Geared to make things move.

Transcription

1 Geared to make things move The Program

2 Geared to make things move Pages 4 5 Workpiece Range and Machining Processes Pages 6 7 KAPP KX-Series Pages 8 15 KAPP CX-Series Pages KAPP VX-Series Pages Machines. Tools. Technologies. Made in Germany. KAPP RX-Series Pages KAPP Special Solutions Pages NILES ZE-Series Pages NILES ZP-Series Pages NILES ZX-Series Pages NILES Special Solutions Pages KAPP Tools Pages KAPP Group Page

3 Geared to make things move. The Program. Jets passing at a whisper; cars achieving 3 litres per 100 km (50 mpg); harnessing the power of wind. KAPP and NILES deliver some vital preconditions to turn these visions into reality. In 1953, Bernhard Kapp the Honorary Degree Doctor of engineering founded his own company in Coburg, Germany,»because I had a couple of ideas that no one else wanted to realise.«today the KAPP Group of which NILES Werkzeugmaschinen GmbH in Berlin has been a member since 1997 is one of the leading machine tool manufacturers for hard finishing of gears and profiles.»we grew and prospered because no job was too small, too big or too impossible for us.«whether in the automotive, rail, marine or aerospace industries, if your company aspires to make things move in today s world, our machines are your ticket to success. Meeting the increasingly high standards for precision, dependability, safety and economic efficiency of the world s leading companies has taken our company to the top and made KAPP an international synonym for»made in Germany«quality. Manufacturing systems for sophisticated high quality gear and profile applications used by manufacturers of Automotive engineering Drive technology Compressors and pumps Railway technology Aviation Construction and mining machinery as well as job shops with corresponding customers Workpiece Range Wheels and shafts External spur and helical gears with or without projecting edges Internal spur and helical gear Gear related profiles Compressor rotors Ball screw tracks Worms Rotary pistons Pump spindles Gerotor designs Vane pump rotors Manufacturing Methods Generating grinding Profile grinding Coroning Honing Tool Concepts Non-dressable CBN or diamond tools Dressable tools, ceramically bonded carbide abrasives or SG Options Integrated dressing unit for generating and profile grinding tools, incl. measuring system for error compensation/nullification Integrated gear and profile measuring system Flexible loading systems for automated production Integrated stock-removal measuring system Topological grinding system 4 5

4 External and internal gears, as well as external and internal profiles, for workpieces up to 6,000 mm in diameter and, in special cases, beyond. Profile grinding, with dressable or non-dressable tools, by single indexing method, applicable for roughing and / or finishing operations. KAPP CBN non-dressable tools are available in a multi-rib version This process is applied in the KAPP KX-Series, KAPP VX-Series, KAPP RX-Series, for KAPP Special Solutions, NILES ZE-Series, NILES ZP-Series and in the NILES ZX-Series. Generating grinding with dressable or non-dressable tools with cylindrically shaped grinding worms, applicable for roughing and / or finishing operations or with globoidal shaped grinding worms, mainly applied for roughing operations This process is applied in the KAPP KX-Series and in the NILES ZX-Series. Coroning with internal geared nondressable coroning ring with a single layer of diamond with external geared non-dressable coroning wheel with a single layer of diamond This process is applied in the KAPP CX-Series. Honing with internal geared dressable tools This process is applied in the KAPP CX-Series. non-dressable tool dressable tool Workpiece Range Machine Processes 6 7

5 Gear Centers KX 150 / KX 150 P; KX 300 / KX 300 P Type KX 150 KX 150 P KX 300 KX 300 P Tip diameter Module Range Generating Grinding Profi le Grinding Face width Helix angle [deg] ± ± 45 Machining technology Based on a modular system in combination with the application possibilities of different tool and process technologies, userspecific, optimal production solutions can be configured. The following methods are possible: continuous generating grinding discontinuous profile grinding combination of both methods Application field and tool concept Thanks to the flexible modular system, the units KX 150 / 300 are equally suitable for all gear requirements and production volumes. External spur and helical gears of modules up to 10 mm, with an outside diameter of 300 mm and a gear width of up to 320 mm can be machined without any problems. Different workpiece data will be considered upon request. In this series the following tool concepts are offered: dressable ceramic tools for the flexible requirements of prototype machining as well as medium- and high-volume machining non-dressable tools for the highly productive manufacturing of medium- and highvolume series The non-dressable tools consist of a hardened steel base body with a ground base profile and a galvanic single layer of CBN abrasives. For further information see page 37. Since the tool spindle can hold several CBN tools, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, several gears can be machined in one set-up. In addition to the mainly used cylindrical grinding worms, single or multi-set CBN profile grinding wheels can be used for full-form machining as an alternative. Profile dressing unit With the machine configuration for the use of dressable tools, the profile dressing unit is integrated. From an easily accessible parking position this unit is automatically swivelled into the work area of the machine. By using the machine axes for dressing, the dressing of the cylindrical grinding worms as well as the profile grinding wheels can be performed very quickly and with a high flexibility. Measuring system The optional measuring unit allows the measurement of all relevant gear values. Especially in combination with the menu-assisted and by KAPP adapted operator interface of the Siemens Sinumerik 840D, the set-up time is considerably decreased when setting up new machining tasks. Machine control and drive concept A total of six NC axes perform the positioning of gear wheel and tool in respect to each other. They swivel the tool to the axis cross angle and carry out the linear and rotary motions necessary for the machining process. Workpiece and tool are directly driven. Automation There are several loading systems at your disposal which can be integrated in the machine arrangement. Depending on the task definition, type and volume of the workpiece loading as well as the additional functions embedded in the automatic sequence can be freely defined. KX-Series 8 9

