cutting gears with a rotary table quotation

I have seen a Rotary Table with dividing plates at a good price, what are the advantages of a Dividing Head over the Rotary Table. I know that a chuck can be fitted to the Rotary Table, it seems to me they do the same job.

Check the rotab can be mounted on its side or you have a big enough angle plate. Sometimes the extra diameter of the rotab gets in the way but otherwise it is just as capable as a dividing head until you get to the more complex "universal" type that can tilt and do differential indexing for prime numbers, or be driven to make spirals.

A rotary table is a very useful but not often used device in most workshops, takes up space as well, I know, as I have one together with the dividing plates. Be careful using the tables for gear cutting as there are some with errors and its very annoying to find that you have a thin tooth for no fault of your own. Recently I made a stepper motor Arduino controller from the article in Model Engineer Workshop issue 249 which I can recommend. No more thin or one tooth short errors, works good. The article used two switches as inputs, where as I and I"m sure others have done, used a 4 x 4 key pad. Not being very well versed in micro electronics I received help from readers on this forum, and from my neighbour Steve, many thanks fella"s. John

Unless you have a CNC machine or stepper driven rotary table, a manual rotary table is one of the few ways to machine cylindrical paths in a way you couldn"t otherwise. You"d struggle to do that with a dividing head. I used my rotab to machine internal and external surfaces with success, although nowadays my CNC machine does a much better job in a fraction of the time.

I have seen a Rotary Table with dividing plates at a good price, what are the advantages of a Dividing Head over the Rotary Table. I know that a chuck can be fitted to the Rotary Table, it seems to me they do the same job.

They are similar devices with similar functionality. But I"d say a Rotary Table is generally more flexible than a Dividing Head. Often a table can be mounted either flat or vertically, whereas heads are typically one-way. It"s occasionally useful to be able to clamp work direct to a table. Heads often only divide while tables usually do angles and divisions.

I have a rotary table, and combined with a calculator can divide any number of divisions, not limited by the plates. BUT it"s even easier to get wrong if not systematic.

My Vertex HV6 is one such. It cost me three scrap items, before realising that the errors were not mine. I made up my own division table, using EXCEL. This showed that the published table had eight errors or omissions!

Thanks for these replies they have been very informative. The reply from Dave Halford about cutting curves on the Rotary Table can be a problem with the worm gear, if not up to it.

I have been given a 4 inch table some time ago unused which was purchased in the mid eighties. It is a import and will cut a curve in steel as I used this to recess a flywheel.

I like the idea of a Rotary Table with plates, the ones I"ve seen advertised by Warco seem quite a good price, but are they any good,can they cut curves in steel with out stripping the worm gear ? Fed up with buying crap, stuff not fit for purpose until modified.

This is what can happen to the gears when cutting a curve if the load is too high. The rotary table was not one of the cheap ones but a quality one, made in Japan.

A rotary table is a handy accessory for your mill for lots of applications.and I would not be without one but would advise that you get the biggest that would fit on your mill table..

I have happily cut curves in mild steel and gauge plate on my Soba 6" but they were within a reasonable expectation of what the table could handle and the depth of cut was also appropriate to my machine and tooling. Take a look back through some of Paul"s other photos and see the size of work being done on his similarly made but "quality labled" table and is it any wonder the gears stripped?

Chain drilling followed by light finishing cuts with a keen cutter may be a sensible alternative to trying to make heavy cuts with less than keen cutters (and not climb milling, either), when using a less robustly built rotary table. So, much in agreement with JB, I suppose.

Apologies to Howard if this is well covered elsewhere, but the calcualation to *check* an entry in a division table is relatively simple. It does involve vulgar fractions. Do schools still teach that?

Whatever about the rotary tables themselves being crap and way out,there is no excuse for the charts to be in error. A simple test run would soon show up any blunders which should then be corrected before production.

If anyone wants to try amending the original spreadsheet for gear ratios other than the original 90:1, the EXCEL spreadsheet is viewable at the top of the thread quoted by Neil. Hopefully, changing the formula from 90:1 to, say, 40:1 will produce sensible answers for Rotary Table or Dividing head with that ratio.

