Machines
For gear grinding we differentiate between two types - discontinuous profile grinding and continuous generating grinding:
Continuous generating grinding
For continuous generating grinding all tooth flanks of the workpiece are machined simultaneously during one stroke of the helical tool. This is accomplished with a synchronised constant rotation of the workpiece relative to the grinding tool. Due to the kinematics of this process, indexing and positioning times are greatly reduced, resulting in low cycle times. Therefore, it is a highly productive and cost-effective gear grinding process well suited for small and medium-sized gears. Both, dressable ceramic tools and non-dressable CBN tools can be used (in cylindrical or globoid design).
Discontinous profile grinding
Profile grinding of gears describes a process in which the tooth flanks are machined gap after gap with single or multi-ribbed profiled tools. This process offers the highest flexibility while still achieving optimum quality. Discontinuous profile gear grinding is mostly utilised for small batch series and prototype manufacturing. Dressable ceramic wheels as well as non-dressable CBN tools can be used for this grinding process.
KAPP NILES provides a wide spectrum of machine models suited to the processes of profile and generating grinding.
Generating(profile)-grinding machines
Most of the following solutions combine continuous generating grinding and discontinuous profile grinding in one machine. For the grinding of your gears, shafts, rotors and special profiles KAPP NILES offers best suitable profile grinding machine and generating gear grinding machine. KAPP NILES generating gear grinding machines are best suitable for the medium and large batch production of gears with very high precision in conjunction with high productivity.
KNG 350 series
KNG 350 core
Gear centre
- Application of dressable tools with high cutting speeds
- Integrated workpiece handling to ensure minimal non-productive times
- Functional, ergonomic machine design with compact footprint
max. tip diameter [mm] | modul range [mm] | batch size | processing method | |
|---|---|---|---|---|
| KNG 350 core | 350 | 0.5 - 6 | prototype to large series | generating grinding |
KNG 350 flex
Gear centre
- Grinding spindle with counter bearing for large grinding worms
- Digital support for optimisation of set-up process
- Flexibility through external and internal grinding
| max. tip diameter [mm] | module range generating / profile [mm] | batch size | processing method | |
|---|---|---|---|---|
| KNG 350 flex | 350 (400) | 0.5 - 8 / 0.5 - 10 | prototype to large series | generating and profile grinding |
KNG 350 flex HS
Gear centre
- Flexibility through generating and profile grinding
- Significantly reduced non-productive times through a machine-integrated loading device
- Highest grinding quality and productivity even when using small tools
| max. tip diameter [mm] | module range generating / profile [mm] | batch size | prototype to large series | |
|---|---|---|---|---|
| KNG 350 flex HS | 350 | 0.5 - 6 / 0.5 - 8 | prototype to large series | generating and profile grinding |
KX series
KX DYNAMIC series
Gear centres
- Automatic change of clamping devices
- Multifunction-axis to discharge measured and tested parts
- Pick-up concept and integrated automation enable fastest changing times
| max. tip diameter [mm] | module range [mm] | batch size | processing method | |
|---|---|---|---|---|
| KX 100 DYNAMIC | 125 | 0.5 - 4.5 | medium and large series | generating grinding |
| KX 260 DYNAMIC | 260 | 0.5 - 6 |
KX TWIN series
Gear centres
- Twin spindle concept with rotary indexing table
- Minimal non-productive times
- Flexible connection to different concepts of automation
| max. tip diameter [mm] | module range [mm] | batch size | processing method | |
|---|---|---|---|---|
| KX 160 TWIN (HS) | 170 | 0.5 - 4.5 | medium and large series | generating and profile grinding |
| KX 260 TWIN (HS) | 260 | 0.5 - 6 |
KX 300 P
Gear centre
- Highest flexibility due to various machining processes
- Manual loading, automation interface or integrated ring loader
- Direct drives in tool spindle and workpiece spindle
| max. tip diameter [mm] | module range generating / profile [mm] | batch size | processing method | |
|---|---|---|---|---|
| KX 300 P | 350 | 0.5 - 8 / 0.5 - 10 | prototype to medium series | generating and profile grinding |
KX 500 FLEX
Gear centre
- Machining of gears and special profiles
- Highest flexibility with the use and combination of different machining processes
- High level of quality from prototype to serial production
| max. tip diameter [mm] | module range generating / profile [mm] | batch size | processing method | |
|---|---|---|---|---|
| KX 500 FLEX | 500 | 0.5 - 8 / 0.5 - 12 | prototype to medium series | generating and profile grinding |
Profile grinding machines
KAPP NILES is one of the market leading manufacturers of profile grinding machines. We offer worldwide service and sales of machines for high-precision profile grinding of gears and profiles. Using KAPP NILES profile grinding machines, you are able to grind such workpieces as gears, shafts and profiles with the highest accuracy.
