.1 | 1.0 || 0.6 a8
Av
The relationship between cutter peripheral speed and th
rotating of cutter is given as follows:
Voutter * 1000 P
y :
‘eutter "3
leutter * 7
do niteUperation Hanval
(2). Selection of worktable travelling speed
The feed of worktable is chosen according to the rotating
speed of the workpiece.
eRe taet er workpiece can bo calculated by the
following formula
x, x4, P
i ‘cutter Crpa)
‘workpiece
“norkpiece
ges ae rotating speed of workpiese — ( rpm )
Netter rotating speed of cutter (pe)
seat number of teeth on cutter
a aoe number of teeth on workpiece
According to the rotating speed of the workpiece, the feed
ef the worktable may be determined. The principle for choosing,
the feed of the worktable is as high as posgible to raise the
productivity on the premise that the required surface finish ant
the cutter life are eatisfied. When the roughing-finishing
shaving method is used in the operation, the feed of the workrable|
can be autonaticslly changed during the shaving operation ant
the reea rate of the worktabie in roughing ghaving 19 7.5 tines
than that in the free pass; for the detailed informetion, see
table 9.
The pelationship between the foed of vorktable ani the
rotating spead of the workpiece is as follows
-Bx¥, 5 Eater (nm/nia.
Veree-pase ‘cutter
4vorkpiege
ns
Venaving ~ **° “rree-pass fomiass-))feed rate of orktable per one revolution of
workpiece, aa usual, S - 0.? nm per one rev. of
4 rate of table in the free pass
\pree-pass —
T
T
|z\4&
|ele
aie
T
Ae
ae
Be pes
the roughing-finish: 7 vanced shaving methot ,
t can raise the productivity and prolong fe of the
ter; and which can be obtained only necessary put t
ae it(8). Selection of plunge-cut feed
The plunge-out shaving only can be adopte nachine
fodel Ywa'252, The plunge-cut shaving feed relates with the
paterial of the workpicce,ete. this
of the change geare; and and furt
Table 10 Change gears toperation Manual
Girection of the cutter and the moving direction of the work
ree operation the sliding direction of tke
face and the axial
inted of workpiece will present @ relationship of both aov
in same or in opposite 4
The movenent relationships shown in “ig.2% are reconnented.
7)
opur\gear * spur gear
\noving direction
Ror workpiece
#ig.23 Relationship between cutter and
moving direction of workp:(70). Papalie shaving
During the parallel shaving, the worktable reciprocates
along the axial direction of workpiece corresponding to
the cutter. The tooth face width of workpiece does not relate
with the tooth face width of the cutter. Any tooth face wisth
of workpiece within the allowed travel lejeth of the worktable
can be shaved on the machine. With this saving mode, there is
8 deficioncies that it needs more cutting time and the wearness
on cutter is not uniform due to the position of crossed axi
point is consiatent during shaving. To ovarcome the deficiencies,
it may de done by adjusting the position af cutter, the
crossed axis point could be set at the one flank of cutter
first, then mount the cutter at the onposite position.
The travel length of worktable can be calculated by
the formula
n= B+ om
the travel length of worktable in the
Parallel shaving (nm)
tooth face width of gear to be shaved (nm)
‘The
module of gear to be shayed (an
faving of the shoulder gear:
hen the ehoulder gear will be shaved by using the
parallel shaving mode, it must check whether the edges of
cutter influence the shoulder of the gear,|the check can be
carried out by the following diagram.
The original date to be checked are ap follows
R radius of cutter periphery
AOperation Manual
Hig.20 Tlustrating the shoulder gear
shaving possibity with sketch
dict centre: workpiece and
distance from £
from the face of cutter to the eros
12 #ind out the intersecting point K of
on the cutter and the shoulder of «or
2. Draw out the aide projection of cutter and make the
end face Line of cutter to pass through the point K* (i.e.
the projection of the point K).
3. Measure the length of !% that should be larger than
width of the clearance spage required for the correctional
section of cutters i.e. MMi > f.
4, On the Fig.24, the point N isthe rotating axie of the
cutter head. To ensure that the cutter meshes with the
workpiece throughout the operation, the didtance from the
face of the cutter to the intersecting point is not less thanWeose Paton arin a
PI MTE the Getter dtaengages tron the|vorepiece, the
eerie.
