Sr. No.Conventional Machine3-axis Machine5-axis Machine
1AC induction or DC motors are used for axis traverse, so axis traverse speeds are fixed.AC servo motors are used for axis traverse so traverse speeds are controllable.AC servo motors are used for axis traverse so traverse speeds are controllable.
2All feeds will be generated through main motor using clutches.Different servo motors are used for radial and axial feed. Elimination of clutches.Different servo motors are used for radial and axial feed. Elimination of clutches.
3Radial feedbox and change gears are used for radial feed.Feedbox is removed and feed is programmable.Feedbox is removed and feed is programmable.
4Axial feedbox and change gears or PIV is used for axial feed.Feedbox is removed and feed is programmable.Feedbox is removed and feed is programmable.
5Feed can be given in fix steps.Infinitely variable feeds can be given so cycle time can be reduced with better quality.Infinitely variable feeds can be given so cycle time can be reduced with better quality.
6Hob spindle speed can be vary using PIV or step pulleys.PIV is removed and infinitely variable speeds can be given.PIV is removed and infinitely variable speeds can be given.
7Radial movement is given through lead screw or hydraulic cylinder.Radial movement is given through high precision ballscrew resulting in high position accuracy and repetability for DOP.Radial movement is given through high precision ballscrew resulting in high position accuracy and repetability for DOP.
8Manual hob shifting or timer based hob shifting.Hob shifting is controlled by servo motor so accurate position hob shifting resulting in better hob life.Hob shifting is controlled by servo motor so accurate position hob shifting resulting in better hob life.
9Incorporate several interlinked drive trains for performing either single or simultaneous movements required of the individual machine groups. So complicated kinematics & use of clutches.Simplified kinematics and clutched are eliminated.Simplified kinematics and clutched are eliminated.
10Linkage between hob and table will be achieved by change gears.Linkage between hob and table will be achieved by change gears.Electronically generating drive for precisely synchronizing the rotary motions of hob and workpiece and for effecting the supplementary differential rotation.
11Special attachments are required to cut taper and crown gears.Interpolation of radial and axial axis is possible so taper and crown gears can be cut.Interpolation of radial and axial axis is possible so taper and crown gears can be cut.
12Axis rapid rates are improved so idle time can be reduced.Axis rapid rates are improved so idle time can be reduced.
13Tailstock operation is manual.Automatic tailstock operation.Automatic tailstock operation.
14Machine setting time is more as all settings are manual.Dedicated cycles for gear cutting are provided through simple dialog program.Cutting cycles are provided with menu driven programming and different set up data can be stored permanently.
15Following axis are controlled through CNC and servomotors
X axis – Radial
Y axis – Tangential
Z axis – Axial
Hob and table through spindle motor.
Following axis are controlled through CNC and servomotors
X axis – Radial
Y axis – Tangential
Z axis – Axial
C axis – Work Table
B axis – Hob spindle
16Helps to reduce both machining and idle times. CNC makes new cycle combinations possible and economically practical.
17Operating requires considerable gear knowledge.CNC substantially reduces skill level as the gear know-how is now part of the software provided with the machine.
18Feed rates and feed directions have to be set with mechanical means and need to be tested. Dead stops, trip dogs and limit switches must be adjusted. These setting and testing operations require experience and knowledge and consume a lot of time.ProgrammableProgrammable
19The silent operation of the electronic drive components which, to a large degree, have replaced the conventional mechanical drive train elements of considerable operating noise, helps to drastically reduce noise levels in the manufacturing area.
20The practically wear-free operation of the electronics, coupled with fewer mechanical operating components, increase the life of the machine.