Advanced CNC Broaching Equipment for Internal Gear Production

• Customization: Available
• After-sales Service: Provide
• Warranty: 1 Year
• Model NO.: IHG8805
• Application: Metal
• Process Usage: Metal-Cutting CNC Machine Tools
• Movement Method: Contour Control
• Control Method: Closed-Loop Control
• Numerical Control: CNC/MNC
• Processing Precision: 0.03~0.04(mm)
• Performance Classification: High-End CNC Machine Tools
• Certification: CE, ISO 9001
• Condition: New
• Transport Package: Standard Export Package
• Trademark: UBRIGHT
• Origin: Cn
• HS Code: 8461300000
• Production Capacity: 100 Set

Product Description

Machine Introduction

 

The IHG8805 Internal Helical Broaching Machine is a groundbreaking piece of equipment in the field of general mechanical transmission, designed specifically to overcome the accuracy bottlenecks, low efficiency and high costs associated with traditional processes. Its core benefits include:

 

1. One-clamp hard broaching with a positioning error of ≤0.02 mm and a tooth profile accuracy reaching national standard Grade 4-5, meeting the requirements for transmission stability and NVH performance.
2. A single-piece machining cycle of 3-8 minutes, with efficiency 10-20 times higher than that of the hobbing + grinding process, enabling a single-shift production capacity of over 300 units.
3. Replacing multiple sets of traditional equipment, cutting equipment investment by 60% and reducing workshop floor space by 40%.
4. Broaching tools can be reconditioned and reused 5-8 times, lowering the comprehensive tool wear cost by more than 50%.
5. Preserving the mechanical properties of the hardened layer, eliminating stress concentration at the tooth root, and improving the fatigue resistance of components by 30%.

 

Whether for mass production or precision customization, the IHG8805 is poised to inject core competitiveness into your production line.

The IHG8805 Internal Helical Broaching Machine is a core precision machining device in the field of general mechanical transmission, specially designed for the batch hard broaching of internal helical broaching components.

 

Its core advantage lies in completing the forming of hardened workpieces (HRC58-62) via one-clamp internal helical broaching, which effectively eliminates the cumulative error caused by multiple clamping operations. Integrated with a customized broach system, closed-loop control for in-process measurement and an automated polishing module, the machine ensures machining accuracy up to National Standard Grade 4-5 and a surface roughness of Ra ≤ 0.8 μm.

 

Suitable for internal helical broaching with a module range of 0.5-5.0 mm and a helix angle range of 5°-30°, this equipment is widely used in industries such as automotive, industrial robotics, wind power and aerospace, helping customers achieve the production goals of quality improvement, efficiency enhancement, cost reduction and profit growth.

Workpiece Basics

Internal helical teeth are spiral meshing tooth profiles machined on the inner bore wall of gears. As core components for high-precision transmission, they are widely used in fields such as automotive gearboxes, construction machinery reducers, and aerospace transmission systems.

 

Compared with external helical teeth, the internal meshing structure of internal helical teeth can significantly reduce the volume of transmission devices and improve torque transmission density. Combined with a reasonable helix angle design, it can reduce meshing impact and noise on tooth surfaces, achieving high-speed and stable transmission. Workpieces for internal helical teeth machining are mostly made of alloy structural steels such as 20CrMnTi and 40Cr. After carburizing and quenching, the tooth surface hardness can reach HRC58-62, meeting the requirements for heavy-load wear resistance.

 

Restricted by the inner bore space, internal helical teeth machining faces challenges such as poor tool accessibility and complex cutting forces. It requires high-precision CNC gear shaping machines or special internal gear hobbing equipment for completion, and has stringent requirements for tool rigidity and matching of machining parameters.

 

 

Core Pain Points

Traditional internal helical broaching processes are plagued by three core bottlenecks:

 

1. Insufficient Precision: Cumulative positioning error from multiple clamping operations is ≥0.1 mm, leading to excessive pitch/tooth orientation deviation, high transmission noise, accelerated wear, and a scrap rate as high as 8%.
2. Low Efficiency: A single-piece machining cycle takes 1-2 hours, with a single-shift output of only 50-100 units, which fails to meet the daily batch demand of 1,000+ units required by automotive OEMs.
3. Excessively High Costs: Heavy investment is required in multi-process equipment (gear hobbing machines, gear grinding machines, heat treatment furnaces) that occupies a large workshop footprint. Tools (hobbing cutters, grinding wheels) suffer from rapid wear, with comprehensive operation and maintenance costs accounting for more than 30% of the total production cost.

 

In addition, post-heat treatment workpiece deformation cannot be corrected, resulting in poor component fatigue resistance and high failure rates during service.

Technological Process

 

The machining process of the IHG8805 is as follows: Blank → Rough Machining → Hard Broaching → Surface Finishing → Inspection.

 

 

Key Points by Segment

  

• The core step is hard broaching, with the details of each stage elaborated below:
   
• Rough Machining: A 5-axis milling machine is adopted to remove most of the material allowance, leaving a broaching allowance of 0.2-0.3 mm to ensure broaching efficiency.
• Hard Broaching: Driven by a rated pulling force of 50 KN and a torque of 45 Nm, the IHG8805 uses a customized broach to complete internal helical broaching forming in a single clamping operation. With a broaching speed of 1-8 m/min, it precisely controls tooth profile symmetry and tooth root fillet.
• Surface Finishing: Automated polishing equipment achieves a surface roughness of Ra ≤ 0.8 μm.
• Inspection: The in-process measurement system collects pitch and tooth orientation data in real time and adjusts process parameters in a closed-loop manner to ensure accuracy compliance.
•  
  Specialized equipment (e.g., customized broaches, in-process measuring instruments) is equipped for each stage, effectively controlling machining risks.

 

Revenue Data

 

• The process value of the IHG8805 is directly reflected through quantified indicators:
   
• Accuracy Indicators: Positioning error ≤ 0.02 mm, pitch error ± 0.03 mm, surface roughness Ra ≤ 0.8 μm, with accuracy meeting National Standard Grade 4-5.
• Efficiency Indicators: Single-piece machining cycle is 3-8 minutes (depending on module and tooth width), efficiency increased by 10-20 times, and the dual-station model achieves a single-shift production capacity of 300-500 units.
• Cost Indicators: Equipment investment reduced by 60%, workshop floor space decreased by 40%, comprehensive tool cost lowered by 50%, and total production cost cut by 35%.
• Performance Indicators: The hard broaching process retains a hardened layer thickness of 0.5-1.0 mm, improves component fatigue resistance by 30%, and reduces service failure rate by 25%.
•  
  These data have been verified through actual production by multiple leading enterprises, creating significant economic benefits for customers.

 

 

Customer Cases

 

Case Study: After a leading automotive gearbox manufacturer introduced the IHG8805, the single-shift production capacity of internal helical broaching was increased from 50 units to 300 units, the scrap rate was reduced from 8% to 0.5%, the total production cost was cut by 50%, and the delivery cycle was shortened by 80%.

 

Application Scenarios: Automotive/new energy vehicles (gearbox countershafts), industrial robots (joint reducers), wind power (internal gears of speed increasers), aerospace (engine accessories) and other fields.

 

Parameters and Configuration

 

Parameter Name	Value	Unit
Rated pulling capacity	50	KN
Rated torque	45	nm
Nominal stroke	800	mm
Max. broach length	990	mm
Cutting speed	1-8	m/min
Return speed	1-12	m/min
Tool feeding speed	1-5	m/min
Tool lifting speed	1-10	m/min
Floor area	2800×2900×4600	mm
Net weight	8500	kg