Geared to make things move.
The Program
www.kapp-coburg.de
www.niles.de
www.kapp-usa.com
www.kapp-asia.com
www.kapptec.com
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 16 – 17
KAPP VX-Series
Pages 18 – 21
Machines. Tools. Technologies.
Made in Germany.
KAPP RX-Series
Pages 22 – 23
KAPP Special Solutions
Pages 24 – 25
NILES ZE-Series
Pages 26 – 27
NILES ZP-Series
Pages 28 – 29
NILES ZX-Series
Pages 30 – 31
NILES Special Solutions
Pages 32 – 35
KAPP Tools
Pages 36 – 37
KAPP Group
Page 38
2
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
4
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
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
Tool Concepts
• Non-dressable CBN
or diamond tools
• Dressable tools, ceramically
bonded carbide abrasives
or SG
5
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
Workpiece Range
6
dressable tool
Machine Processes
7
Gear Centers
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
KX 150 / KX 150 P; KX 300 / KX 300 P
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 max. 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.
Type
max.
Tip diameter
max. Module Range
max.
Face width
max.
Helix angle
[mm]
[deg]
[mm]
Generating
Grinding
[mm]
KX 150
KX 150 P
150
3
6
320
± 45
KX 300
KX 300 P
300
5
10
320
± 45
Profile
Grinding
[mm]
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.
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.
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.
KX-Series
8
9
Gear Center
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.
KX 160 TWIN
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.
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.
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.
Type
KX 160 TWIN
[mm]
max.
Face width
[mm]
max.
Helix angle
[deg]
0.5 – 4.5
320
± 45
max.
Tip diameter
[mm]
Module Range
170 / 250
KX 160 TWIN
10
11
Gear Center
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
KX 500 FLEX
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.
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
Type
KX 500 FLEX
max.
Tip diameter
[mm]
Module Range
500
[mm]
max.
Face width
[mm]
max.
Helix angle
[deg]
0.5 – 10
520
± 35
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,
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.
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
Gear Center
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.
KX 1
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
KX 1
max.
Tip diameter
[mm]
Module Range
[mm]
max.
Face width
[mm]
max.
Helix angle
[deg]
250
0.5 – 10
350
± 35
KX-Series
14
15
Coroning / Honing Machines
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.
CX 250 / CX 250 H / CX 250 I
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 max. 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.
Type
CX 250
max.
Tip diameter
[mm]
max.
Module Range
[mm]
max.
Face width
[mm]
250
0.8 – 3.5
70
CX 250 H
250
0.8 – 5.0
70
CX 250 I
250
0.8 – 3.5
50
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 max. 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
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
max. 16 mm, an outer diameter
up to 630 mm and a workpiece
length of max. 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
Type
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.
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.
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,
max.
Tip diameter
[mm]
max.
Workpiece length
[mm]
max. Module
VX 55 / VX 55 P
500
VX 59 / VX 59 P
630
[mm]
max.
Feed travel
[mm]
Swivel Range
of Grinding Head
[deg]
1,000
16
700
± 90
1,600
16
1,020
± 90
VX-Series
18
19
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
Rotor Grinding Machines
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.
RX 55 / RX 59
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.
max.
Rotor
outside-ø
[mm]
max.
Rotor
length
[mm]
max.
Profile
width
[mm]
max.
Profile
height
[mm]
max.
Workpiece
length
[mm]
RX 55
320
550
180
80
1,200
RX 59
320
850
180
80
1,650
Type
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 RXSeries 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
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
Gear Profile Grinding Machines
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.
ZE
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.
max.
Tip diameter
[mm]
max.
Profile length
[mm]
Stroke length
[mm]
max.
Helix angle
[deg]
ZE 400
400 / 500
35 / 45 / 55
400
± 45
ZE 630
650
35 / 45 / 55
400 / 600
± 45
ZE 800
800
35 / 45 / 55
400 / 600
± 45
ZE 1000
1,000
35 / 45 / 55
600
± 45
ZE 1200
1,200
35 / 45 / 55
600
± 45
Type
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
Gear Profile Grinding Machines
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.