Am wondering if I am clever or brave enough to make two more division plates for my HV6. A "D" plate with 22, 24, 26, 28, 32,34, 38 holes and an "E" plate with 42 and 46 holes. All these should be "doable" with the existing "A", "B" and "C" plates, and would fill a few gaps in the table.

Another project would be to make a small Dividing Head for the mini lathe, (inspired by Stub Mandrel"s one, using the division plates from the HV6. Another "Make it up as you go along job"!

Dividing heads allow you to divide a circle into equal fractions conveniently. Anything that involves regular action around a circle is a candidate for a dividing head.

A rotary table has no stops so it is not convenient to do large numbers of things at equal intervals because you would have to painstakingly determine the interval. Also, the rotary table does not divide the circle. For example, if you were making 13 equally spaced operations using a rotary table you would have to calculate some wierd angle for each operation and dial it in--a tedious process. For example, here are the 13 angles for a circle division:

Do you want to manually set each of these values? Have fun doing that. Now, imagine doing it for 53 divisions. You will be there all night. Not only that, the error will be a lot more than a dividing head.

I have used Aloris Posts and tool holders for 45 years , but do not know what you mean about "quick threading attachment" --is that where the gear is ?

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Fig. 4—On this tilting rotary table, one servo controls rotation, another controls tilt. Both servocontrols are slaves to the CNC with RS-232 communication, providing five-axis capability from a standard three-axis CNC.

Fig. 1—Modern rotary tables such as this one from SMW Systems have large, widely spaced spindle bearings, large diameter wormwheels and built-in spindle brakes.

If you want to make parts similar to the complex valve body (upper left), an indexer using M-code, RS-232, or “full fourth axis” control is appropriate. Only positioning and rotary cutting moves are required. The center workpiece is a cam that requires simultaneous rotary and linear moves. You’ll need full four-axis control for such workpieces. If you want to do parts similar to the impeller on the right, the contour cutting will require simultaneous five-axis machining.

Many plant managers and shop owners dream of having the latest horizontal machining center (HMC) with all its features, benefits and sophisticated capability. While typical HMC features such as an automatic pallet changer and a 100+ cutting tool magazine are valuable, perhaps the most valuable characteristic is the HMC’s ability to machine on more than one side of the workpiece due to a built-in indexer or full fourth axis.

On complex workpieces that require machining on surfaces not 90 or 180 degrees from each other, indexing or fourth-axis rotation is almost essential to produce the piece. Even when rectangular workpieces with all surfaces 90 or 180 degrees from each other are put on a tombstone, the HMC’s built-in fourth axis of rotation creates a productivity advantage. This is true even if machining on more than one side of the part is not essential.

Any time you can increase the “run cycle,” do more cutting in one operation and avoid handling the workpiece, productivity goes up. Workpiece accuracy also improves. Unclamping and refixturing a workpiece to present a different surface to the cutting tool is always going to introduce some error.

The high cost of horizontal machining centers compared to the incredible values available today in vertical machining centers puts horizontals out of reach for many shops. Fortunately, today there are several suppliers of quality accessories that allow the VMC shop to equip its verticals with indexers, fourth axes and tombstones. These add-ons really work and give many of the benefits of an HMC at a fraction of the price.

Earlier rotary tables and indexers didn’t have the accuracy, rigidity or control flexibility of today’s models. Many shops that tried using indexers in the past had been disappointed in the performance of the older models and abandoned their use in favor of multiple operations, multiple holding fixtures and multiple handlings of the workpiece. They decided that the manual, multiple-operation process was better than trying to use ineffective early model indexers and rotary tables. Today, the situation is different. Manufacturers now offer units that are very accurate, very rigid and have a variety of control and interface options.

The best indexer and control system for you depend on the work you need to do. As with most things, different designs compromise certain capabilities to gain others. Unless you understand these trade-offs, you are at risk of selecting something other than the best system for your requirements. Let’s see what’s available, review the differing capabilities and discuss the advantages and disadvantages of each design. Once you understand the options, you can evaluate them against your requirements and then consider prices and suppliers.

