Phone: (855) 364-6674
us.dmgmori.com
EMAG — Booth #1304
The new platform VT and VL Series for
shafts and chucked components will be
on display for visitors to experience the
EMAG modular inverted vertical lathe
design.
With the goal to develop a system of
modular machines geared for use in the
manufacturing of medium and large
batch runs, EMAG offers flexible solutions
on a standard platform. Single
spline hobbing, for example, will be displayed
on a VT vertical lathe for shafts.
With the capability of offering gear cutting
on a standard machine, EMAG
modular machines offer increased flexibility.
Machining is carried out in four
axes at a maximum speed of 6,000 RPM.
The process employs two turrets with
twelve tool stations each, equipped with
turning tools or driven tools. One common
feature of all four VL machine sizes
is the shared modular design. Their small footprint reduces floor space costs
and increases flexibility in floor layout
options. Every VL and VT machine features
an integrated O-automation system
for transporting workpieces.
When combined with the self-loading
pick-up spindles, this automation
concept ensures shorter cycle times and
higher productivity. To accommodate
machine operators, all the service units
are easily within reach, with the various
units (electrics, hydraulics, cooling system,
cooling lubricant and central lubrication
system) accessible at any time so
that the machines can be maintained
with ease. While the standard lathes are
commonly used for gear blanks, a wide
range of technologies can be incorporated
into the machines, including turning,
grinding, hobbing, chamfering, induction
hardening and laser welding.
The technologies in the EMAG Group
cover the entire spectrum of metalworking,
including non-traditional processes.
Laser welding is essential in lightweighting
automotive components while
electro-chemical machining (ECM) is a
deburring option.
- Click image to enlarge
Introducing the latest addition to
this technology portfolio, Eldec will display
induction hardening systems with a
modular induction (MIND) machine at
the show. Featuring Simultaneous Dual
Frequency (SDF) technology where two
different frequencies are applied to the
workpiece, MIND machines can apply
mid-frequencies to penetrate deeper and
heat the root of the gear tooth simultaneous
to high frequencies to accurately
heat the tip of the tooth. Eldec hardening
systems compliment the workpieces
machined by EMAG lathes to create
more efficient, complete production
lines. The flexible machine concepts
and complete systems from EMAG offer
modular and customized solutions for
the production of workpieces in nearly
every industry.
For more information:
Phone: (248) 477-7440
www.emag.com
Emuge — Booth #1901
Emuge Corp. recently announced
a comprehensive line of high-performance
tools for threading demanding
nickel/super alloy materials to 46 HRC.
The new program includes tools ranging
from taps with unique new geometry
designs to solid carbide thread mills
designed for challenging aerospace,
powergen and oil industry applications.
A full line of sizes from no. 4 to ¾" are
available in UNC, UNF and Metric, 87
sku’s in total.
Emuge’s Nickel Alloy Program
includes new DF-NI and C-NI taps.
With Emuge’s industry-first Variable
Helix Correction (VHC) technology, DF-NI taps feature a specially ground
relief geometry in the primary cutting
zone that is designed to generate a smaller
and tightly rolled chip formation for
enhanced chip control to prevent damage
caused by chips jamming in the
tap teeth. With a 10° right hand spiral
flute, VHC taps are also available in STI
thread sizes for jet engine components.
New C-NI taps offer an advanced left
hand helical flute form with rake and
relief to optimize chip evacuation in the
forward direction and add strength to
the cutting teeth.
- Click image to enlarge
Both taps are designed with special
relief geometry in the chamfer and
thread section to help overcome the high
hardness and elastic memory of precipitation
hardened nickel alloys. Taps are
manufactured with premium HSS-E and
are TiCN coated for exceptional heat
and wear resistance. Modified bottoming
chamfer (2-3 threads on VHC taps) is
designed to reduce torque and increase
tool life. Taps are 3BX class of fit for
internal UNJ threading applications.
DIN length is available for improved
chip clearance in hard-to-reach applications.
For more information:
Phone: (800) 323-3013
www.emuge.com
Euro-Tech — Booth #1704
Mytec is introducing its new line of
mechanical arbors and chucks with
accuracy down to .0004" plus high
expansion rates up to .010" or greater in
a stainless steel construction.
Mechanical arbors and chucks are
designed for workholding where high
forces are incurred or auto load applications
where high clearance is required. A
closed expansion system, which is impervious
to dirt and chips, combined with
high wear resistance, offers increased service
life. If space permits, Hydra expansion
elements from Mytec-Hydraclamp
are generally equipped with an adjustment
piston. This makes it possible to set
expansion for fine clamping, particularly
in the case of thin-walled workpieces, so
deformation can be avoided.
Also on display will be Frenco’s INO
system spline gages, an internal standard
for the external dimensional measurement
of spline gages based on national
and international standards suited to even
the most sensitive and complex components
and systems. This product line provides
a quick method of inspecting involute
splines, serration splines and straight
sided splines to ensure interchangeability
of parts even between different manufacturers.
