Cylindrical Gear Solutions

Cylindrical Gear Solutions

Hobbing/Shaving Vertical Gear Hobbing Machines Genesis 130H 130 3 350 Genesis 210H 210 3/4 350 Genesis 260H 260 4/8 400/600 Genesis 400H 400 8/4 400/600 P 400 400 16 400/600 /1000 P 600 600/800 16 400/600 /1000 P 800 800/1200 700/1000 /1300 /1600 Titan 1200H 1200 1000/1600 Titan 1600H 1600 1000/1600 P 2000 2000 P 2400 + profile milling 2400/2800 P 2800 2800 P 3200 3200 P 4000 4000 Larger machines are available on request. 20/30 + (30/40 + ) P 5000 5000 30/40 + P 6000 6000 30/40 + above 2400 only with reduced speed and feed rates. 700/1000 /1300 / 1600 /2200 P 8000/10000 8000/10000 45 on request Horizontal Gear Hobbing Machines P 60 80/100 2.5/3 +,5 220/320 P 90 100/125 2,3/5 +,5 320/400 P 90 EL 100/125 2,3/5 +,5 800 P 210 L 180/210 2,3/4.5 300/400 Worm milling machine P 90 WM 090 2,5/8,5 280 manual loading + profile milling Gear Shaving Machines for vertical workpiece mounting Genesis 130SV(C) 150 4 40 for horizontal workpiece mounting ZS(E) 150 (T) 200 5 (3.5) 100 (45) ZS(E) 300 280 8 100 ZS 600 600 8 100 (C), (E) chamfering and deburring (T) plunge shaving () for plunge shaving 2

Gear Shaping/Deburring Gear Shaping Machines with Electronic Helical Guide P 200 ES 200 6 110 P 300 ES 300 6 110 P 400 ES 400 8/12 110/225 /250 P 600 ES 600/800 8/12 110/225 /250 P 800 ES 800/1200 12 225 P 1200 ES 1200/1600 12 225 Larger machines are available on request. Gear Shaping Machines P 150 S 150 4 30 P 200 S 200 6 55/110 P 300 S 300 6/12 55/110 /225 P 500 S 500 8/12 110/225 P 600 S 600/800 8/12 110/225 P 800 S P 1200 S P 1600 S 800/1200 1200/1600 1600/2000 P 2000 S 2000 12/16 /24 225/380 /650 P 2400 S 2400/2800 P 2800 S 2800 P 3200 S 3200 Larger machines are available on request. with hydraulic shaping head Short Term Delivery Standard Gear Shaping Machine AM 250 300 6 55/110 Chamfering and Deburring Machine ZEA 4* 20/250 0.8-5 40 * also available with two deburring stations for twin gears. 3

Combined Processes Vertical Gear Hobbing Machines with integrated chamfering and deburring unit Genesis 210HiC 210 3/4 350 Genesis 260HiC 260 4/8 400/600 Genesis 400HiC 400 8/4 400/600 Horizontal Gear Hobbing Machine with integrated chamfering and deburring unit P 210 LiC 150 3/4.5 300/400 180TH Multi-functional Machine for Turning, Hobbing, Drilling, Chamfering and Deburring in one single set-up NC-controlled tailstock column with quill to hold tailstock centers. Tool turret to take up to 12 tools (VDI40). Designed for wet or dry machining. Modular design. Individual configuration of chip transport/separation. Gleason chamfering and deburring station attached to turret. Workpiece-specific gripper jaws for loading/unloading via turret. Optional NC steady rest (Z3) axis with surrounding three-point steady rest. Optional measurement on tool turret for tool wear compensation. In combination with other cells for additional turning operations. Technical data Workpiece data: maximum 180 maximum length 500 maximum weight 30 kg 3 axial slide travel 500 / 600* * turning 1200G POWER GRIND Combined Threaded Wheel and Profile Grinding Machine The combination of threaded wheel and profile grinding significantly reduces grinding times by up to 50%. Threaded wheel grinding up to 14 for roughing. Profile grinding up to 44. Advantage in profile grinding. Unique and patented simultaneous double flank twist compensation or asymetrical lead modifications reducing finishing time by 50%. Automatic tool changer. Fully-automatic tool change in less than one minute. Set-up occurs during gear grinding. Optimum grit size for roughing and finishing grinding wheel. No interfering contours between tool/workpiece in the entire range. 4