6 Gear Center KX 160 TWIN Machine Technology The multiple workpiece spindle design concept which was already announced by KAPP 1997, has been systematically refined for the KX 160 TWIN gear center. The KAPP KX 160 TWIN is designed on a shared modular machine platform with features specifically for continuous generating grinding with dressable tools. Short set-up times are especially emphasized in this highly efficient machine technology. Application Field and Tool Concept The KX 160 TWIN is particularly well-suited for mass production gear manufacturing where quality levels are especially demanding. The machine includes two identical workpiece spindles, arranged at opposing sides of an index table. While machining one part, the second workpiece spindle simultaneously unloads / loads and aligns another part. Thus much of the auxiliary functions are done within the machining time to shorten floorto-floor time to a minimum. External spur and helical gears of modules up to 4.5 mm with an outside diameter of 170 (250) mm maximum, and a gear width of up to 320 mm can be ground on the KX 160 TWIN. Different workpiece data will be considered upon request. Profile Dressing Unit The KX 160 TWIN design includes an integrated single spindle dresser for dressing conventional grinding worms. Diamond profile roll sets are used as dressing tools. Depending on the design of the dressing tool, it is possible to dress the grinding worm to allow for root grinding. Machine Control and Drive Concept The KX 160 TWIN features a Siemens Sinumerik 840D machine control system which works in conjunction with a custom Windows-based operator interface. This KAPP designed user interface (HMI) is intuitive for setup and operating of the machine and provides modern grinding schemes for structure enhancement. A total of ten NC-axes are controlled to position the gear wheel and tool, swivel the tool to the cross axis angle, and perform the linear and rotary motions during grinding. The index table and both tailstocks are NC-axes, too. The workpiece spindle and tool spindle are directly driven. Measuring System The optional measuring unit allows measurement of gear profile and tooth width. With the user friendly KAPP HMI, data input tasks can be done quite efficiently reducing set-up time. Additionally, sample inspection of the gear quality can be sequenced to occur periodically during normal production runs. Automation The KX 160 TWIN is optimized for automatic loading. As a standardized turnkey solution, a combination of pallet conveyer and gantry loader is provided according to the specific application. Alternative automation methods, such as pallet or robot system can also be utilized. Type Tip diameter Module Range Face width Helix angle [deg] KX 160 TWIN 170 / ± 45 KX 160 TWIN 10 11

7 Gear Center KX 500 FLEX Machining technology The KAPP KX 500 FLEX is built on a shared modular machine construction platform. Application-specific production solutions can be configured on this versatile machine utilizing flexible process technology such as: Continuous generating grinding Discontinuous profile grinding Combination of both methods Application field and tool concept The KX 500 FLEX is designed to solve different process jobs efficiently and economically. The KX 500 FLEX is suitable for producing high quality gears at both job shops with small lot or single piece orders or in serial production. different technologies can be used for the dressing process, such as topological dressing of grinding worms with a radius tool. Machine control and drive concept The Siemens Sinumerik 840D has been implemented as machine control system of the KX 500 FLEX. Due to the added KAPP adapted operator interface based on Windows XP, the machine can be operated easily and comfortably. A total of eight NC-axes carry out the linear and rotatory motions necessary for the machining process. Index table and tailstock are accomplished as NC-axes, too. The workpiece and tool are directly driven. Type Tip diameter Module Range Face width Helix angle [deg] KX 500 FLEX ± 35 External spur and helical gears of modules up to 10 mm with an outside diameter of maximum 500 mm and a gear width of up to 520 mm can be ground on the KX 500 FLEX. Different workpiece data will be considered upon request. In this series the following tool concepts are offered: Dressable ceramic tools for prototype machining and grinding of medium- to highvolume series Non-dressable tools for the manufacturing of medium- and high-volume series, as well as the grinding of more challenging gear geometry, e.g. by using smallest tools Machine design concept and profile dressing unit KX 500 FLEX design concept features a index table which incorporates the tailstock support. The profile dressing unit is rotated into dressing position at the work spindle by the index table. The profile dressing unit is flexible to enable use of conventional dressable worms or profile grinding wheels. The profile dressing unit can accomodate a single or twin spindle dresser. According to the applied dresser concept, Measuring system The optional measuring unit allows the measurement of all relevant gear values. In combination with the menu-assisted and by KAPP adapted operator interface of the Siemens Sinumerik 840D, tasks for set-up can be done quite efficiently reducing preparation time. Additionally, sample inspection of the gear quality can be sequenced to occur periodically during normal production runs. Loading and automation The workpiece spindle is conveniently positioned on the index table to make it possible for the KX 500 FLEX to be loaded both by hand and by an automatic unit. Automation options include a standardized combination of pallet conveyer and gantry loader, or a robot system. For manual loading, the index table swivels the part to the operator s door. For automatic loading it is shifted laterally 90. A detailed configuration is created for each specific application. KX-Series 12 13