Frenco spline gages are constructed
of HX, a wear-resistant, high alloy,
powder steel. This wear-resistant material
allows for an improved extension in
inspection intervals.
- Click image to enlarge
For more information:
Phone: (262) 781-6777
www.eurotechcorp.com
Erwin Junker Machinery — Booth #1026
The Junker Group will present its product diversity in gear manufacturing:
Grinding machines from Junker and Zema in addition to air filters from
LTA.
Junker’s portfolio has recently been expanded to include non-cylindrical
grinding of camshafts for low to medium lot sizes. By using up to two highperformance
grinding spindles, bearings journals and cam lobes can be
rough and finish ground in a single clamping set-up. High powered grinding
spindles, in combination with proven CBN grinding technology, guarantee
the highest removal rates and performance.
The Lean Selection cam is capable of grinding all cam lobe profiles and
geometries at high-speed – from concave to elliptical – and is suitable for
manufacturing everything from prototypes to large production runs.
Zema will be demonstrating how its
Numerika G-800 accomplishes the precision
grinding of gear shafts. This durable,
cylindrical grinding machine with
its hydrostatic × and Z axes and hydrostatic
grinding spindle reaches the tightest
tolerances reliably and is suited for
an unlimited array of work pieces. In
addition, Zema also offers machines for
ID/OD grinding and large shafts with
diameters of up to 1 meter (40 inch) and
up to 4 meters (157 inch) in length. The
conversational control systems (Fanuc
Based) offered by Zema are operator
friendly, simple and convenient to use.
- Click image to enlarge
LTA Lufttechnik GmbH is extending
its portfolio to include a filter which has
been kept deliberately simple and will be
launched in the market under the name
Basic Line. LTA has developed the new
entry level model to allow customers
from the metalworking industry to benefit
from a simple yet fully functional oil
and emulsion mist filter.
The electrostatic filter is available in
two versions: The smaller of the two
has a single-stage filter, the larger comes
with two filters in series. The filters are
configured for coolant pressures of up
to 40 / 80 bar internal cooling and a
machine room of up to 6 m3. Despite
the suction capacity of 1,200 m3/h, the
blower uses minimal energy, as LTA
exclusively installs fans in accordance
with the ERP directive. The filter elements
used also contribute towards simple
handling: They are optically monitored
and fully washable. Their compact
design allows the BASIC Line filters to
be mounted on all machine tools.
For more information:
Phone: (847) 488-0406
www.junker-group.com
Exsys Tool — Booth #1731
Exsys Tool, Inc. will showcase its new
line of high-quality Eppinger gearboxes
and custom gear-making services for
a wide variety of industries. Exsys just
recently expanded its offerings of productivity
enhancing systems into the
gear sector.
Expo attendees will find spiral bevel,
planetary, planetary bevel, hypoid,
and cycloid-type gearboxes at Exsys’s
booth, many of which are produced by
Eppinger. They will also learn how to
acquire specialty custom-made gears
produced to their specifications.
Eppinger offers BT (bevel torque) and
BM (bevel maximum torque) compact
spiral bevel gears designed to bring high
torque and maximum efficiency to gear
applications that require a high degree of
reliability and variability. Each of these
bevel gearbox types offer minimized
tooth clearance and optimal transmission
properties via precision axes and
bearing seats combined with Gleason
bevel gears built to withstand high loads.
The single-component steel housings
for these bevel gearboxes have mounting
threads on all sides to ensure stable
attachment in a variety of installation
positions. The heavy-duty bevel gears
inside these housings offer high-transmission
precision and reduced stress
on the bearings. A friction-locked, zero
backlash connection of the crown gears
on the drive shaft reduces the mass of
the gearing component. Eppinger also
offers PE (planetary eco) and PP (planetary
precision) gearboxes designed for
applications that require low backlash,
high efficiency, shock resistance and a
high torque-to-weight ratio. They have
a modular design that combines ground
gears and precision gear components.
The present range of planetary gearboxes
comprises five sizes, with each
size offered as a single, dual, or triple
stage design. Each gearbox variant is
also available as a precision design with
reduced backlash. The wide range of
sizes and designs allows users to achieve
overall transmission ratios from i = 3:1 to
i = 512:1 in a variety of applications.
- Click image to enlarge
Eppinger’s BP (bevel planetary) gearboxes
combine features of the company’s
BT series gearboxes with the pre-stages
of its PE gearboxes, creating an innovative
solution for various applications.
The stable housing design and hardened,
super-finished gear components of these
gearboxes help ensure smooth running
and constant backlash control.
These planetary bevel gearboxes
achieve high-output torque and transmission
ratios up to i = 320. Currently
offered in eight sizes, the planetary bevel
gearboxes easily mount to a wide range
of motors.
For more information:
Phone: (800) 397-9748
www.exsys-tool.com/en
\
Gleason — Booth #1017
The Gleason Corporation will be showcasing
a selection of its grinding and
inspection machinery.
