CNC Hard Broaching Machine for Precision Disc Gear Machining

Product Description

Machine Introduction

The FG5710 CNC High-speed Hard Broaching Machine is a high-end special-purpose equipment in the field of precision broaching. It integrates CNC system, servo-hydraulic drive and high-speed broaching technology, and is mainly designed for the efficient forming and machining of high-precision features such as splines, tooth profiles and keyways on hardened workpieces after heat treatment (e.g., motor shafts, disc gears/countershaft gears for new energy vehicles). Its core advantages lie in high-speed cutting + high-precision control + hard surface machining capability, which can meet the stringent requirements for component precision, efficiency and consistency in industries such as new energy vehicles and high-end equipment manufacturing.

The FG5710 CNC High-speed Hard Broaching Machine is a core piece of equipment that addresses the pain points of high-precision machining of hardened workpieces, delivering three core benefits to the new energy vehicle and construction machinery industries:

 

1. It corrects deformation after heat treatment, achieving a machining accuracy of Grade 5;
2. It enables one-time broaching forming, reducing clamping errors and improving consistency by 99%;
3. With an operating speed ranging from 1 to 100 meters per minute, it boosts production capacity by over 30% and cuts the reject rate by 70%.

 

Whether for mass production or the machining of complex tooth profiles, the FG5710 can achieve the goal of "improving quality and efficiency, reducing costs and increasing profits".

 

Workpiece Basics

 

Face gears are core components of motor shafts in new energy vehicles and countershaft gears in construction machinery, undertaking the functions of power transmission and torque distribution. Their commonly used material is high-strength alloy steel (e.g., 20CrMnTi), which can reach a hardness of HRC63 after heat treatment. Featuring complex geometric characteristics such as splines and tooth profiles, face gears have extremely stringent requirements for machining accuracy and consistency (meeting Grade 5-6 of national standards). Traditional manufacturing processes are prone to issues like tooth profile deviation and excessive meshing noise, failing to satisfy the demands of high-end equipment.

 

 

Core Pain Points

The current face gear machining is confronted with five major bottlenecks:
Insufficient precision: Traditional broaching processes cannot rectify deformation after heat treatment, resulting in a reject rate as high as 8%;
Poor consistency: Positioning errors caused by multiple clamping lead to tooth profile deviation of more than ±0.05 mm;
Inadequate production capacity: The single-shift output is only 1200 pieces, which fails to meet the mass order demand of new energy vehicles;
High cost: Severe tool wear (requiring 5 replacements per month) and long manual debugging time (accounting for 20% of the total working hours);
Difficult material adaptability: Low machining efficiency and poor forming performance for complex tooth profiles when processing special alloy steel (e.g., hardened workpieces with HRC63 hardness).
 

Technological Process

 

The FG5710 is engineered with a full-process closed-loop specifically for face gear machining: blank (forging) → rough broaching → finish broaching → surface treatment → inline inspection. Through the collaboration of the CNC system and servo-hydraulic drive, it achieves integrated machining from raw material to finished product, reduces losses in intermediate processes, and ensures that the process parameters of each step are controllable.

 

 

Key Points by Segment

 

• Rough Broaching: High-speed steel broaches (maximum length: 1400 mm) are adopted, with an operating speed of 50-80 m/min to quickly remove the blank allowance. The servo-hydraulic system provides a stable pulling force of 100 kN, avoiding tool wear and workpiece deformation.
• Finish Broaching: The operating speed is adjusted to 20-50 m/min. The CNC system is used to precisely control the broach path, rectifying deformation after heat treatment, and the tooth profile accuracy reaches IT5 grade. The inline inspection system feeds back errors in real time and adjusts parameters in a closed-loop manner.
• Surface Treatment: Automated polishing technology is applied to control the surface roughness at Ra ≤ 0.8 μm, reducing meshing noise. The residual stress is controlled within 50 MPa to extend the service life of workpieces.
• Inline Inspection: Digital twin technology is integrated to compare machining data with design models. Non-conforming products are rejected in real time, and inspection efficiency is improved by 40%.

 

Revenue Data

 

The process value of the FG5710 is verified by quantitative indicators:
Accuracy: Machining accuracy up to IT5 grade, with tooth profile deviation controlled within ±0.01 mm;
Efficiency: Single-shift output reaches 1,560 pieces (increased by 30%), and the operating speed ranges from 1 to 100 m/min;
Cost: Tool wear reduced by 30%, and labor costs decreased by 25%;
Quality: Reject rate reduced to 1.5% (a 70% decrease), with consistency qualification rate reaching 99.5%.

Customer Cases

 

Case Study: After introducing 2 units of FG5710, a leading new energy vehicle component enterprise reduced the face gear reject rate from 8% to 1.5%, increased the single-shift output to 1,560 pieces, achieved a 100% on-time delivery rate, and saved 2 million yuan in costs annually.

 

Application Scenarios: Mass production of face gears for new energy vehicles, machining of countershaft gears for construction machinery, and forming of complex tooth profiles for special alloy steel.

Parameters and Configuration

 

Parameter Name	Value	Unit
Rated Tension	100	KN
Rated Stroke	1250	mm
Maximum Drawbar Length	1400	mm
Working Speed	1~100	m/min
Return Speed	1~100	m/min
Feed Speed	1~5	m/min
Tool Lifting Speed	1~30	m/min
Machine Tool Size (L×W×H)	5000×4300×4900	mm
Net Weight of Machine Tool	18500	kg