ZP
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.
max.
Tip diameter
[mm]
max.
Profile height
[mm]
Stroke length
[mm]
max.
Helix angle
[deg]
ZP 08
800
75 / 100
750 / 1,000 / 1,300
- 45 / + 90
ZP 10
1,000
75 / 100
750 / 1,000 / 1,300
- 45 / + 90
ZP 12
1,250
75 / 100
750 / 1,000 / 1,300
- 45 / + 90
ZP 15
1,500
75 / 100
750 / 1,000 / 1,300
- 45 / + 90
ZP 16
1,600
75 / 100
750 / 1,000 / 1,300
- 45 / + 90
ZP 20
2,000
75 / 100
750 / 1,000 / 1,300
- 45 / + 90
ZP 25
2,500
100
1,250 / 1,550 / 1,750
± 40
ZP 30
3,000
100
1,250 / 1,550 / 1,750
± 40
ZP 40
4,000
100
1,250 / 1,550 / 1,750
± 40
ZP 50
5,000
100
1,250 / 1,550 / 1,750
± 40
ZP 60
6,000
100
1,250 / 1,550 / 1,750
± 40
Type
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-Series
28
29
Gear Center
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.
ZX
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.
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.
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
max. Module
max.
Tip
Diameter
[mm]
Generating
Grinding
[mm]
Profile
Grinding
[mm]
max.
Face
width
[mm]
max.
Helix
angle
[deg]
min. / max.
Center distance
index table - grinding wheel
[mm]
max.
Index table
load
[kg]
630
8
15
400
± 45
205 / 500
1,000
ZX 800
800
8
15
400
± 45
205 / 560
1,000
ZX 1000
1,000
8
15
400
± 45
205 / 710
1,000
Type
ZX 630
ZX-Series
30
31
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
NILES Special Solution
ZPI
Preface
Profile grinding of internal gears
is an extension of the capabilities
of most external profile 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 configuration 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 profile modification 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 profile
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
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.
Non-dressable CBN- and Diamond Tools
1.
1. 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.
2.
3. Diamond Coroning rings and Coroning gears
suitable for the KAPP coroning of external and internal gears as well
as shoulder gears.
3.
4. 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.
4.
5. Diamond dressing gears
for profile dressing of dressable honing rings.
6. Master gears
for double flank roll checking before and after hard finishing.
5.
6.
In addition to manufacturing of new tools, KAPP also replates CBNand diamond tools in Germany, USA, Brazil, Japan and China.
KAPP Tools
36
37
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 so-
lutions 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
KAPP GmbH
Callenberger Straße 52
D-96450 Coburg
Germany
NILES
Werkzeugmaschinen GmbH
Nordring 20
D-12681 Berlin
Germany
KAPP Technologies
2870 Wilderness Place
Boulder, CO 80301
USA
KAPP Asia Technologies
(JiaShan) Co., Ltd.
Kapp Road 1
DaYun Industry Zone
JiaShan 314113 ZheJiang
P.R. China
KAPP TEC
Indústria e Comércio de
Máquinas e Ferramentas Ltda.
Rua Solimoes, 60
09930-570 Diadema S.P.
Brazil
Phone: +49 (9561) 866-0
Fax:
+49 (9561) 866-103
E-Mail: [email protected]
Phone: +49 (30) 93033-600
Fax:
+49 (30) 93033-603
E-Mail: [email protected]
Phone: +1(303) 447 1130
Fax:
+1(303) 447 1131
E-Mail: [email protected]
Phone: +86 (573) 8466 3888
Fax:
+86 (573) 8466 3666
E-Mail: [email protected]
Phone: +55 (11) 409 15 355
Fax:
+55 (11) 409 15 355
E-Mail: [email protected]
www.kapp-coburg.de
www.niles.de
www.kapp-usa.com
www.kapp-asia.com
www.kapptec.com
KAPP Group
Callenberger Straße 52
D-96450 Coburg
Phone: +49 (95 61) 866-0
Fax: +49 (95 61) 866-103
E-Mail: [email protected]