The Genesis 200GX threaded wheel
grinding machine is Gleason’s latest
addition to the Genesis series and offers
many features. The two spindle concept
combines increased productivity
with minimized idle and set up times.
Fast, easy software-guided setup of the
machine allows you to set up machines
from one workpiece to another in just
20 minutes using only one tool. Fully
automatic workflow after setup until
grinding the first workpieces and the
ability to interface with Gleason GMS
machines via QR codes increases productivity.
Easily accessible machine components
make maintenance simpler and
more efficient while standard dimension
grinding wheels and dressing tools allow
you to use your existing tools. All of this
in an energy efficient small footprint
machine designed to meet the needs of
customers in high-productivity, highquality
environments.
The Gleason 300GMSP analytical gear
inspection system is designed to operate
in production environments while
yielding reliable measurement results.
A patent-pending base design includes
an active leveling system to attenuate a
broad spectrum of normal production
environment vibrations, yielding measurement
values in parallel with those
achieved in controlled calibration laboratories,
but without the delay of having
to move to the lab location.
Thermal fluctuations normally associated
with shop floor environments
are proactively compensated for as well,
allowing for the best possible and most
reliable inspection results. The system
identifies and applies a compensation for
factory floor influences in real time. The
300GMSP is designed and tested to perform
as a turn-key gear inspection system
in the manufacturing environment.
Visitors to Gleason — Booth #1017
will also be introduced to a number of
other products, technologies and services,
including: Gleason’s complete line of
gear cutting tool solutions and advanced
workholding solutions.
For cylindrical gear production, visitors
will find a full array of hobs, form
relieved milling cutters, solid carbide
hobs, shaper cutters, chamfering and
deburring tools, shaving cutters,
honing tools, coated diamond and
CBN grinding wheels, diamond
dressing wheels and diamond
dressing rolls. Visitors will have
the opportunity to learn more about
recent advancements in gear hobbing
technology including G90, a
tooling material which closes the
performance gap between HSS
materials and tungsten carbide.
Visitors will also find an assortment
of power skiving tools and learn how
Gleason is the total source for supporting
this process.
Gleason’s bevel cutting tool display
will feature new bevel gear cutting tools
for cutting and grinding straight, spiral
and hypoid bevel gears. Of particular
note is the PentacPlus –RT, which can be
built faster and more precisely than stick
blade cutter systems of the past. With
blade seating stiffness equal to the high
stiffness of the PentacPlus, this new system
offers increased surface finish, tool
life and cycle time.
Gleason designs and produces a complete
range of quick-change, tool-less
workholding equipment for bevel gear,
cylindrical gear and non-Gleason production
machines. These systems reduce
set-up and change-over times for gearing
applications up to 600 mm in diameter.
Quik-Flex Plus, Gleason’s next generation
of modular, quick-change workholding
systems which requires a single
tool, less time and minimal operator
experience will be on display for the first
time at Gear Expo.
Also on display will be Gleason’s line
of hydraulic workholding solutions. The
holding force, increased accuracy and
contamination free design are designed
for dry gear processing applications. In
addition, the stir-able modular workholding
designs allow off-spindle assembly
and truing to reduce changeover
time as well as the amount of total runout
in the fixture.
Gleason will also have offerings from
Gleason Global Services, Gleason Plastic
Gears and Distech Systems.
Gleason customers can rely on factory
trained service professionals located
throughout the Americas, Europe,
and Asia, working around the clock to
deliver the full range of aftermarket service
and support capabilities
including service programs
for preventive maintenance, machine
inspection, troubleshooting and repair
and machine relocations. Learn about
Gleason’s complete range of machine
rebuilding and re-controls now offered
for all types of Gleason machines. In
many instances this work can be completed
right in the customer’s factory in
less than two weeks. Gleason is a leading
source of education for gear technology
and it will be promoting its customer
training classes which offer a full range
of courses and education forums ranging
from the beginner to the most advanced
user covering all aspects of gear design,
production and inspection.
- Click image to enlarge
Offering plastic gear design and injection
molded plastic gears including helical
gears, spur gears, planetary gears and
internal gears, Gleason Plastic Gears
provides customers with the benefit of
a plastic gear with no weld-line for a
stronger, more accurate, and economical
drive train, eliminating the additional
expense of secondary machining.
Gleason will display some of its most
recent innovations and have experts
available to answer any plastic gear related
question.
Distech Systems specializes in the
design and manufacture of factory automation
systems serving a variety of customers
in the automotive and other
industries. Combining customized automation
technology with Gleason products
for gear (and non-gear) production
allows for more complete product for
Gleason customers.
For more information:
Phone: (585) 256-6776
www.gleason.com
Index — Booth #1653
Index recently developed a “bevel gear
hobbing” package, which consists of a
specially designed control cycle and four
Index cutter heads with module-dependent
inserts. Equipped with these features,
the Index R200 and Index R300
turn-mill centers become gear cutting
machines on which spiral bevel gears
can be produced – from bar stock, with
front and rear end machining, complete
in one setup or as a pure two-spindle
gear cutting machine.