Of course, such a system does not exist. Add the “lowest price from the supplier that gives the best service and support” component and it probably never will exist.

Terminology in the area of indexers is not standard. Terms such as fourth axis, indexer, rotary table and so on are used interchangeably by different machine tool and accessory companies. So, when selecting and buying, you must ask a few questions before assuming you know what you’re going to get. Also, beware of terms such as “precision,” “high precision,” “accurate,” and “rigid.” Is the “brake torque” specification some absolute break away spec or the torque at which some “unacceptable” amount of rotary deflection occurs? Is the “ten arc seconds” accuracy specification certified every one degree, or is it inspected only every 15 degrees? There are no industry standards for specifications and testing. So ask questions and deal with a supplier in which you have confidence, or buy with a guarantee of performance to make your parts.

We’ll start with the mechanical hardware and discuss the electronic control options later. There are at least three common mechanical indexer/rotary table types.

These tables provide infinite positioning as well as the possibility of rotary cutting. A servomotor controlled directly either by the CNC or by a secondary servocontrol rotates a wormscrew, which drives a wormwheel on the rotary table spindle.

The absolute position accuracy of these systems is a function of the quality (precision and accuracy) of the wormgear set (wormscrew and wormwheel), the accuracy and resolution of the servosystem, and the means of servoposition feedback. Most of these servosystems utilize an encoder to monitor the position of the motor rather than the rotary spindle directly. To eliminate any inaccuracies in the wormgears and servo system, some high-end systems use a glass scale or other encoder directly on the rotary spindle to monitor actual rotary spindle position. Figure 1 (at right) shows a typical wormgear rotary table cross section.

If controlled directly by the machine tool’s CNC, they are most commonly referred to as a “full fourth axis.” A full fourth axis has the advantages of having only one CNC program, no programming required by the operator on the shop floor, minimum chance of a crash due to operator error, and the ability to make simultaneous rotary and X, Y or Z moves to do true helical milling operations as required by some more exotic workpieces.

Claims of position accuracy are often misleading since there are no industry standards. Although some manufacturers test and certify absolute position accuracy every one degree, most do not state exactly what their specification means.For all except those few expensive systems with glass scales directly on the rotary spindle, any accuracy specification is for a new table before it has been subjected to any “crashes,” which are not uncommon. Even seemingly small crashes can damage wormgear sets.

Typical infinite positioning wormgear systems utilize a friction brake to hold position against cutting forces. When cutting forces are applied directly on the rotary spindle centerline, friction brakes are generally adequate for most work. However, when cutting forces are applied to workpieces far off centerline, such as on the edge of a part on a tombstone fixture, the resulting torque on the rotary spindle can cause it to deflect. This result is especially likely when heavy cuts produce high thrust forces.

These indexers offer discrete positioning only. Depending on the number of teeth on the face gear, the minimum increment of index might be 15 degrees, 5 degrees or 1 degree. Whatever the minimum increment, only workpieces with angles representing some multiple of the minimum can possibly be machined.

Face gear mechanisms used in indexers are similar to those most commonly found in the turrets of CNC lathes, which by function must index very accurately and very rigidly to withstand the high cutting forces the lathe turret encounters. Face gear mechanisms generally fall into two categories, the two-piece and the three-piece design. Two-piece designs require the face plate of the indexer to “lift” to disengage the face gears. Three-piece designs maintain the same accuracy and rigidity of a two-piece without the need to “lift” the faceplate. In Figure 2 (at right), note the massive face gear that locks the indexer spindle in position.

Assuming it’s a quality face gear set, absolute position accuracy is superb and is maintained for the life of the indexer almost in spite of any “crashes” that might occur. Units with true absolute angular position accuracy of 5 arc seconds or less are available. These units are ideal for the highest precision work such as line boring half way from one side, then indexing 180 degrees and line boring half way from the other side.