Hard Processing Profile Grinding Machines for external and internal gears P 90 G 100/125 3 320/400 300TWG 300 8 440 P 400 G 400 P 600 G 600 P 600/800 G 800/1000 P 800 G 800 P 1000 G 1000 Titan 1200G 1200 1000/1600 P 1600 G 1600 P 2000 G 2000 P 2400 G 2400 P 2800 G 2800 P 3200 G 3200 P 4000 G 4000 P 5000 G 5000 P 6000 G 6000 manual loading 35/45 /55 /80 80/120 400/600 /1000 700/1000 /1300 /1600 700/1000 /1300 /1600 Machine suitable for threaded wheel and profile grinding. Larger machines are available on request. Threaded Wheel Grinding Machines P 90 G 100/125 3 320/400 Genesis 160TWG 160 0.5-3 350 300TWG 300 0.5-7 440 manual loading Machine suitable for threaded wheel and profile grinding. Gear Honing Machines 150SPH 150 4 45 150SPH-L* 150 4 45 ZH 250 250 6 100 * for manufacturing of shaft-type workpiece up to 550 length. face width Shaving Cutter Grinding Machine face width SRS 410 400 0.5-15 75 5

Metrology/Workholding Analytical Gear Inspection Systems Module range Center distance* Z-axis travel* 175GMM 175 0.4-6.35 380 305 350GMS 350 0.4-18 650 450 475GMS 475 0.4-18 650 450 650GMS 650 0.4-22 1000 600 1000GMS 1000 0.4-22 1300 1000 1500GMS 1500 0.5-32 1300 1000 2000GMS 2000 0.5-32 2000 1200 3000GMS 3000 0.8-32 2000 1200 * other dimensions on request. Workholding Solutions Gleason designs and manufactures a complete line of workholding equipment for cylindrical gear machines. Designs are both mechanical and hydraulic and include quick change features for both Gleason and non-gleason spindles. Tapered and/or Ball Sleeve designs ensure repeatability of both axial and radial runout tolerances. Mechanical safety features are also designed into the equipment to prevent over-travel. Gleason developed workholding equipment includes UNI-SPAND, ISO-SPAND, Quik-Flex gear arbors and LeCount expanding mandrels. X-Pandisk for full range of solutions The X-Pandisk workholding equipment has resulted in workpiece changeover time being reduced by up to 70% compared to conventional manual workholding concepts. This is achieved by means of automatic clamping and centering of the workpiece. The X-Pandisk workholding equipment is also designed for automatic loading to make production in medium to large-scale series even more economical. Quik-Flex A standardized interface for workholding change without centering work in the micron-range. This selfcentering clamping system can be exchanged within a few seconds with only one tool. This ensures lowest efforts for machine set up work. The key component of the X-Pandisk is the centering disc which centers the workpiece. The workpiece is not clamped in the axial plane by the pressure cover until the centering process is complete. It is this segregation of centering and clamping operations which allows such high workpiece weights (up to 2 tons) to be centered accurately to < 30 µm. 6

Cutting Tools Cutting Tools Hobs Bore- or shank-type hobs, made of high-speed steel and solid carbide. Coated with PVD-coatings based on Titanium, Aluminium, Chromium and Nitride or other coatings for extended tool life or dry cutting processes. Starting at size 0.3 (DP 85) up to 40 (DP 0.635). cutting rates using highly productive OPTI-CUT tools equipped with indexable carbide insert technology. OPTI-CUT is also available for shaper cutters. Whether roughing with EZ cutter (roughing hob) or finishing with top quality finishing cutters Gleason tools always have the right solution. Gashing Cutters Solid and carbide inserted tools for highest accuracy and efficiency in internal and external gearing applications. With the OPTI-CUT tool system you get all the performance benefits of the unique replaceable, indexable carbide insert technology. E-Z Cut Hobs E-Z Cut roughing hobs provide swift removal of metal to permit accurate and economical finishing of the gear tooth profile in a secondary operation. Conventional generating hobs use less than one third of their tooth depth for about two thirds of the metal removal work. E-Z Cut hobs add extra cutting edges by adding specialized flutes. The additional flutes equalize cutting effort and eliminate the problem of overworked tip. Since there is a practical limit to the chip load a tooth can carry, it stands to reason that a hob with more flutes (in a given ) can feed faster through the work Shaper Cutters High-speed steel shaper cutters in disk-, bore- and shank-type designs. Standard range: 0.5 16. Special tooth forms. Wafer technology; hobs and shaper cutters are designed to maximize productivity therefore saving costs. These tools are designed for quick change and eliminate the need for size adjustment. Chamfering and Deburring Tools Chamfer shapes and sizes freely selectable. For wet and dry machining. Integrated burnishing feature. Patented adjustable burnishing gear to adapt helix angle to workpiece. Module range 0.8 6. Extremely long tool life and high efficiency. Shaving Tools For external and internal gears. For all shaving methods. Module range 0.5 18. Cutter width up to 50.8. Shaving Cutter Serration with Opti-Edge for higher tool life. Dressing, Honing and Grinding Tools High-precision diamond dressers and rolls. Multiple replating of diamond dressing tools. Externally and internally toothed fine finishing, ceramic and honing wheels. Honing rings in Opti-Form TM quality. Adjusted outer contour for quick honing wheel change. Threaded wheel grinding worms. Calculation/development and manufacture from one source. Single-layer, replatable CBN and diamond grinding and dressing wheels in a wide range of configurations and sizes. Higher stock removal rates, lower costs per workpiece, long wheel life and more consistent quality. Tool services Support in application engineering. Resharpening and reconditioning services. 7