Yuen shaving the shoulder gear, « proper width of ring
PERERA PIT sates ve seiectea, valcn can be town, fren
Pe PeRret Gee ctasesing te|cutter-{Ir due ahenider Loceted
at the Tort hand of gear, the cutter should be off-set to the
Siehty Af thie sioulder of gear located at ihe rignt hand of
MAGEE A casita te ocf-aat to ene tere, Tre anoust of
Oftcput should’ be idee tien nait the face nidth of cutter
isis tab vad
eee Cie tigen) aoving, Yecatns that the
intersecting point between cutter ant workpiece ia varied
Niche fe esnlestiog ine in the tooth width Aizection of sear,
aes remit, the travel length of worttable will be reduced,
ich 48 favour of the shaving of the shoulder gear.
Yen the dlatonce from the Tace of ger to the shoulder
gurtace is sasller, which is different for] the parallel sheving
sod diagonal shaving, At ie convenient fo shaving the shoulder
ear with snallor spice by means of the uiderpsss or plunge-cut
shaving, but a epecial cutter is necessary for tht
e shaving
methods and the tooth width of cutter should be larger than
tooth face width of workpiece.BW a2s0 pension Manuel
(41). Diagonal shaving
Mis shaving mode is suitable for cutting the gear of
wich the tooth width is within 50 mm. The advantage of the
Gigonal shaving is that the cutting edges on cutter can be
fully used, 60 that the wearneea of cutter is uniform, the
life of cutter will be prolonged and meanvhile the travel of
worktable may be reduced, as well as a larger radial feod may
be chosen to raise the producibility. This shaving mode is
favourable to shave the shoulder gear and no special cutter i
necessary. The diagonal shaving mode is/the most widely-used
shaving mode.
Te angle between the moving direction of worktable and
the axis of the workpiece is called as the diagonal angle.
to 45°, Recommended
She diagonal angle ie normally varied from 0°
diagonal angle is 20° to 45°, If the diagonal angle is over
45°, it is better to use @ special-structure cutter for shaving,
otherwise, the result of the shaving may be no good.
Me diagonal angle ie closely relate with the tooth face
width of workpiece, the face width of the cutter and the crossed
axis engles
After the crossed axis angle ie determined, the direction
of the worktable movonent can be determined according to the
Pig.25 or ¥ig.29.
Tye diagonal angle to be chosen siiould be within the
range of the maximum allowable diagonal angle.
When the tooth face width of workpiece is less than shat
of cutter, the maxigun allowable diagonal angle is 90°, the
diagonal angle may be chosen within the recomended range.
seaterYperation Manual
nen the tooth face width of workpiece ie binger then
that of cutter, the maxinum allowable diagonal angle has to
be calculted according to the following formula and then ckoose
within the range of the recommended diagonal angles (see Fig.26).
Sin 9
crossed axis angle
width of workpiece
ent face width of
Qoutter - 3 2)
Froa Fig.24, th lating forma for travel
@iagonal shaving can be obtained .
Sings w )
theorically calculated travel length of table
actual travel Langth of table (aa)
module of workpiece to be shaveda
y
By
a
helical gear
spur gear
direction of workta!
= ae
ie zx =
\_worktabie \ travelling direc
‘Of worktable
¥ig.25 Relationship between cutter and the travellinga
sexier
Operation Manual
(42). Underpass shaving
The underpass shaving wode may be considered as a special
condition of
90°. The
ce width of it must be over than that of workpiece. The
1¢ diagonal shey
fy ise. the diagonal angle is
faving cutter should be specially designed and the
setting up procedure of underpass st
wving js same to that of
diagonal shaving. The travel length of the worktable in
underpass sheving (i.e, the moving distance of table in forvard
and backward) can be calculated by the folloving formula, vaich
can be evoluted from the calculating formula for the travel
Length of the worktable
dingonal shaving (refer to seo ig.27)
13 = By x tg
15 ___ travel length of table in underpass shaving
to be calculated (am)
By ___ face width of workpiece) (ms)
—— crossed axis angle (aearee)
when the setting-up of the worktable, a proper overtravel
should be added to the travel length 13 calculated from the
above formula. The edjusting procedure for the trip dogs of
‘the worktable vill be performed according to the section "Setting
up of the travel length of worktable".