8 Gear Center KX 1 Machining technology KX 1 is an extremely rigid, quick and easy to set-up gear centre and enables continuous generating grinding as well as discontinuous profile grinding. Application field and tool concept The KX 1 is mainly designed for the hard finishing of external spur and helical gears in the range of medium- and highvolume series, preferably for the machining of shafts. Basically, workpieces of modules up to 10 mm, of an outer diameter up to 25 mm and a flank width up to 350 mm can be ground. Different workpiece data will be considered upon request. Considering the specific task definition, even application-specific solutions can be realised, e.g. the machining of two gears in one single set-up. The KX 1 uses only non-dressable hard precision finishing tools. They consist of a hardened steel base body with a ground base profile and a galvanic single layer of CBN abrasives. For further information see page 37. Machine control and drive concept The Siemens Sinumerik 840D has been implemented as machine control system. Its menuassisted operator interface has been adapted to the specific requirements by KAPP. A total of six NC axes perform the positioning of gear wheel and tool in respect to each other. They swivel the tool to the axis cross angle and carry out the linear and rotary motions necessary for the machining process. Workpiece and tool are directly driven. Automation There are several loading systems at your disposal which can be integrated in the machine arrangement. Depending on the task definition, type and volume of the workpiece loading as well as the additional functions embedded in the automatic sequence can be freely defined. Since the tool spindle can hold several CBN tools, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, several gears can be machined in one set-up. The grinding process used is mainly continuous generating grinding with cylindrical grinding worms. Alternatively, single or multi-set CBN profile grinding wheels can be used for full-form machining. Type Tip diameter Module Range Face width Helix angle [deg] KX ± 35 KX-Series 14 15

9 Coroning / Honing Machines CX 250 / CX 250 H / CX 250 I Type Tip diameter Module Range Face width CX CX 250 H CX 250 I Finishing technology Coroning and respectively honing causes a material abrasion by means of the electronically coupled relative movement of gear and gear shaped tool with a cross axis engagement of tool and workpiece. The generating coupling of these directly driven CNC axes reduces geometrical gear errors from the pre-machining phase. Coroned as well as honed gears offer the advantage of functional flank topology and optimum gear noise characteristics. There is no risk of thermal material damage and due to increased residual compressive stresses the inclination of wear decreases. Besides, the process and the machine offers short machining times, constant machining quality plus short setup times. Application field Coroning on the Coroning machine CX 250 with a non-dressable internal tool is mainly designed for high-volume and mass production of external spur and helical gears with a module range of 0.8 to 3.5 mm a tip diameter of 250 mm and a face width of up to 70 mm. In Coroning, special tool designs enable the cross axis angle between part and tool which is normally required to be reduced to zero degrees. Thus gears can be finished which have a clearance of only 0.5 mm to an adjacent obstructive edge or shoulder. Maximum flexibility in terms of technology and tool concept offers the Honing machine CX 250 H. Based on the design of CX 250 this machine type is able to put a dressable internal geared tool into operation. Due to the rigidity of the machine design the process parameters of this method far exceeding the established limit as well. The Coroning machine CX 250 I for highly productive hard finishing of internal spur and helical gears of medium and high-volume series, machines tip diameters of 250 mm, a module range of 0.8 to 3.5 mm and a face width of up to 50 mm. The tool applied is a non-dressable, external geared coroning tool. Tool concept KAPP supplies the complete production system including tools for Coroning of internal and external gears. The tools consists of a hardened and ground steel body with a galvanically bonded single layer of diamond. There is no need for the user to maintain and service the tool, because KAPP provides the replating service. The same does apply to gear honing on CX 250 H with a dressable honing wheel regarding the necessary diamond dressing gear and roll for dressing of tooth flank and tip. For further information see page 37. Machine control and drive concept All machines of the CX-series are operated via the menu-assisted user interface (HMI) developed by KAPP for the Siemens Sinumerik 840D. A total of five NC axis perform the positioning of gear and tool in respect to each other. The program directs swivel of the tool to the cross axis angle and carrys out the linear and rotary motions necessary for the finishing process. Part and coroning tool respectively honing tool are directly driven. Furthermore, the machine control of the CX 250 H contains user software needed for dressing of the honing wheel. Automation There are several loading systems at your disposal which can be integrated in the machine arrangement. Depending on the task definition, type and volume of the workpiece loading as well as the additional functions embedded in the automatic sequence can be freely defined. CX-Series 16 17

