Gear Shaping Machines. P 800 S to P 3200 S and P 800 ES to P 1200/1600 ES K E E P I N G T H E W O R L D I N M O T I O N TM

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Jeffrey Underwood
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1 Gear Shaping Machines P 800 S to P 3200 S and P 800 ES to P 1200/1600 ES K E E P I N G T H E W O R L D I N M O T I O N TM

2 machine concept New-generation Shaping Machines for large gears: fast, flexible, economical. Faster, more economical production of larger external and internal gears requiring shaping rather than hobbing is possible with the newgeneration Gear Shaping Machines from Gleason-Pfauter. Gear Shaping Machines offer a useful alternative to the soft machining of involute gears where workpiece or tooling geometry does not allow the use of conventional processes such as hobbing or form milling because of interference. Gear Shaping Machine P 2000 S with fully-enclosed work area (outer safety railing removed for photo only). 2

3 common platform This line of machines is designed for workpiece diameters of up to 3,200 mm (higher diameters upon request). The Electronic Helical Guide (ES) design can be applied for workpiece diameters of up to 1,600 mm. The Electronic Helical Guide feature is used to produce helical gears, thus eliminating high procurement costs for conventional mechanical helical guides and retooling times. This broad modular concept provides a variety of benefits for the user: Proven platform. The large-machine platform used for Gleason-Pfauter gear shaping machines is common to Gleason- Pfauter hobbing and grinding machines, operating with unsurpassed rigidity, stability and reliability in hundreds of production environments worldwide. Higher accuracies. The unique design of the machine bed and worktable ensures that cutting forces are absorbed and transferred to the machine foundation. The use of flat guideways and narrow separate guides with pre-loaded roller bearings ensures more precise radial slide movements across the complete speed range. The extremely stiff table bearing combined with a proven backlash-free double-worm index drive allows for a high torque range and high radial and axial runout of the worktable. Modular design. A modular machine bed and table design allows for a larger diameter workpiece to be machined with a smaller machine footprint to optimize machine investment and floor space utilization. For example, the radial travel of the P 800 S can be expanded to accommodate a workpiece diameter as large as 1200 mm (P 800/1200 S model), enabling the user to increase capacity without the investment required for the larger machine. All machine sizes and designs available are summarized in the table below. Versatile shaping heads. Mechanical and hydraulic shaping heads are available for stroke lengths up to 225, 380 and 650 mm. This allows for an optimum, job-oriented and cost-effective choice of shaping heads to cover a broad range of different workpieces. Advanced controls. The use of the latest Siemens CNC control and Siemens digital drive technology ensures maximum performance and the complete compatibility of all drive and control components. Breakthrough technology. Gleason-Pfauter offers Electronic helical guide technology to completely eliminate the expensive, time-consuming procurement and change over of mechanical guides for the production of helical gears. Machine sizes and designs with intermediate sizes. Standardmachine Intermediate size P 800 S P 800/1200 S P 1200 S P 1200/1600 S P 1600 S P 1600/2000 S P 2000 S P 2400 S P 2400/2800 S P 2800 S P 3200 S * with mechanical shaping head. Standard machine with Electronic Helical Guide P 800 ES* P 1200 ES* Intermediate size with Electronic Helical Guide P 800/1200 ES* P 1200/1600 ES* 3

shaping heads Generating cutter loading/unloading system.

Mechanical shaping head. Hydraulic shaping head. The mechanical shaping head.

The cutter spindle has fully hydrostatic bearings and the backlash-free, preloaded double-worm index drive and the helical guides with hydrostatic bearings are produced to the highest precision

