• generating gear grinding
• suitable for medium and large batch production
• minimised idle time
• 2-spindle concept with index table
• dressable and non-dressable CBN tools
• flexible automation system
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.
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 opposite 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, bringing floor to-floor time to a minimum.
External spur and helical gears of modules up to 4.5 or 5 mm with an max. outside diameter of 170 or 260 (280) mm, and a gear width of up to 320 mm can be ground on the KX 160 TWIN. Alternative workpiece data will be considered upon request.
profile dressing unit
The KX 160 TWIN design includes an integrated single spindle dresser for dressing conventional grinding worms. Shifted to the workpiece spindles, the dressing unit is assembled on the tail stock column, too. For dressing, the profile dressing unit is positioned to the tool by turning the tail stock column. 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.
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 set-up 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.
An optional measuring unit allows measurement of gear profile and tooth width. With the KAPP HMI, data input tasks can be done efficiently, reducing setup time. Additionally, sample inspection of the gear quality can be sequenced to occur periodically during normal production runs.
The KX 160 TWIN is optimized for automatic loading. As a standardized turnkey solution, a combination of pallet conveyor and gantry loader is provided according to the specific application. Alternative automation methods, such as pallet or robot system can also be utilized.
|type||max. tip diameter [mm]||module range [mm]||max. face width [mm]||max. helix angle [deg]|
|KX 160 TWIN||170||0.5 – 4.5||320||± 45|
|KX 260 TWIN||260 (280)||0.5 – 5||320||± 45|