By hobbing using a continuous indexing
method – which corresponds to the
Klingelnberg Cyclo-Palloid method
1) – spiral bevel gears can be produced
with constant tooth height in a module
range of 0.6 to 4 mm.
Compared to the conventional process
chain with classic gear cutting machines,
users can achieve shorter cycle times and
better geometry and position tolerances.
“The starting point of the development
by Index lies in its own manufacturing
governed by the principle: quality-
determining components are made
in-house,” says Dr. Volker Sellmeier,
Index-Werke head of technology
development. “When the tool
holder production was reorganized
several years ago, the decision
was made to produce the
required bevel gears ourselves.”
Bevel gear cutting requires a
machine with high rigidity and a
B-axis as the basis. Due to their
increased static, dynamic and
thermal properties, the turn-mill centers
of the Index R-series are designed to
gear-cutting, provided they are equipped
with the “bevel gear hobbing” technology
package. The R machines’ axis configuration
with two milling spindles on
Y-B-axes running in hydrostatic bearings
makes it possible to machine on the
main and counter spindle simultaneously
in five axes.
The ability of the turn-mills to accomplish
complete gear-part machining on
the front and rear ends simultaneously
results in shorter total cycle times and
lower cost per piece.
“When we machine typical bevel
gears with module 1.15 mm and approximately
25 teeth for our tool holders
completely from bar stock, we achieve a
cycle time of less than 3 min. The share
of gear cutting amounts to about 30 seconds,”
Dr. Sellmeier says.
In a classical gear process chain, the
workpiece has to be set up on several
individual machines for turning, drilling,
and milling, gear cutting and deburring.
Index’s approach is to run all operations
on the turn-mill center. Bevel gears
are turned, drilled, milled and finally
cut on a single machine. Even brushes
for deburring can be set up. The soft
machining process is thus completely
autonomous, according to Index with a
process-reliable gear quality of IT5. This is then followed by hardening. A final
finishing process is usually required
only for the mounting distance and the
polygonal shaft/hub connection.
The Index solution works for both
contract manufacturers, which need to
produce small lot sizes with high flexibility,
and mass producers, which want
to produce bevel gears in large quantities
at minimal cost. The investment is
relatively low compared with specialized
machines. Also the consumption
costs are kept within manageable limits,
since the cutter heads are equipped with
interchangeable inserts.
Flexibility is high: In addition to bar
stock machining, which is best primarily
for small quantities, for series production
the R machine can be used as a
pure gear cutting machine, working on
the main and counter spindles simultaneously.
“This requires the use of an automated
workpiece-loading and unloading
system that loads the blanks and
removes the finished parts gently,” said
Dr. Sellmeier. “We offer a quadruple
gripper with two stations on the main
and counter spindle that picks up the finished
parts, rotates and then loads new
blanks. This way we use the machine as
a kind of double-spindle machine, cutting
the time per piece in half.”
Two cutter heads are required per
bevel gear. They differ slightly in their
cutting circle radius in order to produce
the longitudinal crowning. Index offers
the cutter heads in four different sizes
that can be fitted with up to six carbide
inserts and feature internal cooling.
- Click image to enlarge
In contrast to the typical Cyclo-Palloid
method with an interlocking cutter head,
the Index method uses two separate cutter
heads per bevel gear.
A control cycle developed by Index
is another essential part of the technology
package. The user enters there the
same parameters as on a conventional
gear cutting machine. These include, for
example, machine distance, eccentricity
and auxiliary angle. The cycle translates
these values into the movements of each
axis so that at the end the same relative
movements are effected as on a conventional
gear cutting machine.
For more information:
Phone: (317) 770-6392
www.index-usa.com
Kapp Group — Booth #2222
Kapp Niles will be showcasing its ZE
800 profile gear grinder while R&P
Metrology GmbH will present its PM
750/1250 portable gear inspection system.
The ZE 800 offers a compact yet highly
productive solution for a range of
applications. The machine is capable for
25 module (1 DP) external gears and
is prepared for internal grinding using
either CBN or dressable wheels. It will
be shown with new software features
including hob and worm grinding.
R&P’s PM 750/1250 is the first portable
gear checker/CMM with dual functionality
for use in the lab or on the production
floor. Its flexibility enables the
measuring of larger gears on production
machines that may not have onboard
inspection. The design makes it
moveable within the plant. The optional
“docking station” with granite base and
rotary table allows the PM 750/1250 to
become a stand-alone, fully featured four
axis generative gear inspection machine
when not required for portable measurement.
- Click image to enlarge
Kapp CBN tools for direct grinding,
and DIA dressers for grinding and
honing are also featured at the booth,
along with grinding experts, on hand to
answer questions.
