No more time-consuming set-up and reclamping processes

Closely interlocked

Precision Gears Haenel in Bad Friedrichshall stands for high-quality gearing parts. The small and medium series up to a maximum of 10,000 pieces are manufactured in two shifts.

“If Haenel can't do it, nobody can”. With this unofficial slogan, the company is known on the market for its precision gears and has been manufacturing gearing parts of the highest quality for over 45 years.

In the lathe department with five MAZAK turning centers, the company relies on the driven tools, broaching units and static holders from BENZ Tooling.

Haenel Precision Gears – dimensional accuracy and constant control — Dimensional accuracy is standard at Haenel. Constant monitoring of the processing results is important.

Faster to accurately fitting grooves and gear teeth

The Haenel product portfolio includes milled cylindrical gears up to 400 mm diameter and 275 mm tooth width, ground cylindrical gears up to 400 mm diameter and 170 mm tooth width, module ranges from 0.5 to 7 and diametral pitch ranges from DP 48 to DP 5.

The company's 85 employees make a significant contribution to Haenel's outstanding quality. With their experience, their often many years of specialist knowledge and their reliability, they stand for the high standard of the products.

"In addition, there is ongoing investment in production and measurement technology. Our wide range of production processes, such as gear cutting, internal broaching, gear grinding, laser inscription and internal and external cylindrical grinding, enable us to implement any customer requirement quickly and in Haenel quality.”

Jürgen Renner, Head of Toolmaking and Training at Haenel Precision Gears

Haenel Precision Gears – laser inscription of gearing parts — Each gearing part is unique and is given a unique identification according to customer specifications using a laser inscription system

With the CNC tool system specialist BENZ Tooling, Haenel has a special customer-supplier relationship. In 2013, Haenel purchased a BENZ LinA driven unit in order to be able to manufacture molds and profiles in a single clamping operation on its lathes.

At the same time, the Haenel field service visited BENZ Tooling to discuss a product requirement. They were looking for a competent supplier for a sophisticated gear wheel with module 1, Z32, quality 6, which is used in the drive module of a multi-spindle head. The first unit purchased from BENZ Tooling was therefore also used for a BENZ product.

Typical broaching operations: cylindrical gear external spline and internal octagon

"The external cylindrical gear and the internal octagon of the gear are product specifications that are ideal for shaping,” reports Jürgen Renner.

First, the workpiece is turned on a MAZAK Multiplex 6200Y before the broaching unit is used.

“In initial tests, we produced the inner octagon using wobble machining. However, the required tolerances were not achieved and the octagon became conical. That's why we quickly switched to the broaching unit. The required quality was achieved without any problems after brief teething troubles.”

Customer success Haenel Precise Gears with BENZ LinA — Different parts made of various materials are processed with the BENZ LinA broaching unit.

Machine-friendly and resource-efficient

Jürgen Renner and Commercial Manager Jörg Uhlmann are enthusiastic about the potential savings in the production process. “The unit eliminates the need for time-consuming set-up and reclamping processes. A large broach or a separate work step would otherwise be necessary, especially for transmission gears / components with a double groove. This has enabled us to reduce manufacturing costs by an average of around 10% per component."

Jörg Uhlmann, Commercial Manager at Haenel Precision Gears

In addition, the required shapes and profiles of the workpieces can be produced economically due to the high dynamics. At the same time, the machine is hardly exposed to any load and the energy requirement is reduced to a minimum. This is possible thanks to the functional principle of the LinA broaching unit: it uses existing machine functions, such as the turret drive on lathes. With the exact positioning of the main spindle, profiles can be generated in the precise position (even with any partitions).

Success through reversing gears

The key to its success, however, is the reversing gear of the broaching unit, which converts the rotary movement of the motor into a linear movement of the shaping tool.

At the end of the broaching process, an integrated lifting function is controlled by a link. On the one hand, this leads to a continuous feed of the transverse axis and thus enables simple programming. On the other hand, the cutting edge is prevented from sliding along the bottom of the recessed profile during the return stroke – thus preventing wear or breakage of the cutting edge.

BENZ LinA broaching unit (shaping of internal gearing) — Different shapes and profiles can be produced with the BENZ LinA broaching unit.

All components of the linear feed unit must be constantly accelerated and decelerated. It is therefore beneficial for the energy balance if the masses being accelerated are as low as possible. As the entire kinematics of the shaping process are integrated in the compact broaching unit, no heavy components of the lathe are moved for material removal.

The low masses of the BENZ LinA broaching unit therefore allow high dynamics with a stroke rate of 1,000 strokes per minute with 32mm usable broaching stroke (with reduced stroke, values of up to 1,200 strokes per minute can be achieved with 17mm usable broaching stroke, with extended stroke of up to 750 strokes per minute with a total stroke of 53mm). Even at high speeds, good surface qualities can be achieved as the ram is guided in a rigid roller bearing.

Live tool portfolio with BENZ SOLIDFIX® modular quick-change system

The very positive experiences at Haenel with the BENZ broaching unit convinced the new production manager to also rely on BENZ Toolings' expertise for the live tools and static holders for his lathe department.

“As we often produce small batches, fast set-up processes are extremely important for us. With the BENZ Solidfix® modular quick-change system, we have taken an enormous step towards optimizing set-up times. A particular advantage of the system is the variety of tool adapters for all common tool holders, which allows an almost unlimited choice of tools to be used.”

Jürgen Renner, Head of Toolmaking and Training

Ease of use and reduced set-up time

Apart from this, Jürgen Renner particularly highlights the ease of use, as the tool adapters can be changed without any special equipment. And because this can be done within the machine in just a few seconds, set-up times are reduced considerably.

In addition, by using the modular BENZ Solidfix® quick-change system, the tools can be changed in a pre-set manner, which in turn reduces set-up times.

Another advantage is the particularly compact design. It gives the system a high degree of stability, which is also reflected in the machining accuracy. At Haenel, this is an important criteria for high-quality gearing parts. The short design also saves space in the machining area.

BENZ live tools in radial / axial design

Reliable production thanks to regularly maintained units

Meanwhile, Hänel owns over 20 BENZ units, which are sent to the manufacturer for maintenance at regular intervals. As part of this after-sales service, the units are inspected and the next steps are discussed with the customer. This significantly reduces any production downtime caused by damaged units and increases the life expectancy of the units.

“BENZ Tooling is a reliable partner for us for all live tools and static holders. The good quality, expert technical support and excellent service are the basis for a successful collaboration,” says Jürgen Renner, summing up the partnership.

Are you looking for a solution for your broaching processes?

Thanks to our many years of expertise and the broaching units of the BENZ LinTec series, we contribute to making your production even more efficient saving resources.

Cause our goal is to support you in your tasks – challenge us!

get in touch

BENZ GmbH Werkzeugsysteme

+49 7803 504 300-0
info@benztooling.com
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Kinzigpark 3
77723 Gengenbach
Germany

About us

BENZ Tooling is one of the world's leading manufacturers and suppliers of components and systems for tool and machine tooling technology. The company employs about 300 people and is represented in over 30 countries worldwide. BENZ is part of the measuring and process systems division of Schenck and belongs to the Dürr Group.

+49 7803 504 300-0

info@benztooling.com

Contact form