ZP series

gear profile grinding machines

machine concept

The gear profile grinding machines of the ZP series is well known worldwide for profile grinding of external and internal gears. The ZP machine represents quality, durability and outstanding flexibility.

Even the basic gear profile grinding machines are equipped with coolant filtration unit, dresser, in process measuring system, balancing unit, acoustic emission sensor, and comprehensive software for grinding and measuring of involute profiles. Further outstanding features are, amongst others, a well dimensioned rotary table with electrical direct drive and large table bores; optional hydrostatic bearing and guideways for highly accurate positioning, excellent load capacity and almost unlimited lifetime. The latest drive and control technology enables grinding of even very complex gear geometries using a five machine axes interpolation. The machine perfectly fits to customer-specific requirements, no matter if it is prototype grinding, small batches or series production.

All gear profile grinding machines of the ZP series can be equipped with internal gear grinding attachment. From standard applications to customer-specific grinding tasks either with dressable wheels or CBN grinding wheels; KAPP NILES will provide the right solution for your requirements.

Multiple spindle configurations are available. The gear profile grinding machine can be equipped with stronger motor and grinding spindle and optimised axes with increased stroking speed for productive grinding of large module workpieces.

Gears with short run-out or workpieces with interfering shoulders can be ground with a spindle and wheel adaptor for smallest grinding wheels. Some machines even allow the use of two grinding spindles for even more flexibility.

control and software

The control system Sinumerik 840D sl is equipped with an operator-friendly menu-driven user interface, developed by KAPP NILES to match the specific machining requirements. Workpiece data can be entered and handled directly from the drawing including modifications. The software supports the operator to choose the right grinding process. The programme automatically calculates grinding and dressing technology based on the important process parameters.

The standard software package comes with very sophisticated alignment and measuring modules as automatic synchronisation, including the autonomous locating of the tooth gap, and inspection of the blank profile. This determines the amount of stock and thereby the grindability of the gear. The control can be expanded further by application-specific software packages.

measuring system

The high precision measuring system is an integrated part of the machine. Besides the various alignment, analysis and correction possibilities the system allows the final evaluation of the ground gear by measuring of all relevant gear parameters. The measuring results can be evaluated according to DIN and AGMA, also under consideration of modifications.

  max. tip diameter [mm] max. workpiece length [mm] max. module
max. stroke lengh [mm] max. helix
angle [deg]
ZP 16 - 18 1,600 / 2,000 / 2,400 / 2,800 2,200 40 1,000 / 1,500 / 1,800 - 45 / + 120
ZP 30 - 80 3,200 / 4,000 / 5,000 / 6,000 / 8,000 on request 50 1,500 / 1,800 / 2,000 - 45 / + 120