For more information:
Phone: (303) 447-1130
www.kapp-niles.com
KISSsoft — Booth #1830
KISSsoft is a modular calculation
system for the design, optimization
and analysis of machine elements
and complete gearboxes.
The scope of the software ranges
from a single machine element up
to the automatic sizing of complete
gearboxes. KISSsys is KISSsoft’s system
add-on that enables the modeling
of complete gear units and drive
trains and is valuable for multistages
gear transmissions or shifted
transmissions. KISSsys also provides
the calculations for efficiency and
losses, static analysis with housing
stiffness and modal analysis.
The software includes internationally
recognized calculation standards
and a large variety of design
and optimization options, based on
the experience of KISSsoft’s customers
and development engineers,
ensuring that the software is always
at the forefront of technology.
- Click image to enlarge
At the Gear Expo, KISSsoft will be
presenting the latest version of the
software. KISSsoft 03/2015 is being
released with a number of innovations
that have been implemented.
KISSsoft will be at booth 1830. Dr.
Kissling and Dr. Beermann, founders
of KISSsoft, will be on hand to
answer questions. A free trial version
of the KISSsoft Release 03/2015
is available at http://www.kisssoft.com.
For more information:
+41 (55) 254-20-50
http://www.kisssoft.com
Liebherr Gear
Technology — Booth #1809
For Platform 2 (LSE/LFS 200 to 500)
and Platform 3 (LSE/LSF 600 to 1600)
machines, Liebherr Gear Technology
is introducing a smaller shaping head
option which facilitates electronically
controlled machining of spur and helical
gear teeth.
“The smaller SKE 120 shaping head
enables users to machine a considerably
wider range of components on our
Platform 2 and Platform 3 gear-shaping
machines,” says Dr. Hansjörg Geiser,
manager development and design
gear cutting machines at Liebherr-
Verzahntechnik GmbH. “We are thus
better able to meet contract manufacturers’
gear-cutting requirements.”
The new SKE 120 shaping head with
highly dynamic rotary drive and moveable
shaping head slide occupies less
space at a stroke length of 120 mm. The
design engineers used the space gained
to enlarge the stroke position travel
range on Platform 2 machines. The SKE 120’s stroke position travel range, at
650 mm on Platform 2 machines, is more
than twice as large as that of the SKE
240, which is 300 mm. The same applies
to Platform 3 machines where the difference
is 350 mm. Even 900 mm are feasible
if raised column slides are used.
The shaping spindle is hydrostatically
mounted and channeled.
Some workpieces require a longer
stroke length (for wider teeth), while
others require a wider stroke position
travel range (longer workpieces with correspondingly
higher gear teeth). The
optionally available NC swivel column
slide, which lets you produce conical
gear teeth at a shaping spindle angle of
between -1° and +12°, has been optimized
to achieve a higher degree of
rigidity. If NC swivel column slides are
not used, the shaping spindle angle can
be adjusted by up to ±0.45° using a cam.
The direct-drive electronic lead guide
provides users with latitude and flexibility.
They only need enter a helix
angle of between 0° and 45° and the control
system calculates the rest. The new
SKE 120 shaping head differs primarily
from the larger shaping head with electronic
lead guide, SKE 240, by a smaller
stroke length. The crank drive features
automatic mass counterbalance,
which ensures optimum concentricity.
The spindle itself has a somewhat narrower
design than the SKE 240, which
has a positive impact on interference
conditions.
SKE 120 and SKE 240 shaping heads
featuring the electronic lead guide provide
contract manufacturers with a range
of new opportunities. For example, frequent
workpiece changeovers are easier.
To be able to machine different helix
angles on gears, the motion of the shaping
head must replicate the gear´s helix
angle. This can be performed by a
mechanical lead guide. Set-up times are
shortened because where an electronic
lead guide is used only the shaping tool
needs to be changed, if at all.
An added benefit is that customers
do not have to invest in multiple lead
guides. They are not dependent on the
control’s processing time, which makes
them even more flexible. Added opportunities
are provided in combination with the stroke position adjustment
detail.
A further requirement was the ability
to manufacture efficiently and to optimum
quality, in addition to the flexible
range of workpieces. The process itself is
highly productive, given the high number
of strokes at 1,200 double strokes
per minute. This figure is based on a
dynamic drive mechanism combined
with effective control technology at optimum
rigidity.
Liebherr developed its Type LSE range
of machines based on its proven LFS
machines. Besides the option of using
electronic lead guides, these machines
also enable you to correct helix angles.
Tooth flank angular deviation (fh) can
be corrected simply and precisely when
setting up the shaping machine.
It is possible to retain the helix angle
for subsequent tempering. For even better
quality, μm corrections can be undertaken:
the machine achieves tooth flank
quality grade 4 as per DIN3962-2.
Along with increased quality and
flexibility requirements, materials have
also changed. For example the tensile
strength of workpieces to be shaped has
increased substantially. The LFS/LSE
machines have been designed to shape
high-strength materials.
