New software functions enable independent calculation of even complex chamfers. A new interface allows for the first time the switch between FlexChamfer and ChamferCut on one machine. Additional features improve safety and efficiency in operation.
FlexChamfer is a CNC-based, flexible chamfering process with end mills, particularly suitable for workpieces with collision contours or internal gears. The machining can occur in parallel on an integrated chamfering unit. Standard tools make the process cost-effective and eliminate waiting times due to workpiece-specific special tools. It is suitable for prototypes and small series, for example in contract gear cutting or in aerospace, but also for medium and larger quantities, such as in the commercial vehicle industry.
Independently programming complex chamfers
"In discussions with customers and users, the need emerged to independently define and calculate chamfers for both simple and more complex component geometries. Therefore, we have specifically further developed the software – for more flexibility, easier operation, and expanded application possibilities," explains Dr. Oliver Winkel, head of application technology.
Until now, an external calculation was required specifically for programming complex chamfers. Now, even more demanding geometries such as chamfers on large end faces can be programmed directly in the software.
"We wanted to enable users to independently represent such cases," says Oliver Winkel. If the machining result in one cycle is not satisfactory, it can be optimized through the separate definition of two machining areas by chamfering vertical and inclined surfaces independently in two cycles.
Head switching: one machine, two processes
Another highlight is the integration of an improved interface that allows for easy and quick conversion between FlexChamfer and ChamferCut technology. This means the machine offers the possibility to use both processes from the start. With standard power and compressed air connections, the chamfering unit is prepared for both technologies, and the conversion takes less than 2 minutes. The switching then occurs via software. This enables economical machining of various batch sizes on one machine, increases flexibility, and reduces investment costs. New machines are preconfigured accordingly, and existing machines can be retrofitted.
Operation further simplified
In parallel with the functional expansion, the user guidance has also been further improved: "An extended plausibility check now provides concrete indications of the causes of implausible inputs, instead of just issuing a warning as before," explains Oliver Winkel. In setup mode, a visibility stop allows for control with the machine door open. This enables the operating personnel to directly monitor new workpieces during the ramp-up phase and to detect potential collisions early, such as with interference contours.
FlexChamfering of large workpieces
For larger workpieces, a solution for chamfering on the machine is now available for the first time: Thanks to new milling heads with an integrated, foldable chamfer spindle, components with diameters of up to six meters can now be chamfered using FlexChamfer technology – although not in parallel time, but highly precisely and in one clamping. Manual deburring and chamfering is eliminated.
Successful in practice
Machines with the new FlexChamfer software are already in use with initial customers, including the Italian manufacturer of drive components OMSI Trasmissioni S.p.A. Managing Director Renato Soncina states: "We are already using the Gratomat chamfering technology on our Liebherr machines. With FlexChamfer, we can now program the desired chamfer dimensions and thus work significantly more flexibly and precisely."
Contact:
