GermanyKarl KlinkCarl Kelinkobroaching machine

-vertical broaching machine

-horizontal broaching machine

-external broaching machine

-Dry bed

-Hard pull bed

-hydraulic broaching machine

-CNC lathe

Company outline

GermanyKarl KlinkCarl KelinkoIt is a company with a hundred years of history and proficient in various cutting techniques. In the past80For many years, we have been active in the field of cutting technology and are an internationally leading manufacturer. Our clients cover all major automobile manufacturers and suppliers. In addition to mechanical engineering, we also manufacture our own cutting tools and provide small and large batch machining services. In addition to the inventory of regular lathes, we also have spiral lathes and hard cutting lathes in stock. However, our machining capabilities are not limited to cutting. In our production facilities, we are able to perform various types of machining, directly processing workpieces to the desired level“Prepare to assemble”.

The company's headquarters is located in GermanyNiefernThe subsidiary is located in France and has a total of approximately220Name of employee. Thanks to innovative tool and machine technology,Karl KlinkIn the past few years, it has held a significant market share. Active employees, customer-oriented approach, investment in modern production technology, and based onDIN EN ISO 9001，VDA6.4Require research and development, production, and service to enableKarl KlinkBecome an expert in the field of cutting.

technology

For large-scale production of cutting complex contours on metal workpieces, wire drawing is the most reasonable processing method. If high cutting ability and accuracy are required. This advantage lies in its technical principle: the contour is cut by a multi tooth cutting tool in one go, and the material to be cut from the workpiece is sequentially removed by one cutting edge after another on the puller. Here, the technical complexity is replaced by the feed motion of other processes with the movement of toothed cutting edges. For internal machining, processing starts from the opening, while for external machining, it starts from the outside of the workpiece. The cutting stroke can be vertical or horizontal, and the cutting motion can be linear or spiral.

·Internal sharpening

A typical example is the formation of a straight tooth profile, which begins with a circular hole on the workpiece. cutting motioncorrectA straight line, the workpiece is placed on an unclamped lathe support and coaxial with the lathe. A special form of internal cutting is spiral cutting.

·External cutting

In external machining, machining starts from the outer surface of the workpiece. Due to the bias force, the workpiece must be clamped with a fixture.

·Hard cutting

Precision drawing of hard workpieces, with a cutting speed exceeding60m/min,Use a special puller with a hard alloy coated puller sleeve.

·Spiral cutting

Use a spiral cutting tool to cut the inner spiral profile, and the spiral motion of the cutting edge relative to the workpieceIt's CNC.

·Dry cutting

At the cutting speed25m/minUse a specially coated cutting tool for coolant free cutting.

machine tool

（1）Bed classification

Dual column drive

Automatic loading and unloading system

From a kinematic perspective, a lathe is a relatively simple machine tool, and its structure can be classified as follows:

·According to the cutting process, it can be divided into an external lathe and an internal lathe

·According to the spindle position, it is divided into horizontal and vertical lathes

·According to the spindle drive, it can be divided into hydraulic driven lathe and electromechanical driven lathe

·Specialized lathe (such as cylindrical lathe, chain lathe)

Advantages of vertical result design

·The required floor area is relatively small

·No bending under static load of the blade

·Better cooling effect

·Better connection to the production line

Advantages of horizontal structure design

·Lower overall height

·Larger travel length

·Simpler lateral feed for heavy-duty workpieces

·No need for a work platform

Due to the relatively simple nature of bed pulling, it mainly usesPLCControl. Cutting tasks such as spiral cutting usually involve complex movements and require higher flexibility to adapt to machining contours. Therefore, the latest CNC technology is now being used.

Comparison Table of Hydraulic Drive and Electromechanical Drive:

There is no significant difference between the two in terms of the cutting process. Although people say that hydraulic driven machine tools have damping characteristics and are therefore more popular among users.

Karl Klink Karl Klink bed from Germany

To meet different processing requirements, various forms of vertical and horizontal internal lathes are provided

·Karl Klink from Germany stands uprightinternal broaching machine

(1)GermanyKarl KlinkCarl KelinkoElevating desktopwithinbroaching machine

The machine tool adopts fixed cutting tools, and the lifting worktable of the workpiece moves from bottom to top to pull and cut the workpiece.

The advantages of this machine tool are:

The foundation does not require digging pits or high tool shafts. During the machining process, there are few moving parts, only the workpiece worktable moves, and machining and axis movement occur simultaneously, resulting in high precision and short machining cycle.

(2)GermanyKarl KlinkCarl KelinkoDouble column lifting desktop lathe

Double column lifting worktable with dual drive, special design:

·Design of Special Rigid Machine Tool Body

·All guide rails and drive units with a lathe workstation (each2), using linear motion.

·The drive device located above the work area adopts an open design that can be easily adjusted from front to back.

·The special rigidity of the machine tool body and the central pressure application located on the guide column minimize the tilting and bending torque as well as the lateral pressure during the machining process.

Placing the drive device outside the work area and in an open design, with one side overheating, is beneficial for quickly balancing the temperature.

This makes the machine tool highly stableGood dimensional accuracy of the workpiece, long tool life, and minimal guide wear The result is to achieve optimal process reliability during the long-term operation phase

High degree of machine tool automationAutomatic loading and unloading can be achieved from the rear of the machine tool on different horizontal planes At the same time, the front of the machine tool is kept clean, allowing for easy installation, tool replacement, and manual loading and unloading

In order to apply the dual column lifting platform concept to relevant practical situations, we have three basic series of hydraulic or electromechanical drives

·Hydraulic or electrical mechanical drive

·Bed pulling itinerary600–3000 mm

·broaching force25–1200 kN

(3)GermanyKarl KlinkCarl KelinkoSpecially designed double column lifting table top lathe

The double column lifting table machine tool has expanded from ordinary applications to hard pulling, dry pulling, and complex spiral cutting processes.

Karl KlinkDouble column lifting desktop machine toolDThe driver is specifically developed for the following processes:

·Hard Pulling Bed

·Dry Pulling Bed

·Spiral bed

（4）GermanyKarl KlinkCarl KelinkoSingle column lifting desktop lathe

Compared with the double column lifting platform lathe, the single column design is suitable for cheaper prices/High cost-effectiveness or limited installation area

（5）GermanyKarl KlinkCarl KelinkohardtypePulling bed

The excellent configuration features of this special design include:

·servo-Hydraulic or electromechanical rapid cutting drive

·Workpiece contour positioning calibration unit

·Fully automatic cooling and filtering system(Parallel cycle time)

The cutting speed of hard cutting must exceed60 m/min. This extremely high speed during the cutting process can usually be achieved through the use of hydraulic or electromechanical drive

Compared to electromechanical drive, hydraulic driveIt has superior dynamism and low investment costs Modern hydraulic drive, with the charging of the accumulator, can effectively reduce the connection load compared to other driving methods, while also providing better dynamic performance

servo-Hydraulic drive serves as a hydraulic CNC shaft with programmable cutting speed during the cutting stroke, and the allowed speed in industrial production is 120 m/min

For hard cuttingThe workpiece must be placed in the calibrated cutting position to allow the cutting tool to be loaded in a suitable manner At the same time, the workpiece also needs to be calibrated properly Here, the workpiece is aligned with the feeding claw through the core shaft

Cutting oil is used for cooling and lubricating workpiecesThe very small and hard chips generated during the hard pulling process must be reliably filtered out

If the chips pass through the coolant circuit to the Dala cutting station, it will cause high tool wearThe automatic edge gap filter ensures optimal filtering performance and combines minimal maintenance work The cleaning process is optimally integrated into the machine cycle by the control system, without interrupting the production process

（6）GermanyKarl KlinkCarl KelinkoshieldtypePulling bed

The typical design features of dry cutting include:

·Hydraulic or electromechanical drive, with a cutting speed of up to30 m/min

·Funnel shaped machine tool hole filling

·Effective negative pressure chip extraction through side ducts

·Tool cooling

·Brush fixture for pulling knife and cutting support

·Noise reducing lining

In industrial productionThe storage, treatment, cleaning, and recycling of cooling lubricants have become increasingly difficult, and most importantly, due to strict environmental requirements and occupational safety regulations, the cost is also very high

In wet drawing chamber machining (oscillation cooling), the coolant directly completes three tasks at the cutting point. Secondly, it is extremely close to the inner cavity of the machine tool:

·lubrication

·cooling

·Chip transportation

These direct functions of the coolant can be replaced by modern hard material coatings with good sliding performance, high wear resistance, and thermal insulation on suitable substrates.

When the cutting speed is 25 m/min, the longest tool life and optimal surface characteristics can be achieved Compared with wet grinding, its cutting force is only slightly larger, thanks to the good sliding performance of the dry drawing area

In terms of drivingHydraulic drives with accumulator charging are more popular because of their better dynamic performance and lower investment costs

（7）GermanyKarl KlinkCarl KelinkoSpiral bed

Modern spiral bed has the following characteristics:

·Numerical Control Motion Characteristics

·Electromechanical driveAnd it has good rigidity

·The cutting speed during the cutting stroke is programmable

·Programmable spiral unit for cutting tools or workpieces, achieved through gears without reverse clearance

·Hydraulic clamping of workpieces during the cutting process, with programmable clamping pressure

go overThe rotational motion of the tool or workpiece required for the spiral cutting machine is provided by the main motor coupling

In order to obtain the most flexible machine tool technologyIn modern spiral lathes, the spiral relative motion of the cutting edge of the tool is achieved through CNC linear interpolation of the workpiece Through numerical control programming, dynamic performance is applicable to new tooth profiles

CNC spiral lathe requires high rigidity driveThis means maintaining the programmed cutting speed as accurately as possible (straightness) during the cutting stroke Only electromechanical drives can meet these requirements, as they widely use roller spindles

The rotation of workpieces or cutting tools requires gear units with high torsional stiffness and low backlashConvert the required torque to the helix angle

Compared to simple internal cutting applications, in spiral cutting, the workpiece must be clamped so that it cannot rotateThis is done through hydraulic fixtures. If it is a thin-walled sun gear, the clamping pressure must be changed during the cutting stroke

（8）GermanyKarl KlinkCarl KelinkoNon elevating desktop vertical internal bed

In traditional vertical internal lathe, the puller passes through the workpiece from top to bottom There must be a base

（9）Non elevating desktop vertical sliding bed

Pulling knife passes through the workpiece from top to bottom

The tool is pre clamped by hydraulic pressure between the downward cutting guide rail and the upward driving cutting guide rail,Obtain high precision in eccentricity and axial runout.Due to the risk of knife breakageThe use of push type cutting is limited

·GermanyKarl KlinkCarl Kelinkohorizontal internal broaching machine

Perform internal cutting in the horizontal direction.

GermanyKarl KlinkCarl Kelinkoexternal broaching machine

60During the year,KARL KLINKDesign, manufacture, and continuously improve vertical and horizontal external pull beds

To meet different processing requirements, various forms of vertical and horizontal external lathes are provided

（1）GermanyKarl KlinkCarl Kelinkovertical external broaching machine

KARL KLINKThe vertical flat bed has the following design features:

·Extremely stable and low vibration bed, low heat generation

·Main drive arranged at the center of the bedA torque free connection with a large slide rail or roller rail for a lathe slide table, equipped with hydraulic clearance compensation

Four series cover a variety of workpieces:

·Hydraulic or electromechanical drive

·Pulling stroke1000–3000 mm

·broaching force63 – 1200 kN

·Slide width400 – 1200 mm

The design of workbench functions is also diversified:

·Fixed workbench

·Sliding workbench

·rotary table

·Sliding rotating worktable

·Tilting Table

·Dual station design with two independent tool slides and worktable

（2）GermanyKarl KlinkCarl KelinkoVertical lifting desktop machine tool

KARL KLINK has also applied the concept of a lifting worktable to a vertical flat lathe, transforming it into a modern patented machine tool concept

（3）GermanyKarl KlinkCarl KelinkoHorizontal external pull bed

Due to their complex shapesA flat lathe usually consists of several parts, which are screwed or clamped onto the handle of a lathe

If the tool size or weight is large or the cutting stroke is long, a horizontal lathe is usually used.

Special Pulling Bed

The special lathe adopts a special design to provide the optimal solution for special cutting applications.

Here, emphasis can be placed on the scope of the workpiece (such as turbines), the use of special cutting tools (such as cylindrical cutting tools), the application of special processes, such as using a chain lathe for external cutting, or integrating into an internally connected production system.

（1）GermanyKarl KlinkCarl KelinkoCylindrical bed

If the external contour covers the entire surface of the workpiece, such as the hobbing of the outer teeth of the synchronizer wheel hub, a cylindrical puller is requiredThese tools have specialized cylindrical lathes, in which the pressure rod moves together with the workpiece on the fixture from bottom to top, through a fixed tube and built-in puller, with a narrow guide device inside the tube

（2）GermanyKarl KlinkCarl KelinkoSpecial inner and outer pull bed

It is used for complete machining of internal and external teethCombining an internal lathe and a cylindrical lathe

（3）GermanyKarl KlinkCarl KelinkoChain bed

Chain type lathe is a special machine tool for continuous surface cutting with extremely high production capacity

（4）GermanyKarl KlinkCarl KelinkoBlind hole inner contour short stroke lathe

If the workpiece size does not allow the puller to pass through, the tool can be divided into several short parts and several single operationsThis internal cutting method is called short stroke cutting

（5）GermanyKarl KlinkCarl KelinkoTransmission line cutting unit

If the machine tool is integrated into the transmission line, we call it a lathe unit

（6）GermanyKarl KlinkCarl KelinkoComposite cuttingprocessing system

These systems integrate various machining processes, such as turning, drilling, milling, thread tapping, and finally pulling

（7）GermanyKarl KlinkCarl KelinkoPull cutting production line

generallyThis is an automated chain for a lathe, which includes various machining processes required for a workpiece

cutting tool

Pulling knife is a multi tooth cutting tool,The cutting edges are distributed in geometric order,Gradually increase the cutting thickness.Here we distinguish between flat and inner knives.We applied similar parameters to these two types of knives.for example,The cutting speed of green manufacturing applications is2-20 m/minbetween.Use easily cut materials, suitable coolant, and optimized tools,The tool life can be achieved300m.

New cutting tool technology allows for non use of coolant during cutting.Dry cutting method can achieve similar tool life.The dry cutting speed is close to25 m/min,Therefore, higher yields can be obtained.Tools coated with hard alloy are used for cutting hard workpieces.The speed requirement for hard cutting is> 60 m/min.In the optimized process,The tool life exceeds1000 m.

The following are the new research and development achievements in recent years:

（1）GermanyKarl KlinkCarl Kelinkohardbroach

Precision drawing of hard workpieces, with a cutting speed exceeding60m/min, using a special puller with a hard alloy coated puller sleeve.

（2）GermanyKarl KlinkCarl Kelinkospiralbroach

Using a spiral cutting tool to cut the inner spiral profile, the spiral motion of the cutting edge relative to the workpiece is controlled.

（3）GermanyKarl KlinkCarl KelinkoDry cutting and pulling knife
At the cutting speed25m/minUse a specially coated cutting tool for coolant free cutting.

（4）GermanyKarl KlinkCarl Kelinkoinside broach

The composition of the internal knife includes:handle,guide,Coarse teeth cutting,Precision Teeth Cutting,Backup teeth and rear support handle.Handle and back support handle.The handle and rear support handle are used to support the puller inside the lathe and standardize it.

The following contours can be generated by an internal puller:

·hole

·Keyway

·spline

·polygon

·Surface Profile

·sawtooth

·Involute gear

·Special contour

（5）GermanyKarl KlinkCarl KelinkoSpecial toothed internal cutter

The spiral puller can cut the inner contour of a spiral shape.Spiral cutters require specific machine tool technology,Mechanical or numerical control control of the spiral relative motion of the cutting edge of the cutting tool.

Hard knives can be used to cut hard workpieces,With or without machining allowance.These cutting tools typically include a tool holder, a hard alloy, and a specially coated cutting sleeve.

Dry cutting tools with special coating,Used for machining workpieces without coolant.

（6）GermanyKarl KlinkCarl KelinkoExternal broach

Due to their complex shapes,An external cylindrical puller usually consists of several blade parts for cutting,Screw into the puller holder. In addition to high-performance high-speed steel and crushed steel,The cutting edges of these tools can also be welded hard alloy plates.

The following workpieces are suitable for using a flat puller:

·Connecting rod and cover

·Steering rack

·Turbine blades

·Bearing cap

·Cylinder block

·Cross toothed flange

·class

（7）GermanyKarl KlinkCarl KelinkoSpecial forms of flat knives

Cylindrical cutting tool for machining gear external teeth(Synchronizer wheel hub),Disc flywheel,Parking brake wheels, etc.

application

The shape of the contour of the inner and outer surfaces is completed by a puller in one process. In principle, all workpieces with continuous shapes in the cutting direction cross-section can be subjected to tensile cutting. Grinding, as a machining process, is mainly used for processing inner or outer surfaces with high surface quality and dimensional accuracy. Due to the fact that a lathe is a very expensive specialized tool, it is mainly used for large-scale production.