- Click image to enlarge
Liebherr has already applied the
results of internal tests in this segment
using appropriately configured and coated
replaceable cutting inserts to industrial
applications and put these in practice.
The choice of high-alloy substrates with
correspondingly efficient coatings demonstrates
that machining performance
and tool service lives can be enhanced.
For more information:
Phone: (734) 429-7225
www.liebherr.com
Koepfer America — Booth #1822
Koepfer America will showcase a selection
of gear hobbing machines.
First is the “Repowered” Koepfer
Model 160 gear hobbing machine. This
K160 Repowered machine is part of
the K-Repowered services offered by
Koepfer America. This service offers a
complete CNC re-control package for
existing Koepfer models 160 and 200
gear hobbing machines. This re-control
renews the reliability of customers’ existing
Koepfer hobbing machines.
The Koepfer Model 200 horizontal
gear hobbing machine offers increased
flexibility, automation, and quality for
the hobbing of fine- to medium-pitch
gears. German engineering has developed
this model for over 20 years, leading
to a machine designed for manufacturing
facilities across the globe. Koepfer
America will feature a Koepfer Model
200, highlighting its easy setup, quick
changeover, flexible automation, and
rigid construction.
- Click image to enlarge
From Helios Gear Products, Koepfer
America will also display the first
Ra-Cut fine-pitch carbide hobs, which
feature up to double the number of cutting
faces on an otherwise like design.
Ra-Cut hobs can achieve higher-quality
finish cut gears and increased productivity
using re-hobbing or skiving processes.
For more information:
Phone: (847) 931-4121
www.koepferamerica.com
Klingelnberg — Booth #1410
Klingelnberg will be exhibiting its capabilities
with a presentation of cuttingedge
technology “made in Germany” in
the form of the G 30 bevel gear grinding
machine and the P 26 precision measuring
center.
Klingelnberg, utilizes this platform
for an intense professional exchange
on equal footing. Not only will visitors
encounter a team of Klingelnberg
experts who are available for professional
dialogue, but Klingelnberg will also
unveil its “home-made” technology from
two different business units with its G 30
bevel gear grinding machine and P 26
precision measuring center.
The Oerlikon G 30 bevel gear grinding
machine continuously advances the
vertical concept for grinding technology.
All bevel gear machines in this series
are equipped with a heat-stable, vibration-
damping machine bed. An optimized
axis arrangement ensures reduced
approach paths and less load on the
drive components – and a stiffer design
of the overall system. The G 30 can be
optionally equipped with a side loading
door, allowing for easier loading in
automatic mode using a machine integrated
loading shuttle or handling robot.
For series production, the machine also
offers a range of process monitoring
functions.
Klingelnberg has also continued to
develop the P 40 measuring center. A
height adjustable electric control console
and the vibration isolation that can be
integrated, now provide even better prerequisites
for shop-floor use in the new
P 40.
The fully automatic CNC-controlled
precision measuring center is designed
as a compact unit for the workpiece
diameter range up to 400 mm. At the
heart of the P 40 is
an accurate, durable
rotar y table.
Configured as a measuring
axis (C axis),
it provides concentric
seating of the workpieces
to be tested. In
combination with the
three linear measuring
axes, tangential (X
axis), radial (Y axis)
and vertical (Z axis), the precision measuring centers trace
and inspect the functional surfaces of
gearings and general drive components
in generator mode.
- Click image to enlarge
Measuring centers are equipped with
heavy-duty, stable beds and guide bodies
made of cast iron. At the same time, all
bearings and guides are backlash-free at
the measuring axes. These form the basis
for the measuring centers’ high basic
mechanical accuracy. The integrated 3-D
measurement system enables both discrete-
point probing and scanning, continuous
measured value logging. The
powerful GINA software makes it possible
to evaluate the results quickly and
easily.
For more information:
Phone: (734) 470-6278
www.klingelnberg.com
Marposs Corp. — Booth #2039
Marposs Corp. will demonstrate its Artis
process monitoring system for gear cutting
applications at Gear Expo 2015. The
Artis CTM V6 system will be installed
on a Kashifuji KE 201 CNC hobbing
machine powered by a Fanuc Oi-CNC
control, which will be demonstrated in
the Involute Gear & Machine Co. booth
#1029.
The Artis system for gear cutting has
the ability to detect and track tool wear,
provide a real and graphical tool life
count and trending according to the cutting
conditions, and instantly stop the
process lights-out in case of chip welding,
damaged or broken teeth or other
conditions such as peeling coatings.
The Artis system utilizes an algorithm
representing the life cycle of a hobbing
tool that can be used to identify the
optimum time to take the tool out of
service for re-sharpening based on its
actual condition. Additionally, a system
of machine mounted sensors monitors
process parameters including spindle
torque, spindle vibration, true power
consumption and a number of others
depending on the specific application.
Using these inputs, the system then captures
the signature of each operation in
the process and automatically generates
a “good” tolerance band for the process
based on that signature.