Some face gear systems use a servodrive to achieve approximate position and then rely on the face gear for final accurate positioning. These systems are bi-directional and fast. Any random move can be programmed with one simple command. Some other systems use a pneumatic piston to rotate to the approximate position. Typically, these systems rotate only in one direction. All moves must be equal and may require a pause to utilize more then one M-code signal to achieve position. These work but can be tedious to program, set up and operate. They are more prone to crash due to operator error then servodriven units.

These indexers are becoming a thing of the past. They have all the disadvantages of the pneumatic piston driven incremental face gear indexers. Plus, compared to face gear units, they are neither particularly accurate nor rigid. Index positions are usually limited to 15-degree increments. Position is controlled by a pin in a hole or more often by a dog in a notch on the outside of a ring.

Whether you select an infinite positioning wormgear rotary system or a facegear system as the best mechanical design for your work, your next decision involves how you will control the rotary axis.

With a pneumatic incremental indexer, you probably will have no choice. Your machine’s CNC will control the indexer by communicating with a special indexer control via an M-code.

If you select a system with a servodrive, you have three choices: 1.) direct “full fourth axis” using only the machine’s CNC, 2.) an M-code command from the CNC to a separate rotary control, or 3.) RS-232 communication between the machine’s CNC and a separate rotary control. Each of these choices has advantages and disadvantages.

A single, four-axis CNC is the easiest to use and provides the most control. Four-axis CNC is best for certain kinds of workpieces. Full four-axis control systems are usually ordered for delivery with a new machine. Systems can be retrofitted; however, retrofitting is complicated and expensive. The advantages of a single four-axis control are numerous, and the disadvantages are primarily related to cost.

The single CNC constantly tracks all three linear axes (X,Y,Z) and the rotary axis. This provides the ability to do precise helical cutting with simultaneous rotary and X, Y or Z moves.

While a few machine builders offer a full four-axis control with rotary table for about 10 percent of the base price of the machine, most charge more than 20 percent.

Very few machine builders make it easy to retrofit a full four-axis rotary table. For most builders, retrofitting is a complicated process, and the cost typically exceeds 30 percent of a base machine price.

The motor for the rotary axis must be matched to the servodrive of the CNC. Because cable connections are not standard from one machine builder to another, rotary tables can not generally be used on more than one machine.

Some applications may require the accuracy and rigidity of a face gear system. However, many machine builders don’t offer face gear systems with a full four-axis control, although such systems are feasible.

An M-code actuated system provides a fourth axis of motion by combining a standard three-axis CNC with a rotary table or face gear indexer that has its own separate rotary servocontrol. The rotary program is entered and stored in the separate rotary servocontrol. The CNC communicates with the rotary control via an M-code. When the rotary control receives the M-code signal, it executes the next rotary move stored in its memory, then sends a signal back to the CNC, telling it that the move has been completed.

Typically, the rotary program includes many separate rotary moves. One move might be a simple index to position at full rapid speed. Another might be a slower rotary move to machine a groove or other feature on the workpiece. Figure 3 (at right) shows a typical rotary servocontrol system.

High quality M-code controlled systems are available from several suppliers for a price of about 10 percent of a base machine price. (For example, a 5C rotary system at $6,000; a 6-inch faceplate system at $7,000; a 9-inch system at $10,000; and so on).

Requiring only one M-code, 110V power and an air line for operation, these systems can be retrofitted to almost any CNC machine, typically with less than a day of downtime.

Systems can be moved from one machine to another as long as the next machine can issue M-codes. A shop with multiple machines and multiple rotary systems can select the best system for each job regardless of the machine. For example, a small indexer can be used for small parts to avoid cutting tool interference problems and to minimize indexing times. A big indexer can be used for big parts. A face gear indexer can be used when the maximum in accuracy and rigidity are needed and the work can be accommodated by multiples of 5 degrees of index.

The machine operator needs to enter the rotary program into the rotary servocontrol, or select the right program if it’s already stored in the rotary control’s memory. This takes some time, and there is the chance of an error.

If the machining cycle is ever interrupted in mid-cycle, such as to inspect a workpiece feature or replace a worn cutting tool, the operator must be sure to back up the rotary program and the CNC program to a point that keeps the two programs in sync. This step can be confusing, and any error can result in a “crash,” with a cutting tool coming down to a workpiece rotated to the wrong position.

Although it is possible to perform simultaneous rotary and X, Y or Z moves, they are not recommended. If you have patience and can afford to scrap a few parts, you can use trial and error to find the right rotary speed to match the linear move and determine starting points that match.

Recently developed, RS-232 communication between a three-axis CNC and a rotary servocontrol offers advantages of full four-axis and M-code operation. RS-232 is the commonly used, standard electrical interface for connecting peripheral devices to a computer. Personal computers often use the RS-232 communication protocol to send information to a printer. Another common use for RS-232 communications is connecting a PC to an external modem.

Nearly all CNC units have an RS-232 port, and it is commonly used to exchange CNC programs between a computer system and the CNC. More recently, RS-232 connections have been used by CNCs to communicate with robots and rotary tables. To communicate with the rotary table’s control, a special line of code is inserted into the CNC program. This line of code sends a string of numbers and letters through the RS-232 port to the rotary table control, which translates the string of code into rotary moves.

RS-232 communication between a three-axis CNC and a rotary servocontrol provides much of the best of both worlds of full four-axis and M-code operation. Both the linear and rotary moves are stored in the CNC as part of the workpiece program. When a rotary move is required, the CNC sends the commands for that one move (rotary speed and angle of rotation) through an RS-232 line to the rotary control.

The rotary control executes that one move and sends back a signal to the CNC, indicating that this move has been completed. The CNC then commands its next linear move. The separate rotary servocontrol simply works as a slave to the CNC. The machine operator turns the rotary control on in the morning and does not need to attend to it the rest of the day. Figure 4 (at right) shows a tilting rotary table system utilizing two rotary servocontrols with RS-232, providing five-axis capability from a standard three-axis CNC.

Crashes are nearly as unlikely as with a full four-axis control. The correct rotary program is always selected because it is part of the total workpiece program stored in the machine’s CNC. Note: Rotary moves should be programmed in “absolute position” so that if the machining cycle is interrupted, the operator can back up the CNC program to just in front of a rotary move, then safely resume the program.

Retrofitting is easy provided the machine’s CNC has an RS-232 port and appropriate communication software, which may already reside in the CNC or be available from the machine builder.

With RS-232, two rotary controls can be operated by most three-axis CNCs with only one RS-232 port. Five-axis capability with a tilting rotary table setup can be retrofitted to a three-axis machine for about $25,000 (a new, full five-axis VMC option is typically priced at $95,000).

Both the work you need to do and the machines you own or intend to purchase will influence what you select for a rotary axis. These guidelines summarize what you should consider.

When buying a new machine, get prices on everything the builder offers, no matter what kind of workpieces you’ll be machining. If the builder offers a full four-axis system with a high-quality, infinite-positioning rotary table at a price of about 10 percent off the base machine, this system will probably be your best choice.

If your workpieces can take advantage of the accuracy and rigidity of a face-gear system, and you can live with the 5-degree minimum increment, a face gear system controlled by RS-232 or M-code is a good choice. A few builders offer a face gear system with true four-axis control.

If you’re doing a variety of work that requires simultaneous rotary and linear helical moves, you’ll probably want a true four-axis system regardless of the cost. However, you should consider a more economically priced RS-232 or M-code system when you are retrofitting an existing machine and have only a couple of jobs requiring these moves, especially if these jobs are long run and you can afford some extra programming and setup time. These systems are worth considering if you simply can’t afford the price of a true fourth axis.

If you’re retrofitting existing machines, especially if you have several and want to do rotary work on more then one of them, check with the builder on the cost of upgrading to full four axis. You may conclude that the cost and flexibility advantages of RS-232 or M-code will make one of them the best choice.