KNG 3P ready
KNG 3P ready
Gear profile grinding machine
- Function-oriented basic model
- Ergonomic control and set-up concept optimised for manual loading
- Intuitive KN grind control with touch screen HMI
| max. tip diameter [mm] | module range [mm] | batch size | processing method | |
|---|---|---|---|---|
| KNG 3P ready | 320 | 0.5 - 10 | prototype to medium series | profile grinding |
KNG 5P expert
KNG 5P expert
Verzahnungs-Profilschleifmaschine
- External and internal gears as well as special profiles
- Optimal accessibility for dressing tool change
- Easy operation of the swivelling tailstock
| max. tip diameter | module range | batch size | processing method | |
|---|---|---|---|---|
| KNG 5P expert | 500 (600) mm | 0,5 - 25 mm | prototype to large series | profile grinding |
KNG master series
KNG master series
Gear profile grinding machines
- Highest quality already at lot size 1
- Wear-free due to optional hydrostatics
- Wide guides and high drive power
| max. tip diameter [mm] | module range [mm] | batch size | processing method | |
|---|---|---|---|---|
| KNG 10P master | 1,000 | 0.5 - 35 | prototype to medium series | profile grinding |
| KNG 12P master | 1,250 |
ZE series
ZE series
Gear profile grinding machines
- Wear-free due to optional hydrostatics
- Small footprint and optimal accessibility
- Special spindles for various machining tasks
| max. tip diameter [mm] | module range [mm] | batch size | processing method | |
|---|---|---|---|---|
| ZE 400 | 400 (500) | 0.5 - 20 (25) | prototype to large series | profile grinding |
| ZE 630 / 800 | 650 / 800 | |||
| ZE 1000 / 1200 | 1,000 / 1,200 |
ZP series
ZP series
Gear profile grinding machines
- Special spindles (option) for the use of small grinding wheels
- Maximum precision
- External gears and internal gears, special profiles
| max. tip diameter [mm] | max. module [mm] | batch size | processing method | |
|---|---|---|---|---|
| ZP 10 / 12 / 16 | 1,000 / 1,250 / 1,600 | 40 | prototype to medium series | profile grinding |
| ZP 20 / 24 | 2,000 / 2,400 (2,800) | |||
| ZP 30 - 80 | 3,000 / 4,000 / 5,000 / 6,000 / 8,000 |
KX series
KX 300 P
Gear centre
- Highest flexibility due to various machining processes
- Flexible connection to different automatic loading solutions
- Direct drives in tool spindle and workpiece spindle
| max. tip diameter [mm] | module range generating / profile [mm] | batch size | processing method | |
|---|---|---|---|---|
| KX 300 P | 350 | 0.5 - 8 / 0.5 - 10 | prototype to medium series | generating and profile grinding |
KX 500 FLEX
Gear centre
- Machining of gears and special profiles
- Highest flexibility with the use and combination of different machining processes
- High level of quality from prototype to serial production
| max. tip diameter [mm] | module range generating / profile [mm] | batch size | processing method | |
|---|---|---|---|---|
| KX 500 FLEX | 500 | 0.5 - 8 / 0.5 - 12 | prototype to medium series | generating and profile grinding |
VX series
VX series
Gear profile grinding machines
- Suitable for prototyping and small batch production
- External, internal, spur and helical gears as well as special profiles
- Machining parts of complex geometry
| max. tip diameter [mm] | module range [mm] | batch size | processing method | |
|---|---|---|---|---|
| VX 55 | 500 | 0.5 - 16 | prototype to small series | profile grinding |
| VX 59 | 630 |
RX series
Special solutions
HGS
HGS
Special machines
- Individual solutions for special profiles
- Use of non-dressable CBN grinding wheels
ZP special machines
ZP B model
Gear centre
External gears, bores and end faces in one set-up
| max. tip diameter [mm] | max. module [mm] | batch size | processing method | |
|---|---|---|---|---|
| ZP B | on request | on request | prototype to medium series | gear profile, bore and face grinding |
ZPI model
Gear profile grinding machine
High stiffness and strong grinding power for highly precise internal gears with large modules
| max. tip diameter [mm] | max. module [mm] | batch size | processing method | |
|---|---|---|---|---|
| ZPI | on request | on request | prototype to medium series | profile grinding |
ZP I/E model
Gear profile grinding machine
Grinding arm that can be swivelled quickly for machining internal and external gears with large modules and gear widths
| max. tip diameter [mm] | max. module [mm] | batch size | processing method | |
|---|---|---|---|---|
| ZP I/E | on request | on request | prototype to medium series | profile grinding |
ZP E/I model
Gear profile grinding machine
Changeover between external and internal machining that does not require set-up
| max. tip diameter [mm] | max. module [mm] | batch size | processing method | |
|---|---|---|---|---|
| ZP E/I | on request | on request | prototype to medium series | profile grinding |
The innovative KN grind user interface allows intuitive parameterisation of the machining task. The user is guided and supported when entering the workpiece and technology data. A flexible machining sequence is then defined via a sequence control. The user can view and influence the status of the machining process at any time.