While the concept of monitoring process
inputs is not unique, the Artis system
couples it with powerful software
specifically designed to detect the exact
kinds of anomalies produced by worn
and/or damaged hobs from conditions
such as chips weld, peeling coatings or
broken teeth. The Artis software can
identify and quantify each of these signatures
to generate either an approaching
end-of-life warning for normal wear,
or an automatic machine stop in case of
actual tool damage.
In the case of normal wear, the Artis
system notifies with ample time to
schedule the downtime required to minimize
the impact on production.
For more information:
Phone: (616) 891-1091
www.marposs.com
Mazak — Booth #1322
At Gear Expo 2015 in booth 1322,
Mazak will use its Integrex i-100ST,
equipped with the latest Mazatrol
SmoothX CNC, to demonstrate how
advanced multitasking machines can
effectively perform today’s gear-making
processes, from hobbing to skiving to
gashing.
Mazak multitasking machines, including
the Integrex i-100ST and over 90
other model configurations, when
paired with the right software and CAD/
CAM system, can serve as adaptive gear
machining solutions that produce precision
gears of all shapes and sizes. Unlike
dedicated gear cutting equipment, these
machines have the flexibility to perform
a variety of operations in a single setup.
Shops with occasional gear work, for
example, can use a Mazak multitasking
machine to turn a part’s I.D. and O.D.,
process its mating features, and power
skive its gear tooth pattern. Performing
all of these functions on one machine
improves overall accuracy because every
part feature runs true to the gear teeth.
And, when the machine is not busy with
gear work, it can continue to earn its
keep by processing a range of complex,
non-gear components.
One of the most compact models in
the Mazak multitasking machine family,
the Integrex i-100ST, processes small
complex workpieces in single setups. It
employs two 15-hp, 6,000-rpm turning
spindles, a nine-tool lower turret and a
10-hp, 12,000-rpm milling spindle. Each
turning spindle features a 6" chuck with
a 2.4" bore size that can accommodate
bar stock of up to 2" in diameter. The
machine’s 36-tool magazine accommodates
tools up to 5.1" in diameter when
neighboring stations are empty and up
to 3.5" in diameter when stations are
occupied.
Gear Expo attendees will be among
the first to see the Integrex i-100ST
equipped with the new Smooth
Technology process-performance platform,
which has transformed the way
the company’s multi-axis machines perform.
According to Mazak, new CNC
technology, progressive machine design
and unequaled engineering resources
set the foundation for the platform and,
together, provide users with unsurpassed
ease of operation and unmatched productivity.
- Click image to enlarge
The Mazatrol SmoothX
CNC, a key element of
Smooth Technology, operates
four times faster than
Mazak’s previous-generation
controls. Gear makers,
especially, will benefit from
faster rotary axis speeds,
which allow the machine
tool to quickly perform gear
hobbing and skiving operations.
Gear Expo attendees can also inquire
about the company’s other gear production
options while in booth 1322. The
company’s larger multitasking machines
with full 5-axis capabilities are known
for being able to produce low-volume
spiral-bevel gear sets. The Integrex
e-1550V/10, for example, can machine
a spiral-bevel gear set with a 29-tooth,
22"-diameter pinion gear and a 114-
tooth, 6’-diameter gear ring in a matter
of days as opposed to months.
For more information:
Phone: (859) 342-1700
www.mazakusa.com
Machine Tools Builders — Booth
#1804
At Gear Expo 2015, MTB will display
a P900 gear hobbing machine rebuilt
with all mechanical linkages, gearing
and other driving mechanisms replaced
with new, modern servo drives and electronic
controls via CNC. All guide ways
have been refinished, seals and bearings
replaced, hydraulics completely
replaced, lubrication systems replaced,
and a new electrical system installed.
During the course of the rebuild, the
machine was converted to CNC control
for the × (radial), Y (tangential), Z
(axial), C (worktable), and A (hob head
swivel) axis, along with the B (cutter)
spindle. Overall features will include
a hob head swivel converted to CNC,
enclosure with manually operated door
and access panels for maintenance and a
new magnetic style chip conveyor.
MTB is also showcasing a Challenger
muscle car, which has been retrofitted
and customized.
At MTB, classic machine design
challenges are overcome by shortening
the drive (gear) train for efficiency
and accuracy, and by converting them
to servo-driven ballscrews. Motors are
designed with the proper torque and
speed to move the axes at the required
accelerations and speeds, which is very
similar to the dynamics of supercharging
an engine. MTB finds the processes of
rebuilding cars and gearing equipment
to be very similar. The remanufacturing
or rebuilding of a machine includes
a rebuild, a recontrol and modifications
to reduce or eliminate as much as possible
the mechanical linkages, gearing and
other driving mechanisms. Generally
these are then replaced with new modern
servo drives, and electronic control
via CNC or PLC motion cards. The
reduction in the number of bearings,
seals, shafts and other
mechanical elements
translates to less mechanical
wear areas, and a more
reliable and accurate
machine tool. As a result,
it’s a modern machine
tool.