Adding a rotary axis to a VMC is worthwhile whether you want to do full four-axis simultaneous machining of exotic workpieces, simple indexing of parts that need machining on surfaces not at 90 degrees from each other, or tombstone processing of rectangular parts that benefit from a longer unmanned machining cycle. Today, many good options exist. If you’re buying a new machine, have the builder quote the optional systems it offers. If you’re going to retrofit an existing machine, contact either the original supplier or the companies that offer complete indexer and rotary table systems. Retrofitting is highly affordable. (Systems from SMW Systems, for example, generally cost a little over $1,000 per inch of faceplate diameter, including installation and training.) MMS

Mitee-Bite Products’ fixtures demonstrated their powerful clamping support in a project with Akron Gear & Engineering to vertically hold a 1-ton ring during machining.

Gear cutting is the only technology currently available which provides both the accuracy and the ability to process the hard materials required by modern exacting mechanisms. Simultaneously, Coordinate Measuring Machines (CMM) are one of the most reliable and accurate metrological tools. In order to integrate these two machines in gear manufacturing industry, an analytical methodology is developed for Numerical Control (NC) data generation to produce and measure gears on machine tools and coordinate measuring machines without rotary table. Homogeneous transformation matrices are used for expressing the ability function matrices of the employed machines and in the generation of the desired tool location matrices. NC data equations are determined by equating the corresponding elements of the machine’s ability function matrices to the desired tool location matrices. To verify the validity of this methodology, a designed gear meshed with rack was machined and then its surfaces were measured by a CMM equipped with a touch-trigger probe. This methodology is a general one and is applicable to various spatial gears. It combines the activities of design, manufacturing, and measurement, thus making the production process more flexible, automatic, and controllable.

Gotta keep track of those partial degrees and add them up and move the dial accurately. One mistake in your math or turning the knob and you have scrap.

Index Designs is an all-American company. Their founders were part of the team that helped design, engineer, manufacture and market the very successful line of Fadal Machining Centers – starting in the 1970s. Index Designs entered the rotary table market in 2006 with the goal of creating a line of high-end, rugged and accurate rotary products that we could sell at affordable prices, but still be able to provide reliable delivery and superior customer service and support. Thier products are completely manufactured in our Chatsworth, California facility. Index Designs uses state-of-the-art, HMC’s, VMC’s and CNC gear cutting machines.

4th Axis rotary table for use with the Pulsar milling machine. Bipolar 200 step drive motor with adjustable worm gear (90:1 ratio) engagement for zero backlash. Includes tail stock.

The TR160 5 Axis Rotary Tables, manufactured by Haas, consist of dual axis Trunnion rotary table that is capable of tilting up to 160 mm. It also has a scale assessment ...

The TR210 is HAAS"S rotary table developed and configured to be integrated with HAAS"S mills 4th and 5th axis drivers to provide complete and optimum operation. It has a diameter of 210 mm made from trunnion ...

... space with high load capacity. The individual rotary tables are equipped with Harmonic Drive units, which ensure high moment load capacities and high concentricity and axial runout accuracies.

The work table is graduated 360 degrees around its circumference and is driven by a precision Worm and Gear providing a 90:1 reduction ratio. One turn of the Handle moves the Table through 4 degrees. ...

... Tilt-Yaw (A/B) two-axis rotary assembly provides high-speed machining capabilities for complex 3D part geometries. The precision-aligned system allows accurate positioning on a hemispherical surface. ...

... ) MDR two-axis rotary assembly provides high-speed machining capabilities for complex 3D part geometries. The precision-aligned system allows accurate positioning on a hemispherical surface. Uses cost-effective ...

... ) MDR two-axis rotary assembly provides high-speed machining capabilities for complex 3D part geometries. The precision-aligned system allows accurate positioning on a hemispherical surface. Uses cost-effective ...

Our FÖRSTER swivel welding tables offer maximum working comfort for all-round welding of complex assemblies. Ideal for all tasks due to a variable arrangement of our patented T-slot system.

The hydrostatic rotary tables from ZOLLERN impress with their durability and a high concentricity and axial runout accuracy. Thanks to the ZOLLERN bearing clearance compensator, the optimal pocket pressure ...

... the table is the rotation, the user may require the rotary table for drilling operations and milling. Using the servo drives in conjunction with the machine CNC control ...

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