10 Universal Gear Grinding Machines VX 55 / VX 55 P; VX 59 / VX 59 P Machining technology All machine types of the gear profile grinding machines VX are based on a modular system which is designed for the use of different tool technologies. All versions are exclusively configured for discontinuous profile grinding. Application field and tool concept The machines of the VX-Series are extremely suitable for meeting the highest requirements concerning the end quality of the final gears. Based on changeable grinding units it is possible to work within this row both external and internal gears as external spur and helical gears and other profiles. Workpieces with a module of 16 mm, an outer diameter up to 630 mm and a workpiece length of 1600 mm can be machined. Different workpiece data will be considered upon request. The following tool concepts are offered: dressable ceramic tools for the flexible requirements of machining for the highly productive manufacturing of prototypes and mediumvolume series non-dressable tools for the high-productive manufacturing of medium- and highvolume series The non-dressable tools consist of a hardened steel base body with a ground base profile and a galvanic single layer of CBN abrasives. Since the grinding adapter can hold two exchangeable grinding spindles, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, two or more gears can be machined in one set-up. Profile dressing unit The CNC dresser is integrated in the work area of the VX machines and allows any grinding wheel profiles to be generated by using the machine control and machine axes. The combination of measuring system and profile dressing unit allows the automatic machining according to the so-called GMG strategy (Grinding Measuring Grinding). After entering the gear data, the dressing and grinding program will be automatically generated on their basis. The grinding wheel will be dressed and the pilot gap will be ground. Then this gap will be measured. The actual values and the nominal values will be compared and in case of a deviation, the dressing path will be automatically corrected and the grinding wheel will be dressed again. Then, the complete gear will be ground. Machine control and measuring system The VX-Series is equipped with modern control technics. The application-specific user interface guide the user through the input of required workpiece- and technology data. Lead modifications, technological corrections as well as the corrections of axis can be operated via modification editor. The optional measuring unit allows the measurement of all relevant gear values such as involute, lead, pitch, tooth thickness and tip diameter (according to DIN 3960). The measuring values are measured by a touch probe installed in the work area, then processed by the machine control and displayed on screen or printed out. CNC Axes X Feed axis for the generating of the feed motion of grinding tool in direction of the workpiece axis Y Infeed axis for the adjustment of axis distance between the grinding tool and workpiece Z Shift axis moves the grinding tool in direction of the axis or tangential to the workpiece cylinder A Work spindle, index drive for positioning of slot in grinding position B Swivel axis, swivels the grinding tool in the helix angle of the workpiece Special features Topological grinding: By using special KAPP CBN grinding wheels with a workpiece-independent and circular arc-shaped profile any topological modifications with irregular or periodical expansion in profile and flank line direction can be generated. The grinding wheel is moved line by line over the workpiece surface and generates at point contact the desired flank topology. Type Tip diameter Workpiece length Module Feed travel Swivel Range of Grinding Head [deg] VX 55 / VX 55 P 500 1, ± 90 VX 59 / VX 59 P 630 1, ,020 ± 90 VX-Series 18 19

11 Universal Gear Grinding Machines VX 55 / VX 55 P; VX 59 / VX 59 P Grinding with a dressable grinding wheel Grinding of a helical gear with a dressable grinding wheel. This provides the flexibility for producing prototypes or gears with special modifications in a short time. Grinding with non-dressable CBN grinding wheel Finishing of a double helical gear with two wheels mounted in tandem on a single spindle, a semi-finish wheel for removing distortion and a finishing wheel for final geometry and surface finish. The apex is getting measured by touch probe after grinding. Measuring a gear For measuring the gear, a touch probe is installed in the machine but swivelled to safe or park position during grinding and dressing processes. Machine axes Y and A are used for the measuring of an external gear. Internal grinding with a dressable grinding wheel Grinding of an internal gear with a dressable grinding wheel. Grinding arms are available for applications requiring wheel diameters down to 50 mm. Internal grinding with non-dressable CBN grinding wheel Equipped with two grinding arms, each of them with a non-dressable CBN grinding wheel for semi-finish and finish grinding of the internal gear. The grinding wheels are driven by a precision toothed belt. VX-Series 20 21

