Machining gears with KMT hob
The history of the Pritzwalk gear factory dates back to the story of the founder GDR. The VEB Zahnradwerk (gear factory) was established in 1969 and the factory was privatized in September 1993. The company is now managed by Heiner van de Loo, Maximilian van de Loo and Dr. Carsten Binder. In the past, the company focused more on the manufacture of clutches, and now focuses on the production of gears and shafts with gear diameters up to 1500 mm and shaft diameters up to 500 mm for parallel mounting of gears.
In recent years, an investment of about 60 million euros has affected the production structure. The Pritzwalk factory has established another heat treatment workshop, and the number of staff has tripled. “Replenishing a new generation of skilled workers with qualifications is the current priority†Maximilian van de Loo said. “So we are continuing to expand. Of the 400 employees we have, 30 are beginners in machining and EDM, which makes it necessary to introduce external basic training after the second year of study.â€
Regarding the industry in which the gear factory serves, the answer from Pritzwalk employees is very consistent: “In addition to the automotive industry, we serve any gear that needs to be.†The manufacturer of wind turbines is a major customer, contributing more than 1/3. Sales, but railway construction and shipbuilding are also very important. Regionally, the core business is more in Germany, with only about 30% of the parts used for export, mainly exported to Scandinavia.
The number of manufacturing orders ranges from 1 to 5000 sets. Each part is a special solution for the customer; no product is stored as an inventory standard. From the development of the company in recent years, the strategy is successful.
Heinz Wiechert, Production Planning Manager at the Gear Factory, describes the company's self-concept as follows: “We consider ourselves to be a service provider. Customers come to us with parts drawings and tooth system information, and then we manufacture based on this information. To some extent, we work with our customers to optimize gears."
Employees from Kennametal's Advanced Engineering department found the ideal conditions for testing new gear hobs.
“We have a long and successful cooperation with Kennametal in milling and turning,†said Heinz Wiechert. “We always have an open attitude towards common development and optimization. So we are very happy to test the hob. We have also tested other competitive products, but we are still impressed by such strong productivity.â€
Details of the hob - machine settings
The first milling test with the Kennametal hob was in early 2009, with a gear modulus of 7-70 teeth - tooth width 145 mm. This is almost immediately visible. The original hob used took 40 minutes to complete the process; the same production process can now be completed in 24 minutes. At the same time, the Kennametal hob increases the life of each tool to 70 to 80 pieces, compared to a maximum of 25 pieces for the original tool.
Another advantage of the hob is the ability to quickly change the blade outside of the machine. “There is only a blade replacement, and for us the tool body is almost always usable, with no unproductive time for grinding or coating,†says Heinz Wiechert.
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