Skiving is one of the most efficient methods for producing gear teeth. It combines flexibility with high productivity and offers clear advantages over conventional methods such as hobbing, gear shaping, and broaching. Even complex internal gear teeth can be manufactured precisely in a very short time, and machining close to interfering contours or block tooth machining can also be carried out without any problems.
Another plus — the kinematics can be mapped on many universal machines with the appropriate software, so special machines are not necessary. Several machining steps, such as turning, drilling, and even gear skiving, can be performed in a single clamping. In summary, this results in a number of benefits for the user: short machining times, reduced non-productive and setup times, long tool life, low tool costs, excellent surface quality, and expanded application possibilities.
Technically DemandingHowever, despite these strengths, the process is not yet in widespread use. The reason — it requires precise interaction between the process, tool, and machine and is extremely demanding from a technical standpoint. This poses challenges for many users.
Sascha Beblein, head of RD&E gear cutting at LMT Tools, said: “In skiving, the tool is positioned at an angle to the axis of the workpiece being machined. The gear teeth are formed by this so-called axis cross angle in conjunction with a synchronous movement between the tool and workpiece axes and an axial feed. It is a very precise and fast process, but complex to use. Many of our customers would like to use skiving, but lack practical and process knowledge. We are now closing this gap. Our new digital engineering portal makes working with our tools noticeably easier and makes skiving usable for everyone.”
German headquartered
LMT Tools is one of the most renowned experts in the development and production of precision tools and has unique tool expertise, comprehensive technology and application experience, and a high level of vertical integration. All process steps are carried out in-house – from raw materials to the finished tool. This ensures quality, flexibility, and cost efficiency. Customers also appreciate the company's forward-looking approach, holistic methodology, and collaborative partnership.
The group's gear cutting specialist is LMT Fette, a subsidiary of LMT Tools. The company supplies high-performance, reliable tools for skiving, combining the latest research findings with proven application and manufacturing expertise. With their unique combination of excellent cutting edge preparation and individual process simulation, the skiving wheels set standards in terms of machining time, manufacturing costs, component quality, tool life, and process reliability, guaranteeing maximum performance in the production of internal and external gears.
Specially developed simulation software allows a detailed assessment of the relevant process parameters to be made during the design phase, considering the respective customer requirements, and provides valuable support on the way to safe and successful tool use.
Digital AssistanceEach skiving wheel is unique: the cutting material, cutting geometry, coating, and cutting edge preparation are precisely tailored to the component and the customer-specific process. Accordingly, each tool is individually parameterised and calibrated on the machine. However, the complex adjustment and calibration processes are anything but trivial and regularly cause even experienced users to ponder. A key problem is that if deviations occur in the measurement report – for example, during initial commissioning, after prolonged use, or after regrinding this usually requires consultation with LMT Tools — that costs time.
André Bollow, head of the gear cutting product line at LMT Tools, said: “As the manufacturer, we know our tools best and know exactly what correction values are required in the event of deviations from the target value. With the new engineering portal, we now enable users to analyse deviations independently and correct them immediately without having to forego our expertise – quickly, easily, and without detours.”
After entering the material and serial number (indicated on the tool) and the relevant measured values, the tool calculates the appropriate correction values in seconds and provides clear adjustment instructions, including for the cross angle and kappa angle – two key parameters in skiving. This transforms a complex correction process into a streamlined workflow. The application is deliberately designed to be simple and intuitive so that machine operators of all experience levels can use the digital engineering portal with confidence. This is groundbreaking considering the shortage of skilled workers and demographic change.
A New StandardThe engineering portal is automatically available with every tool purchase and can be used immediately after a one-time online registration. Determining correction values for deviations from the target value is an essential function, but not the only one. Other features include the retrieval of cutting data, an overview of available tools, the provision of setting data sheets, drawings, and tool information, as well as practical application aids. All information is accessible at any time and from any device – be it a PC, tablet, or smartphone.
“Our motto, ‘To ease machining,’ is both a benchmark and a promise. We don't just supply tools, we supply solutions. We support our customers throughout the entire life cycle of our tools – from the initial idea to recycling – and are always available to assist them. With the new digital engineering portal, we offer practical support and give users a decisive competitive edge."
The advantages are obvious: time savings thanks to immediately available correction values, autonomy thanks to independence from experts, higher gear quality thanks to precise parameterisation, and greater process reliability by minimising sources of error. This leads to measurably higher productivity and lower unit costs.
With its engineering portal, LMT Tools is breaking new ground and making it easier to access skiving. This innovative tool simplifies the use of this complex technology and combines expertise, data, and support in a single solution. It is the only one of its kind in the world.
André Bollow concluded: “Customer and market requirements are key drivers of innovation for us. Digitalisation plays a key role in this. We see ourselves as partners to our customers and want to make working with our products as easy and efficient as possible. The customer experience platform is the next logical step: it makes our tool and process expertise digitally accessible and opens up skiving to many users.”
Currently, the engineering portal focuses primarily on skiving but also includes other tool families. ChamferCut and hobs are already integrated, with additional tools and services to follow gradually.