12 Rotor Grinding Machines RX 55 / RX 59 Type Rotor outside-ø Rotor length Profi le width Profi le height Workpiece length RX ,200 RX ,650 Machining technology The KAPP RX-Series machines are designed exclusively for discontinuous profile grinding. A special highlight is the extremely high stock removal rate, caused by the drive power possibility which is required for efficient grinding of rotor profiles. Application field and tool concept The machines of the RX-Series are employed for pre- and finishing grinding of pre-profiled profiles of steel and cast iron. The production of small and large batches takes the center stage. RX is optimally suitable for machining of prototypes and single-part production as well as series production. The part spectrum covers screwtype compressors rotors, rotary pistons, screw-type pump spindles etc.. Within this requirements, workpieces with a maximum of 320 mm in diameter, a profile length up to 800 mm, and a total length of 1,650 mm can be ground. Different workpiece data will be considered upon request. The RX-Series uses only non-dressable CBN electroplated precision finishing tools. The directly driven grinding spindle of the RX machine can hold two grinding wheels in parallel, whereas the tools are sequentially moved into the work position. This allows the prefinish and finish grinding in one set-up. Machine control and special software components The Siemens Sinumerik 840D with Windows XP has been implemented as machine control system. Thanks to the KAPP adapted operator interface based on Windows XP, the machine can be operated easily and has following options: Alignment of pre-machined profiles via a non-contact sensor in reference to one or all gaps Precise alignment of pre-machined profiles with a probe Measurement control for compensation of temperature influence by using of measuring unit with probe Run-out inspection to control the bearing journal on the tailstock side Automatic feed control of the feed axis prevents a power overload during the grinding process sometimes caused by an excessive stock removal rate. Feed control is programmable for the single limits Measuring system The optional measuring unit allows the control of all relevant profile parameter. A measuring unit (optional) provides an accurate inspection of all relevant part values. The measurement of a ground profile takes place via a touch probe which is installed in the machine s working area. The machine control calculates out of the measured values corresponding adjustments. The measuring results are then processed by the machine control system, displayed on a screen or a plotter. In combination with the KAPP operator interface, RX machine set-up times are significantly decreased. Additionally, a sample inspection of the part can be done during normal production runs, further increasing productivity. Drive concept Due to its innovative drive concept, the machines of RX- Series reaches up to 46 kw in the speed range of 2,000 to 8,000 min -1. Especially for rough grinding, it results in the highest stock removal rates and thus shortest machining times. In connection with tools technology, respectively adapted in optimal way to the new machining tasks, it ensures a high productive and efficient working process. RX-Series 22 23

13 KAPP Special Solutions GAS / GIS GAS / GIS The model GAS, thread grinding machine for external screw threads, is used for grinding of e.g. external ball screw threads for vehicle steering systems or for drive worms. The GIS, thread grinding machine for internal screw threads, grinds internal ball screw threads for vehicle steering systems. Depending on the workpiece size this machine type can be offered with horizontal or vertical workpiece axis. With all types of the G series non-dressable KAPP CBN profile grinding wheels are used. For further information see page 37. HGS HGS The high-speed grinding machine HGS is mainly used for grinding slots in pump rotors into the solid, through-hardened material. Slot widths of 0.5 to 2.0 mm can be produced with high efficiency due to package clamping and automatic unloading and loading. The integrated measuring control ensures that the slot width tolerances are kept. With the HGS only non-dressable KAPP CBN profile grinding wheels are used. For further information see page 37. HSP HSP The high-speed profile grinding machine HSP has been developed for the highly productive soft finishing of gears and profiles with an outer diameter of up to 400 mm. Grinding from the solid can be realised with the HSP in addition to the machining of pre-profiled materials. Since the grinding head of the machine can hold two grinding wheels, the simple cut segmentation in pre- and finishing grinding is possible. Besides, the HSP is equipped with integrated gear measuring technology. Siemens Sinumerik 840D is used for machine control. The continuously programmable grinding spindle drive reaches a performance of up to 110 kw in the speed range of 16,000 22,000 min -1. The maximum cutting speed is 210 m/s. Non-dressable KAPP CBN profile grinding wheels are used as grinding tool. For further information see page 37. KAPP Special Solutions 24 25