- Click image to enlarge
Several members will
be available for questions.
Christoph Donner
(from Donner+Pfister
AG) will be visiting from
Switzerland to answer
questions and provide
insight on gear checking
and measurement systems,
along with upgrades
to MAAG gear grinding machines. Rick
Claeyssen, heat treatment 30 plus year
veteran, will be available to answer questions
and provide insight on atmosphere
equipment. Ken Flowers (MTB co-owner
and engineer) will be available for
answering gear related questions.
For more information:
Phone: (815) 636-7502
www.machinetoolbuilders.com
Reishauer — Booth #2242
Reishauer AG will be demonstrating
the RZ 160. The concept is based on
the RZ 150 series. The RZ 160 has been
increased in size and all relevant components
have been adapted to handle higher
loads and forces which occur when
grinding larger gears. The RZ 160 can
grind gears with an outside diameter of
160 mm and modules up to 4 mm.
The RZ160’s design focuses on adaptability
to the different production
requirements of numerous customers.
The machine can be fitted with one or
two work spindles. The version with
two work spindles is used to minimize
the loading times. When grinding gears
with space limitations, one can use the
changeable Profile Grinding Spindle,
enabling the use of a small plated or
dressable wheel to grind gears using the
discontinuous profile method. Both versions
of the RZ 160 can be equipped
with a fixed or CNC-controlled axis for
swiveling the dressing tool. This option
can increase the flexibility of the dressing
tools since the same tool can be used
for a range of gears as compared to the
fixed dresser where the tools are normally
workpiece specific.
Felsomat, a member of the Reishauer
Group, has developed an automation
system that is designed to match to the
specific requirements of the RZ 160. In
combination with the Felsomat FRC600
robot cell, the machine is suited for small
to medium lot sizes. Available options
include composite checking, de-oiling,
SPC and NOK drawers.
Reishauer will be demonstrating polish
grinding on a helical gear used in a
truck transmission. The grinding wheel
has two different sectors and compositions.
One area is used to grind and
remove the heat treat distortion while
the other is for polishing the tooth surface.
The geometry of the grinding wheel is
produced by using conventional dressing
systems. Grinding various workpieces
requires a variable shift jump to reach
the polish grinding sector. The shift feed
rate and the shift jump can be optimized
for polish grinding depending on the
dressing frequency.
- Click image to enlarge
This process achieves a surface finish
of Ra .10 μm. In addition to the
improved surface, the polish ground
process rounds out the edges at the transition
of the workpiece flank and face.
The topography of the flanks remains
unchanged.
Many of Reishauer’s common features
are present in the RZ 160, including
the Reishauer Generating Module for
gear quality, Reishauer LNS Low Noise
Shifting technology for low gear noise
emissions, Polish and Fine Grinding for
surface roughness reduction, Reishauer
Twist Control grinding technology to
create defined values for flank twist and
the Reishauer HMI for fast change over
and set-up times.
Reishauer will be at booth 2242 at
Gear Expo.
For more information:
Phone: (847) 888-3828
www.reishauer.com
Riten — Booth #2201
Riten Industries will display its Raptor
series of live centers, specially engineered
for gear hobbing and gear grinding.
Unlike the prevailing foreign import,
these centers are made and serviced in
the U.S., and are available for immediate
delivery. Other featured products
are the Adjusta-Point live
center that corrects for off-center
workpiece center holes, and
the C4T live center with permanent
bearing protection. Also
on display are face drivers and a sampling
of the world’s largest selection of
live and dead centers.
- Click image to enlarge
For more information:
Phone: (800) 338-0027
www.riten.com
Star SU — Booth #2109
Star SU will be showcasing its Bourn &
Koch 25H Horizontal Hobbing CNC
Machine. The machine hobs shafts,
gears, and special parts up to 25 mm in
diameter. It is designed without hydraulics
reducing wear parts and heat.
Also on display will be a variety of
gear cutting tool solutions, including:
gear hobs, milling cutters, gear shaper
cutters, shaving tools, chamfer and
deburring tools, master gears, ring and
plug gauges, and broaches. The company
also offers precision tool re-sharpening
services and advanced coatings,
including Oerlikon Balzers Altensa and
Alcrona Pro, which can extend the life of
your tools and lower your costs.
Star SU partners Profilator/GMTA
and Sandvik Coromant will also be present in the booth during this year’s
show. Star SU has formed an alliance
with Profilator to manufacture Scudding
tools for the global market. Scudding
can complement shaping, broaching and
other gear cutting processes to produce
gear and spline teeth for both cycle time
and tool cost.
See the latest in indexable gear milling
solutions from sandvik coromant.
As national sales channel partner for
Sandvik Coromant’s line of indexable
gear milling solutions, Star SU presents
several new solutions and products
enabling optimal production of small
to large batch sizes, both in dedicated
machines as well as multi-task machines.
For more information:
Phone: (847) 649-1450
www.star-su.com
