Dressing the complex wheel profile is critical, ANCA developed the latest acoustic emission monitoring system (AEMS). AEMS can be taught to pick up the right sound of perfect dressing in noisy production environment.  Built upon supervised machine learning algorithm, AEMS ensures the wheel profile is dressed within micron accuracy with the least possible time while minimising the reduction in size.

Large disk type skiving cutters and shaper cutters require higher headstock accuracy, as the impact of A-axis positional error will linearly increase with diameter. This option improves the A-axis accuracy by a factor of 10. The positional accuracy is now ±0.00034 degrees.

The GCX Linear software package includes multiple software components for manufacturing and resharpening pinion type gear cutters. It includes design, simulation, grinding sequence programming, wheel editing and wheel dressing, supporting full virtualisation of the manufacturing process.

Gear cutting tools, such as skiving and shaper cutters have complex geometries. The design process relies largely on iterative optimisation. Using the design station, the cutter can be designed from basic gear workpiece data or the transverse section of the enveloping gear. The skiving kinematics can also be simulated to verify the cutter design and potential collision rectified.

Virtualisation of the full manufacturing process reduces setup time and scrap allowing streamlined manufacturing. Software modules include:
 

• Specialised import wizard - guides the user through the process of creating the wheel packs and setup grinding points.
• iGrind software – provides dedicated flank index generation grinding operation, supports both stepped and conical rake face as well as fluting, cylindrical grinding, step geometry editing operations and more.
• CIMulator3D - simulate the grinding process and analyse the parameters of each operation.
• Dresser software - supports standard and formed dresser roll, visualise the dressing process with errors over 1μm highlighted.
• Tool file management – take your saved tool file straight to the machine or upload to the tool library.

To ensure the design and calculation of skiving and pinion type cutters reach unparalleled levels of excellence, ANCA relies on esco's sophisticated PTM software. esco is a software company that specialises in mathematical solutions for process kinematics to produce threads and threading tools, gears and gear cutting tools like hobs, shaper- and skiving cutters. PTM offers comprehensive process simulation, tool design, and manufacturing simulation, ensuring the documented quality of tools and workpieces.

Once the gear cutter is designed in esco's PTM, the grinding path and grinding wheel shape are seamlessly exported to ANCA’s iGrind software. This integration empowers operators with the ability to effortlessly set up the grinding program and initiate the grinding process. Additionally, the grinding path compensation, utilising ANCA’s Integrated Gear Tool Measurement, takes place on the shop floor, ensuring optimal precision and repeatability. The workpiece data is saved and can be effortlessly reproduced whenever required.