4 shaping heads Generating cutter loading/unloading system. The availability of a great choice of shaping heads enables Gleason- Pfauter Gear Shaping Machines to be more easily customized to meet the widest possible range of application requirements. Mechanical shaping head. Hydraulic shaping head. The mechanical shaping head. For smaller to moderate requirements with regard to shaping performance, module and shaping stroke, the shaping head with mechanically-driven cutter spindle is ideal. The cutter spindle has fully hydrostatic bearings and the backlash-free, preloaded double-worm index drive and the helical guides with hydrostatic bearings are produced to the highest precision specification. The ideal conditions for top-quality and pitch variation pattern result from the rigid shaper cutter holding fixture of a taper shank design. The drive of the cam for cutter spindle back-off movement is affected by a backlashfree direct drive in the form of an NC axis. The mechanical shaping head is available with the unique Electronic Helical Guide as an option. Shaping heads with hydraulically-driven cutter spindle. To cover larger performance ranges Gleason-Pfauter offers a shaping head with hydraulically-driven cutter spindles. This design with its fully hydrostatic bearing and highperformance hydraulic drive technology provides considerable benefit in terms of shaping force, cutting speed, module and stroke length. lnnovative, and extreme rigid backoffconcept for hydraulic shaping heads. Gleason-Pfauter is once again setting standards with its innovative, unique concept of cutter spindle back-off movement using hydrostatic drive and guide elements. This solution renders superfluous mechanical components for the back-off movement. The results are: maximum precision of movement in combination with optimum process design, no costs for special cams, flexible change between external and internal gears. In this instance, the high-precision shaping movement also guarantees a backlash-free, preloaded double worm index drive. There are two sizes of this shaping head design available featuring different performance data. All available shaping heads can be used on all machine sizes. 4

electronic helical guide Now available: Electronic Helical Guide (ES) technology for large machines. Shaping head design with Electronic Helical Guide (ES).

5 electronic helical guide Now available: Electronic Helical Guide (ES) technology for large machines. Shaping head design with Electronic Helical Guide (ES). The mechanical helical guides of conventional CNC-controlled gear shaping machines present the user with significant disadvantages. A mechanical guide has serious limitation such as: High cost, long lead times, complicated logistics for the initial purchase and regrinding of mechanical guides as well as long change over time when required to change a guide, typically a mechanical guide is made to cut a specific gear, i.e. is made to the lead and hand of the cutter and it is highly unlikely the guide can be used to make another helical gear as you would need to have the same hand and lead of the cutter, can not normally cut two or more helical gears in a single part clamping for previously stated lead and hand of cutter issues, can not normally shape a helical gear with a shaper cutter s lead less than 400 mm, unable to have the flexibility to change the lead of the gear shaped, i.e. change lead results to compensate for helix unwind in heat treat. The mechanical shaping head has been completely redesigned with a backlash-free direct drive for the cutter spindle in order to deliver higher flexibility and operating ranges than previously using conventional shaping machines. Gleason s ES technology provides the user with huge potential for savings: No investment in mechanical helical guides required. Elimination of lead times needed to purchase mechanical guides. No time-consuming changeover. Flexible setting of any helix angle, including angles above 45. Simple helix angle corrections (e.g. lead angle errors due to hardening). Machining of different helix angles in one setup (suitable tool arbor required). Technical data for shaping heads * Special shaping cycles available for oversize face widths. Mechanical shaping head Hydraulic shaping head 1 Hydraulic shaping head 2 S series ES series S series S series Generation of a helical gear s lead mechanical electronic mechanical mechanical Spindle stroke drive electro-mechanical electro-mechanical hydraulic hydraulic Nominal module 12 mm 12 mm 16 mm 24 mm Cutter spindle diameter 110 mm 110 mm 130 mm 160 mm Max. cutter spindle rotary speed 27 rpm 235 rpm 8 rpm 8 rpm Maximum stroke length 225 mm 225 mm 380 mm 650 mm Maximum face width* 200 mm 200 mm 350 mm 600 mm Cutter spindle stroke speed range (strokes per minute) Cutter spindle drive motor 22 kw 22 kw hydraulic hydraulic Maximum cutting speed 50 m/min 30 m/min Tooling arbor taper HSK - B 80 HSK - B 80 HSK - 80 HSK Minimum lead of guide 400 mm 850 mm 850 mm 5

existing work is still being completed. Saving and archiving jobs allows fast and accurate access to machining data for repeat batches.

Technical data and parts programming information can be created or reviewed off-line or even off-site on a PC, via Ethernet networking. lmagine the possibilities.

6 performance Display with input screens Simplifying the operating interface creates considerable advantages for users of Gleason-Pfauter machines for the different machining operations, i.e. hobbing, shaping and profile grinding. In addition, it offers a host of user benefits, including: Dialogue-guided input enables operators to rapidly change over from one type of workpiece to the next even entering a new job while the existing work is still being completed. Saving and archiving jobs allows fast and accurate access to machining data for repeat batches. Exporting data to other machines is simplified to help speed throughput and increase operating flexibility. Technical data and parts programming information can be created or reviewed off-line or even off-site on a PC, via Ethernet networking. lmagine the possibilities. The new generation of machines, in combination with the latest series of control technology from Siemens and the Gleason-Pfauter Dialog Program, provides new features and capabilities in gear shaping technology, including: Production of external/internal gears by generating or index cutting. Production of involute and non-involute gears. Up to six different gears per workpiece/job. A maximum of six cuts per cycle with radial or rotational feed options. The ability to shape gears with face width larger than the machine maximum stroke length capacity. Wide range of lead modifications. Tool indexing to improve tool life and tool utilization. Reduced machining times through accelerated return stroke. Use of direct-drive servo spindle motor for the cutter spindle allowing for a nearly constant cutting speed, thus improving tool life vs. the non-constant velocity of conventional eccentric drives. 6