14 Gear Profile Grinding Machines ZE Type Tip diameter Profi le length Stroke length Helix angle [deg] ZE / / 45 / ± 45 ZE / 45 / / 600 ± 45 ZE / 45 / / 600 ± 45 ZE , / 45 / ± 45 ZE , / 45 / ± 45 Machine concept The NILES gear profile grinding machines of the ZE-Series are for precise grinding of external and internal gears with a tip diameter from 400 mm to 1,200 mm. The ZE machine concept represents quality, long life time and ergonomics. The ZE machines are known for their compact design and for the overall value. Base equipment of the machines The base equipment of the machines includes refrigerated coolant and filtration unit, dresser, tailstock, integrated measuring system, balancing unit, acoustic emission sensor, modem for remote diagnostics and comprehensive software for grinding and measuring of involute profiles. Further outstanding features of ZE machines are: Well dimensioned rotary table with electrical direct drive, hydrostatic bearing and large table bores. Ergonomic design by wide opening round doors and the position of the outer column under 90 to the main column. High torque drive of grinding spindle for optimum grinding power using tooth belt transmission between grinding motor and grinding spindle. Isolation prevents heat transfer into the grinding spindle and allows a compact grinding head design. Integrated measuring unit to support the operator for setup and optimization of the grinding process. Extensions All machines of the ZE-Series can be equipped with an internal gear grinding attachment. It s spectrum ranges from standardized internal grinding arms with touch probe for machining of workpieces by using dressable grinding wheels up to workpiece-specific internal grinding units with KAPP CBN grinding wheels for most sophisticated internal gears. The machinery with more drive power, stronger spindles and optimized drives using high feed rates for high productive grinding of workpieces with tooth size of 25 module in midsize and large series production grinding is possible. The compact design enables all operation and set-up from the shop floor without platforms. The wide opening round door enhances easy handling for single piece or small lot size production. Gears with short runout or workpieces with interfering edges can be ground with optional spindle adaptors. Control / Software The standard included software package contains very extensive software for grinding of involute profiles. Workpiece data can be input and handled direct from the drawing. Editors support the input and programming of lead and profile modifications. The state of the art machine software assists the operator by selecting the right grinding process parameter and uses the operator experience to learn. The machine automatically calculates grinding and dressing technology based on the important process parameters specific time removal rate Q w and specific material removal rate V w. The standard software package comes with very sophisticated alignment and measuring programs. Automatic alignment of wheel to gear tooth determines the shape of the gear and informs about stock per flank and if all teeth can be fully ground based on tooth thickness specified. The evaluation software compares results against DIN or AGMA. ZE-Series 26 27

15 Gear Profile Grinding Machines ZP Type Tip diameter Profi le height Stroke length Helix angle [deg] ZP / / 1,000 / 1, / + 90 ZP 10 1, / / 1,000 / 1, / + 90 ZP 12 1, / / 1,000 / 1, / + 90 ZP 15 1, / / 1,000 / 1, / + 90 ZP 16 1, / / 1,000 / 1, / + 90 ZP 20 2, / / 1,000 / 1, / + 90 ZP 25 2, ,250 / 1,550 / 1,750 ± 40 ZP 30 3, ,250 / 1,550 / 1,750 ± 40 ZP 40 4, ,250 / 1,550 / 1,750 ± 40 ZP 50 5, ,250 / 1,550 / 1,750 ± 40 Machine concept The NILES ZP-Series is well known worldwide for profile grinding of external and internal gears with diameters from 800 to 6,000 mm. The ZP concept represents quality, durability and flexibility. Base equipment of the machines The base equipment of the machines includes refrigerated coolant and filtration unit, dresser, integrated measuring system, balancing unit, acoustic emission sensor, modem for remote diagnostics and comprehensive software for grinding and measuring of involute profiles. Further outstanding features of ZP machines are: Well dimensioned rotary table with electrical direct drive, hydrostatic bearing and large table bores. Hydrostatic guideways for high accurate positioning, excellent load capacity and almost unlimited lifetime. High torque drive of grinding spindle for optimum grinding power using tooth belt transmission between grinding motor and grinding spindle. Isolation prevents heat transfer into the grinding spindle and allows a compact grinding head design. Integrated measuring unit to support the operator for set-up and optimization of the grinding process. Extensions All machines of the ZP-Series can be equipped with an internal gear grinding attachment. It s spectrum ranges from standardized internal grinding arms with touch probe for machining of workpieces by using dressable grinding wheels up to workpiece-specific internal grinding units with KAPP CBN grinding wheels for most sophisticated internal gears. The machine can be equipped with more drive power, stronger spindles and optimized drives using high feed rates for high productive grinding of course pitch workpieces in midsize and large series production grinding. The machine design concept of the ZP series allows the integration or combination of further grinding processes. For example, instead of the outer support column a special column for complete machining or process additions can be installed. Control / Software The standard included software package contains very extensive software for grinding of involute profiles. Workpiece data can be input and handled direct from the drawing. Editors support the input and programming of lead and profile modifications. The state of the art machine software assists the operator by selecting the right grinding process parameter and uses the operator experience to learn. The machine automatically calculates grinding and dressing technology based on the important process parameters specific time removal rate Q w and specific material removal rate V w. The standard software package comes with very sophisticated alignment and measuring programs. Automatic alignment of wheel to gear tooth determines the shape of the gear and informs about stock per flank and if all teeth can be fully ground based on tooth thickness specified. The evaluation software compares results against DIN or AGMA. Target modifications as crown, slope and reliefs will be considered and can be analyzed according to DIN as well. ZP 60 6, ,250 / 1,550 / 1,750 ± 40 ZP-Series 28 29