Cooperation Chamfering/deburring with Gleason- Manutec: Strong, precise and agile in tight spaces. Gleason and Manutec have years of experience in solving complex chamfering and deburring tasks. The collective use of know-how means that the end user is now offered new, flexible and reproducible solutions for the field of gear tooth systems. The combination of gear cutting machine and chamfering/deburring robots results in an efficient and effective solution from a single source. The Gleason-Manutec solution is distinguished by its high work speeds and path accuracy. Complex prograing work can be dispensed with and is replaced by a simple, quick and automated duty cycle. Chamfer shapes and angles can be freely selected via data entry. As standard the R500CHD with a table load of 500 kg is available. For table loads up to 6000 kg Gleason-Manutec offers the models R1000CHD, R2000CHD, R4000CHD and R6000CHD. Higher table loads on request. Axis 3 Axis 4 Axis 2 Axis 5 Axis 6 Traverse angle: Axis 1 ± 165 Axis 2 ± 110 Axis 3 1 ) ± 133 Axis 4 ± 190 Axis 5 ± 120 Axis 6 2 ) n/a 1 ) The travel range of axis 3 is dependent Axis 1 on the position of axis 2. 2 ) Axis 6 has no axis limitation. The information and specifications in this publication are subject to change without notice. For requirements beyond specified values consult Gleason Application Engineering. 1000 University Avenue P. O. Box 22970 Rochester, NY 14692-2970, USA Tel. +1-585-473-1000 Fax +1-585-461-4348 gleason-corporation@gleason.com 1000 University Avenue P. O. Box 22970 Rochester, NY 14692-2970, USA Tel. +1-585-473-1000 Fax +1-585-461-4348 gleason-works@gleason.com Maschinenfabrik GmbH Daimlerstrasse 14 D-71636 Ludwigsburg, Germany Tel. +49-(0)7141-404-0 Fax +49-(0)7141-404-500 gleason-pfauter@gleason.com 1351 Windsor Road Loves Park, IL, 61111, USA Tel. +1-815-877-8900 Fax +1-815-877-0264 gctc@gleason.com Maschinen und Werkzeuge GmbH Moosacher Strasse 42-46 D-80809 München, Germany Tel. +49-(0)89-35401-0 Fax +49-(0)89-35401-463 gleason-hurth@gleason.com Maschinenfabrik GmbH Subsidiary Studen Büetigenstrasse 80 CH-2557 Studen, Switzerland Tel. +41-(0)32-366 61 71 Fax +41-(0)32-365 30 03 gleason-pfauter-ch@gleason-pfauter.ch 300 Progress Road Dayton, OH 45449, USA Tel. +1-937-859-8273 Fax +1-937-859-4452 gleason-metrology@gleason.com No. 85 Yangpu Road, Suzhou Industrial Park Jiangsu, 215024, China Tel. +86 (512)6732 5806 Fax +86 (512)6810 2033 ggts@gleason.com W 212/8/2/812 e www.gleason.com sales@gleason.com Visit www.gleason.com for Worldwide Sales Locations and Additional Information. Printed in Germany.