am
Fig.2? Calculating
diagram for underpass
shaving travelBisoxe preeatan Pest
ywan232)
(13). Set-up of plunge shaving Conly for Mod:
In the plunge shaving, there is no transversal reci-
procation between the cutter and the workpiece, ive. there
4s no reciprocation of the worktable, this shaving only is
carried out in the radial direction and it is @ chaving mode
with the most producing efficiency. The cutter for the plunge
shaving must be especially designed. Compaping with the other
shaving modes, the quality of the shaved gear is better and
the Life of the cutter cen be prolonged. The cutting cycle
aketeh for the plunge shaving is shown in Fig.28.
staying. tine rapid sicro- staying tine
L
intela Gutter micro-return
Prounteran
gapid return
Radial infeed
cutter rorwara | cutrer rotation
‘rotation rotation
¥ig.28 Plunge-cut shaving cycle
When plunge-cut shaving, the worktabie should be put at
the middie position in the traneversal direction,and longi tudial
position of the vorktable should be adjusted to bring the
Worktable exactly to align vith the cutter,
¢ trip dogs of
Padial feed should be set according to the description in the
aection 4 "Adjusting radial feed and micro-return back (b)",Wy a2s2 Uperation anual
and the selection of radial feed rete refers to the section
8 "Selection of plunge feed". According to the requirerents,
shaving times I and IT can be controlled by the relays and or
may be adjusted by the user-self.
Plunge-cut
shaving
Woretable Te
sounted
Noving direction
Underpass shay"
toy,
Fig.29 Moving direction sketch of table in
four different shaving modesBiysose Opens Heat Feanal
seexoiter
2. Setting-up of the crowning gear cutting with the diagonal
shi
ing node!
Because that the calculating formula for the crown gear
shaving with the diagonal shaving mode is complex, up to no¥,
a perfect diagram is not enable to design for the operator
to consult.
The setting angle r of the crowning device will be found
out from the above curve and should be prdperly increased and
corrected by the experience of the operator.
When the angle r of the crowning device is set, first,
loosen the square head 1 of the crowning device (eee Fig.31),
then set-up the crowning device ty turning the square head 2,
the ewing angle of ‘the crowning device can be read out fron
‘he praduated disk 5. After the adjustment has been done,
tighten the locking square head 1 again. The setting angle for
the crowing device should not be bigger than the maximum angle
graduated on the praduated disk. Now, the [sha
6 operation ean
be carried out. If the crown snount on the shaved gear is
Little different with the value marked on the curve diagran ,
St Wi2L de connected ty the operator ta thain axnenianee.
As shaving the crown gear by using the diagonal shaving
node, the setting angle of the crowning device is bigger than
that in the paraiiel shaving mode, it relates with the diagona
angle, the crossed axis angle and the tooth face width of cutter,
fetes. During the underpass and plunge shavings, the crown
amount on the gear depends upon the cutter, it is no necessary
to set up the machine.
The setting-up of the crovning device should be performed
after all other adjustments have been finished.Bysose Dperevian eal
(1s). Crowning shaving
The crowning gear can improve the contact area, reduce
the noise, compensate the mounting clearance ond raise the
Lire of gear. The reconmended crowning amount is generally from
0.01 to 0.015
parellel shaving
Because that this calculating formula is nore complex,
we have draved out the curve dingran by geans of the calcul
results. The operator can find out the adjusting angle of the
crowning device and the travel length 4° of worktable, which
is approximately equal to the By, according to the tooth
face width By of gear to be shaved and the required crown
amount a3 (see Fig.30 ).
Br (an)
TAFT ET SARA EAT MY Ba BEET Kicgrce)
Fig.30 Curve dingran of angle afijuctment of
rowning deviceoperation Manual
45, Tapered gear shaving
Bo shave the ‘tapered gear, the axis of the workpiece will
tilt an angle to the axis of the cutter, i.e. the worktable
will be tilted by an angie.
As adjusting, loosen the locking screw 3 firat (see ¥iz.30).
Then turn the square head 4 fixed at the eroxning device to
swing the ecoenter eleeve, so that the table is tilted. There
is the scale line on the face of the eccester sleeve. one
division line is equal that the eccenter sleeve has been swinged
by 5 degrees. The relationship between the tilting angle of
the worktable and the ewinging angle of the eccenter sleeve
is as follows
ax
445,
tgA>
tilting angle of worktable surface
swinging angle of eccenter sleeve (one divisior
is equal to 5 degrees)
‘Mghten the locking screw 3 after adjustments have been done|
Acter all relatively adjusting items ahvé been finished,
the selector switch "Seni-automstic/Manual” should be set at
the position "(}" to carry out the trie] shave in the
semi-automatic operating cycle. The workpiece should be put on
the carriage and close the guide door and then press the
pushbutton "C7" located at the worktable. Therefore, the
achine enters into the seni-automatic cy¢le. Through the
‘test shaving, should check the accuracy of the shaved gear.