16 Gear Center ZX Preface Continuous generating grinding is renowned for its main benefit of ultra-high-productivity for smaller diameter mass produced parts. Productivity continues to increase thanks to the development of new tools and the innovations in control and drive technology. With the ZX-Series, we now offer machines which extend this productivity also to the 1,000 mm workpiece diameter range without compromising the demands for high flexibility. In case of small lot sizes or very high quality requirements, profile grinding is recommended and preferred so this process is included in the standard machine model. Machine Base and Index Table For the highly dynamic generating grinding, a very rigid basis was developed. All main components are made from vibration damping grey cast iron. The bed is a single unit offering extremely high rigidity. The installation is realized with alignment shoes only. The index table is generously dimensioned and supports high table loads. It is driven by an electric high-accuracy direct drive. Dressing Process Several dressing processes are available: double-flank dressing with simultaneous tip dressing for mass production Single-flank dressing with separate tip dressing for economical costs on small lots topological dressing for nearly infinite modifications and gear types for prototypes Measuring System and Handling Another vital factor for flexible machining is the ability to measure the finished parts right on the machine. This option allows the operator to inspect and evaluate the quality achieved without disturbing the clamping thus shortening set-up times considerably. Furthermore, high ease of operation is another distinctive advantage of this machine. All operating points are in easy reach from one position while loading can be done either manually or by crane another plus from an ergonomic standpoint. Technology The machine software was adopted from the proven KAPP model, where it has successfully been used for many years. This control unit offers many useful functions considerably increasing the flexibility of the machine, as e.g. the automatic centering of the dressing tool in the worm or the automatic centering in the worm in the workpiece or the topological dressing. The advantages of this machine concept are convincing which is reflected by its popularity since its market introduction. Type Tip Diameter Module Generating Grinding Profi le Grinding Face width Helix angle [deg] min. / Center distance index table - grinding wheel Index table load [kg] ZX ± / 500 1,000 ZX ± / 560 1,000 ZX , ± / 710 1,000 ZX-Series 30 31

17 NILES Special Solutions ZP 10 B / ZP 30 B Machining technology The machines of the ZP B-series have been designed for the complete finish machining of external spur gears. Special feature of this Series gear teeth, bores and end faces of the gears may be machined on a single machine. Application field and tool concept Like all machines of the internationally renowned and well proven ZP-series, the ZP B-machines by NILES may be employed in all fields of large gear grinding thanks to their comprehensive equipment. Due to the combination of internal cylindrical grinding and face grinding, these machines are mainly used for the grinding of gears where quality and economic benefits can be derived by performing all tasks in a single clamping. Various tools are used on the ZP B-Machines. For grinding of gears as well as for bore and end face grinding, dressable ceramic tools for flexible machining options are offered. Non-dressable tools may be used in gear grinding. Dressing devices The machines of the ZP B-Series come equipped with two dressing devices. For gear grinding, the machines offer a CNC dressing unit for the profiling of corundum and sintered aluminium oxide grinding wheels. Via the machine control and controlled axis, customer defined profiles may be generated. A second dresser trues the tool for bore and face grinding. The cup grinding wheel dressing tool can dress the outer diameter and the end faces of the grinding tool. Additionally, a comfortable operator interface for internal cylindrical grinding and face grinding has been developed. The measuring system may be employed here to determine the optimum center position of the gear to minimize the volume of grinding stock. Special features The machines of the ZP B-series have been designed and built to comply with the highest demands in large gear grinding. Thanks to the combination of two machining processes, they offer a high saving potential or to be more precise: Savings in set-up, aligning and idle times Realisation of smaller allowances No machining of auxiliary surfaces Reduction of cycle times Reduction of scrap and reworking percentage Smaller footprint It was not until the electrical direct drive, that the combination of gear cutting and internal cylindrical grinding became possible. This hybrid process allows for maximum positioning accuracy in gear grinding in conjunction with a fast rotation for the internal cylindrical grinding. The two-column concept offers an exceptionally high rigidity. In excess of this, it allows a high modularity. The second column may be fitted with various equipment and options depending on the intended application. Machine control and measuring system As machine control, the Siemens Sinumerik 840D is used. The operation and data input for gear grinding is identical to those of the ZP-series. NILES Special Solutions 32 33

