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Home / 5-axis CNC machine – Gearbox housing processing solutions

5-axis CNC machine – Gearbox housing processing solutions

2024/12/20 By Topstar

5-axis CNC machine 1-1

As one of the new global productivity representatives, the manufacturing process of new energy vehicles’ three core components (motor, battery, and electronic control) has put higher requirements for metal housing processing. The gearbox housing accommodates gears and bearings that transmit power and torque in the mechanical system and has high precision, rigidity, and stability requirements. For more manufacturing industries to cope with the challenges of high precision, high beat requirements, and complex contours in processing new energy vehicle parts, Topstar brings a 5-axis CNC machine-gearbox housing processing solution to meet industry production’s precision and lightweight requirements.

5-axis CNC machine meets high precision requirements

One of the biggest challenges in machining gearbox housings is to meet the high precision requirements of various components (including bearing holes, gear shafts, and mounting surfaces) and to ensure the accuracy of gearbox housing processing. The gearbox housing requires strict accuracy control to ensure the smooth operation of internal gears, bearings, and seals. 5-axis CNC machine can achieve high dynamic response and excellent rotation accuracy.

Among them, the C axis of the GMU-600 5-axis machining center is directly driven by a DD motor with a speed of 80 rpm, providing excellent dynamic response and rotational accuracy, which can achieve exact positioning. By using a direct drive motor, excellent angular positioning accuracy can be achieved. This ensures the machining process achieves the highest precision, the gearbox housing meets strict quality standards, and reliable, high-performance components are produced.

5-axis CNC machine 1-2

5-axis CNC machine meets high cycle requirements

Many gearbox manufacturers must produce parts in large quantities, so they must use Machining Centers that simultaneously handle high throughput and excellent precision. The GMU-600 5-axis machining center optimizes the machining process and is ideal for mass production of gearbox housings.

The design of the GMU-600 reduces non-productive time by improving the efficiency of each machining cycle. It achieves this goal through advanced design features, including a powerful drive system and optimized tool paths, which enable the machine to reduce idle time between processes. At the same time, it also has a high-speed tool change function, which enhances its ability to handle multiple operations in a single cycle, further improving production efficiency. The combination of speed and precision makes it an excellent choice for companies looking to produce gearbox housings in large quantities.

Complex contours and thin-walled parts

Gearbox housings often have complex geometries, including contours, cavities, and thin-walled sections prone to vibration during machining. The 5-axis CNC machines uniquely equip themselves to meet these challenges easily.

The GMU-600 5-axis machining center uses a high-rigidity bed structure, precision transmission system design, and fine-cutting parameters—the three work together to minimize vibration and maintain stability during machining. The system can precisely control the cutting force to ensure that thin-walled parts are machined without compromising their structural integrity. In addition, the 5-axis CNC machine’s ability to move the tool in multiple directions simultaneously means that it can reach areas that are difficult or impossible to reach with traditional machine tools. This ability is critical for machining the complex contours familiar in gearbox housings, allowing manufacturers to achieve complex geometries with high precision.

CNC machining gearbox housing

High concentricity requirements for bearing holes

The design team must ensure that the bearing holes in gearbox housings meet stringent concentricity requirements to align the gears and bearings properly during operation. The GMU-600’s A-axis has a DIN5 grade high-precision gear drive, providing 3500Nm of static torque. This high-precision gear drive allows accurate and consistent bearing bore machining with excellent concentricity. The ability of a 5-axis machining center to provide this high-precision machining capability helps improve the overall performance and life of the gearbox. In addition, the GMU-600’s advanced control system machines the bearing bore to a concentricity tolerance of 0.01 mm, which is critical to ensure that the bearings fit perfectly and run smoothly.

5-axis capabilities enhance machining flexibility

One of the main advantages of 5-axis CNC machine technology is its enhanced flexibility during machining. Conventional 3-axis machines limit their ability to reach certain areas of a part, especially when dealing with complex geometries or deep cavities. On the other hand, a 5-axis CNC machine can move the cutting tool in multiple directions simultaneously, enabling it to reach nearly any surface of the gearbox housing with greater precision and efficiency.

The GMU-600’s 5-axis capabilities enable manufacturers to machine parts with a single setup, reducing the need for multiple tool changes and setups. This simplifies the machining process, saving time and money while improving overall part consistency. This feature is very useful for achieving the complex geometries required by modern designs.

5-axis CNC machine enable high-precision machining of gearbox housings

Regarding machining gearbox housings, automotive, aerospace, and industrial manufacturers prefer 5-axis CNC machines due to their high accuracy, ability to handle complex geometries, and features that reduce vibration and ensure concentricity. The combination of enhanced rigidity, optimized machining processes, and high-precision gearing enables manufacturers to produce gearbox housings that meet the highest quality and performance standards.

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