w ork area dimensions +Z A +A2 +Z2 Work area dimensions. +X +Y C 2 +C A Machine NC axes.

Workpiece rotation Work area dimensions P 800 S P 1200 S P 1600 S P 2000 S P 2400 S P 2800 S P 3200 S P 800 ES P 1200 ES Nominal workpiece diameter internal and external gear A mm 800/1200 1200/1600

center distance B mechanical shaping head mm 0/520/720 200/720/920 260/920/1120 460/1120 460/1320/1520 hydraulic shaping head H1 mm 0/550/750 0/750/950 0/950/1150 0/1150 0/1350/1550 520/1550 520/1750

7 w ork area dimensions +Z A +A2 +Z2 Work area dimensions. +X +Y C 2 +C A Machine NC axes. C Standard NC axes X = Radial axis Y = Column lateral offset D Z = Axial slide position range B Z2 = Stroke length setting A = Cutter spindle drive E F G A2 = Tool backoff C2 = Cutter rotation C' = Workpiece rotation Work area dimensions P 800 S P 1200 S P 1600 S P 2000 S P 2400 S P 2800 S P 3200 S P 800 ES P 1200 ES Nominal workpiece diameter internal and external gear A mm 800/ / / / Maximum workpiece swing without tailstock (internal gear) 200/ / / / Min./max. center distance B mechanical shaping head mm 0/520/ /720/ /920/ / /1320/1520 hydraulic shaping head H1 mm 0/550/750 0/750/950 0/950/1150 0/1150 0/1350/ / /1750 hydraulic shaping head H2 mm 0/570/770 0/770/970 0/970/1170 0/1170 0/1370/ / /1770 Axial slide position range C mechanical shaping head mm 250/ / / / /400 hydraulic shaping head mm Lowest cutter spindle position above table D mechanical shaping head mm* hydraulic shaping head H1 mm** hydraulic shaping head H2 mm** Table diameter E mm Table bore diameter F mm Depth of table bore G mm Values for intermediate sizes, e.g. on P 800 S for P 800/1200 S or on P 1200 ES for P 1200/1600 ES. Shaping head for S and ES series. Shaping head for S series only. * middle stroke position. ** upper stroke position. 7

8 dimensions/technical data B C A Machine dimensions of gear shaping machines with mechanical shaping head. Machine dimensions P 800 S P 1200 S P 1600 S P 2000 S P 2400 S P 2800 S P 3200 S P 800 ES P 1200 ES A mm 6,550 6,550 7,800 8,000 8,000 8,200 8,200 B mm 6,000 7,100 10,500 10,800 11,000 11,400 11,600 C mm 4,250 4,850 5,200 5,200 5,200 5,250 5,250 Technical data Column lateral offset, mechanical mm ± 25 ± 25 ± 25 ± 25 ± 25 Column lateral offset, hydraulic mm ± 50 ± 50 ± 50 ± 50 ± 50 ± 50 ± 50 Maximum table speed rpm Maximum table load kg 10,000 15,000 20,000 30,000 40,000 40,000 40,000 Total power rating of machine mechanical shaping head (approx.) kva hydraulic shaping head (approx.) kva Machine weight (approx.) kg 22,000 24,000 35,000 40,000 44,000 60,000 61,000 Machine dimensions of gear shaping machines with hydraulic shaping head on request. Shaping head for S and ES series. Shaping head for S series only. The information and specifications in this publication are subject to change without notice University Avenue P.O. Box Rochester, NY , USA Tel Fax sales@gleason.com 1000 University Avenue P.O. Box Rochester, NY , USA Tel Fax sales@gleason.com Maschinenfabrik GmbH Daimlerstrasse 14 D Ludwigsburg, Germany Tel. +49-(0) Fax+49-(0) pfauter@gleason.com sales@gleason.com For Worldwide Locations and Additional Information. W 192/2/3/707 e Printed in Germany.

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