18 NILES Special Solution ZPI Preface Profi le grinding of internal gears is an extension of the capabilities of most external profi le grinding machines provided by a simple and relatively small attachment that is adequate for the smaller demands but not optimum for larger gear sizes. Now the number of internal grinding operations has been on the increase with the start of the series production of windmill gears being the latest. Hand in hand with the rising number of applications goes the demand for higher productivity, especially in the case of larger gears. An optimal solution has now been developed and is offered by NILES. Internal Grinding Unit As with grinding external gears, particularly large modules require maximum rigidity. For this purpose, NILES developed a highly rigid internal grinding head from grey cast iron. This head mounted to the main column and incorporates a powerful 25 kw drive and a toothed belt driven grinding spindle. This special confi - guration increases the torque at the grinding spindle, thermally decouples the spindle and reduces the necessary installation space. The CNC dresser is positioned immediately above the grinding wheel so that dressing can also be performed without the long travel to an external dresser thus cutting down on machining time even more. The dressing paths are generated by the dresser axis and the tangential axis. This concept allows for any type of profi le modifi cation as it is known from external grinding. mination prior to and following a gear measurement right after the grinding process. No change to the set-up or chucking is necessary. The gear measurement may be done automatically after the grinding process as necessary. For the optimal work set-up, the GMG strategy (Grinding-Measuring-Grinding) is available together with the measuring system - a method well known from external gear grinding. The machine automatically compensates the profi le deviations measured in a pilot gap. Circular Table The new NILES ZPI utilizes the high-accuracy and proven circular table group of the NILES ZP 25/30. The circular table with double-sided hydrostatic bearings is positioned by an electric high-precision direct drive. In this way, the circular table - as the heart of the machine - is practically wear-free maintaining its high quality during its entire life. Measuring System However, the feature worth mentioning the most is the integrated measuring system of the NILES internal grinding head. It is located below the grinding spindle drive and is simply swivelled in for measuring operations. The measuring system permits centering with high process stability and the precise allowance deter- NILES Special Solution 34 35

19 Non-dressable CBN- and Diamond Tools KAPP manufactures non-dressable, galvanically plated CBN and diamond grinding tools for hard and soft finishing of gears and profiles. KAPP grinding tools have had the best reputation since nearly 30 years worldwide, guaranteeing highest quality, efficiency and economic grinding CBN profile grinding wheels single or multi-ribbed roughing and finishing wheels suitable for grinding of external and internal gears of the automotive and aircraft industry radial, screw, rotor and worm profile wheels high speed grinding of profiles and gears as well as plunge grinding, abrasive cutting, cylindrical grinding 2. CBN grinding worms roughing and finishing worms in form of cylindrical worms and globoidal worms for highly efficient grinding of external gears and profiles Diamond Coroning rings and Coroning gears suitable for the KAPP coroning of external and internal gears as well as shoulder gears Diamond dressing rolls with and respectively without tip dresser for flexible or workpiece based dressing of ceramic tools or CBN tools for continuous generating grinding of external gears Diamond dressing gears for profile dressing of dressable honing rings. 6. Master gears for double flank roll checking before and after hard finishing In addition to manufacturing of new tools, KAPP also replates CBNand diamond tools in Germany, USA, Brazil, Japan and China. KAPP Tools 36 37

20 KAPP GmbH, Coburg NILES Werkzeugmaschinen GmbH, Berlin KAPP 2 Technologie GmbH, Coburg KAPP TECH, Boulder/USA KAPP TEC, Diadema/Brazil KAPP Asia, P.R. China»Geared to make things move«the vision of the KAPP Group. The enterprise group, one of the world-wide leading machine tool manufacturers, offers system solutions for hard finishing and soft precision finishing of gears and profiles. To the KAPP Group belong following companies from Coburg: the KAPP GmbH, producing and selling production solutions for the above mentioned applications in the diameter range up to 500 mm, the KAPP 2 Technologie GmbH, producing tools with a single layer of CBN and diamond coating. In 1997 the NILES Werkzeugmaschinen GmbH in Berlin, producing and selling machines for gears in the diameter range above 500 mm up to 6,000 mm was acquired. Besides, KAPP has subsidiaries in the USA, Brazil, China and Japan. The machines from KAPP Group are classed as topquality products of the branch. Customer-specific and optimized production solutions combined with technical advice given during the development and production process support the customers of the KAPP Group with their multiple tasks, such as increase of efficiency in drives, in order to increase the performance while reducing the fuel consumption. In addition to the mentioned products and solutions, an essential key to the success of the KAPP Group is the closeness to the customer, the innovativeness as well as the motivated and highly qualified employees of the enterprise. KAPP Group 38 39

21 KAPP GmbH Callenberger Straße 52 D Coburg Germany NILES Werkzeugmaschinen GmbH Nordring 20 D Berlin Germany KAPP Technologies 2870 Wilderness Place Boulder, CO USA KAPP Asia Technologies (JiaShan) Co., Ltd. Kapp Road 1 DaYun Industry Zone JiaShan ZheJiang P.R. China KAPP TEC Indústria e Comércio de Máquinas e Ferramentas Ltda. Rua Solimoes, Diadema S.P. Brazil Phone: +49 (9561) Fax: +49 (9561) info@kapp-coburg.de Phone: +49 (30) Fax: +49 (30) info@niles.de Phone: +1(303) Fax: +1(303) info@kapp-usa.com Phone: +86 (573) Fax: +86 (573) info@kapp-asia.com Phone: +55 (11) Fax: +55 (11) info@kapptec.com KAPP Group Callenberger Straße 52 D Coburg Phone: +49 (95 61) Fax: +49 (95 61) info@kapp-niles.de