If necessary, the relative itens will be further adjusted
until the accuracy of the testing workpie¢e is qualified.
Up to this tine, the machine can be used for the batch productiorOperation Manual
Fig. 16 Control panel for Yw232
table ON/OFF selector awiten
cutter forvard/backward rotation selector switch
it ON/OFF selector switen
2 feed selector switch
i selector switch
relationship between cutter and table selector awit
1 tailstock advance/withdraw selector svitcn
Slide moving direction selector awiteh
table positioning etop selector awiteh
emergency stop pushbutton
hyaraulic stare’ pushbutton
[~auto/manual selector switch
tet xotza?avaxorter
4242 Operation Manua
¥igst6 Control panel for Ywis4232
4. table ON/OFF selector switch
21 cutter advance/witharaw rotation elector switch
3: coolant ON/OFF selector ewitcn
4&2 table transversal feed selector witch
5: free-pass number selector switch
onship detween cutter and title selector switch
ilstock advance/wsthdew selector switch
‘ide moving direction selector ovitch
Le positioning stop selector switeh
401 energency stop pushbutton
Wile start. pushbutton
‘auto/aanual selector avites
43, shaving mode selector switchP32 Operation Manual
Ag shaving spur gear
Intl cutter workpiece’ workpiece Rall cutter
=
cutter axis —
[workpiece axis —]
g =62
KB cutter
Saat,
Rut worl
Lilt workpiece
_- cutter axis
workpiece axis —
directions of cutter
and won
o= 39h
B, — helix angle of workpiece
fz — helix angie of cucter
Y — Croosed axis angle
¥ig.19° Adjusting sketch of crossed axis angle between
cutter and workpieceweoxottat
S
Wi a2s2 Operation Manual
Table travel length adjusting device sketchOperation Manual
Crowning & tapering adjus
ing device aketenOperation Menual
genent of rolling bearings
Arrangement of rolling bearings for Nodel Yw252 is
shown in Pig. 32a
Arrangement of rolling bearings for Model TwA4232 is
shown in Fig. 52b.=
o
| rte sonpe
51-24
sealing
Ping
cation
Povecine
Operation Hanus
List of O11 seals
ex1.9
1241.9
20x24
28x3.1
3253.5
35x31
40x3.4
55x3-1
90x5-7
95x31
1053.1
5x35x10
Poeeoxt0
25x82%10
25x85 10
35x55K12
Aox62x12
ASx62x12
sox7ext2
6 5x90x12
5x1 10x12
Mounting position
oi] distributor board, oil
Giatributor at eoluaa
oil distributor at column,
transveral feedbox oll dis
tributor, of1 distributor
board and table
bed, fadiel feedbox cylinder
radial feedbox cylinder
main drive box, radial feed
Griving box
radial feedbox cylinder
ved
head and tailstocks
redial feedbox
main driving box
cutter head
head nd tailetock
aiteo
aitto
magnetic separator
aivto
aitto
radia} feedbox
main driving box
main driving box, traneversal
Teedbox
main driving box
main driving box, transverse!
Peedbox
slide
cutter head
Wote: The quantity of the sealing rings in fhe brackets is
the machine Model Ywa4232.
supplied forOperation Manual
Basy-ear Part
others &
hantering y4g*
heat treats
jent: C61 at conical
part, others O48
except thread partas ieee : Bees open tae a
- | “Re pleatate,chemeate stsctse Lierea’ en follor, Pn
. | 3 . i. gohe 220¥ dete 220v Sor, 440 gs] 42
LBRS | Seatenation | ag, [attri Stias | Pate lattes | Bot epBes Bison [Ser] Benanke
ct | He 80 HU fyarauiie motor | gozi2h ass 150 fp Aoy126 (25K, teemini2 7H (et t 72
ma | Abpeda tu footie motor | aopi2e |v | aozi2h 05h llot fa, 2.88) | De
mh ABU Fer | pobsee asus Yo | oboe statins 0] =i 73
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se | tape -enita Facial feed notol | 22-6 asta, sofia, 2498 |
nb | akaediay pooner aver et | a
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