Manufacturing Internal and External Profiles: Precise Engineering Optimizes Production Processes Pendulum Machining and Interlocking on Turning and Milling Centers

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Whether internal or external profiles or gear teeth. The company Hommel+Keller specializes in tool developments that enable precisely such manufacturing processes to be reliably and productively carried out on CNC machine tools in components up to 35 HRC hardness.

Companies in the machining industry face great challenges in times of difficult conditions and seek solutions to make production even more efficient. This often only works in close collaboration with innovative technology suppliers, such as modern tool manufacturers. They support machinists with their contemporary tool solutions so that they can manufacture their products profitably, in the highest quality, and resource-efficiently. An example is Hommel+Keller Präzisionswerkzeuge GmbH from Aldingen (Germany): With their standard tools and custom solutions for processes like broaching and gear cutting, component manufacturers "make money at the cutting edge."

Knurling, marking, smoothing, gear cutting, and pendulum broaching—whether standard tool or custom solution tailored to the requirements—in the industry, Hommel+Keller stands for high-quality precision tools for use on machining centers as well as turning and gear cutting machines.

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Sigmund Grimm, Managing Director of Hommel+Keller Präzisionswerkzeuge GmbH: "Innovative solutions for demanding machining processes? We have the tools for that. For example, pendulum broaching tools for manufacturing internal and external profiles."

Pendulum Broaching: Fast, Precise Profile and Perfect Chip Removal

Pendulum broaching is often used in finishing or for producing precise shapes and profiles, especially with difficult materials or complex contours. Since a lot of material can be removed very efficiently in pendulum broaching, it is ideal for applications where fast and precise cuts are required.

Process-Reliable up to 35 HRC Achievable

According to the manufacturer, Hommel+Keller broaching tools with or without internal cooling are "precision sprinters." Thanks to the broaching holder and the punch for the respective profile, users can safely produce internal profiles such as square, hexagon, Torx and Torx Plus, triangle, pentagon, or octagon in components made from materials up to 35 HRC in seconds, in a single pass. For high precision in bearing seats and wobble spindles, the components of the broaching tools are hardened and ground. The "Inox-Plus coating" developed for the punches ensures long service life and extreme wear resistance.

Pendulum Broaching Tools for External Profiles

Efficiency and quality are also the focus when creating external profiles: With the pendulum broaching holder, an adapter, and a broaching insert (various profiles are available on request), the respective profile is quickly and reliably produced in a single operation through concentric motion.

Thanks to the concentric design of Hommel+Keller's broaching tools, they can be used on CNC turning and milling machines as well as conventional machines, which can bring advantages in terms of quality, process reliability, and cost structure. This is because the need for retooling workpieces on special machines such as broaching or slotting machines, or outsourcing to cost-intensive manufacturing processes like wire EDM, can ideally be eliminated. With numerous variants of shank connections and adapters, a suitable connection to the respective machine tool is available for a wide range of applications.

S. Grimm: "The 2.0-degree tilt of our products reduces the cutting force by 20 to 30 percent, depending on the application. This means our pendulum broaching tools score not only in versatility and precision but also in efficiency."

Special Profiles are Possible on Request

Pulleys, spline gearings, gears, etc.—Gear cutting tools are needed in countless manufacturing processes for a wide variety of components. The company's "quick gear cutting tools" have the right sharpness for high industrial demands and also ensure high accuracy and cost efficiency in production.

Sigmund Grimm: "In the manufacture of gears, the geometries must be produced precisely so that the components fit together perfectly. No errors are allowed. That's why we only use the latest technology and optimize through customer-oriented engineering. Geometry and coating are optimally matched to each other and to the application and process. It's not just the pure product that counts. Beyond that, we offer comprehensive after-sales services such as stripping, re-sharpening, or cutting edge preparation, 'all from a single source.' This creates additional value without major logistical effort for the customer and is environmentally friendly."

Hard Machining Also Possible

Be it standard size, custom-designed to individual customer requirements, or for different areas of application—"Quick hob and tandem cutters, slotting and power skiving tools with bores and shanks, as well as form and disc cutters, have long service lives thanks to high-performance coatings like 'nACo', 'nACo3', 'nACRo'—suitable for machining with coolant, dry machining, and hard milling.

Process Analyses can Optimize Production

The company's process optimization engineering is increasingly in demand, where significant production improvements are pursued through optimization of gear cutting processes based on a joint process analysis with the user.

Sigmund Grimm: "The results speak for themselves and often even surprise seasoned manufacturing professionals: With our hob and form cutters, machining results can be achieved with up to 60 percent time savings compared to conventional tools or other methods. In another example, our hob cutter reduced the production costs per good part from 4.83 euros (5.41 USD) to just 0.32 euros (0.36 USD) compared to a previously used slotting cutter for spline cutting on a component. An incredible saving for 250,000 pieces per year."

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